Document e51pvBN5L3kkNbDOVr7EmdLKy

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGION 5 77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604 SUBJECT: FROM: THRU: TO: CLEAN AIR ACT INSPECTION REPORT Flint Hills Resources Pine Bend Refinery, Rosemount, MN Brittany Cobb, Environmental Engineer AECAB (MI/WI) Sarah Marshall, Section Supervisor AECAB (MI/WI) File BASIC INFORMATION Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 EPA Inspector(s): 1. Constantinos Loukeris, Environmental Engineer 2. Brittany Cobb, Environmental Engineer 3. Tess Russell, Environmental Engineer 4. Karyn Defranco, Environmental Engineer Other 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Attendees: Jon Carlson, Environmental Director Anne Lee, Environmental Manager (LDAR) Chris Koerner, Environmental Manager (Air Program) Chris Buresh, Senior Wastewater Engineer Robert Covey, Wastewater Compliance Supervisor Shelly Stanton, BWON Compliance Supervisor Sean Tuff, Wastewater Operations Engineer Nick Peyer, LDAR Supervisor Katie Plas, Legal Intern Matt Tamminga, Business Team Leader for Wastewater Andrew Paulsen, Wastewater Lead Operator Candy Meyer, Compliance and BWON Specialist Plant Page 1 of 8 13. Mark Williamson, Senior Environmental Engineer (corporate office) 14. Erin Connell, Environmental Compliance Data & Systems Coordinator 15. Jim Bean, Senior Inspector - API Gap Seal Inspector Contact Email Address: anne.lee@fhr.com Purpose of Inspection: Determine Compliance with the Clean Air Act Facility Type: Refinery Regulations Central to Inspection: 40 C.F.R Part 61, Subpart FF - National Emission Standard for Benzene Waste Operations (BWON); 40 C.F.R Part 60 Subpart QQQ - Standards of Performance for VOC Emissions From Petroleum Refinery Wastewater Systems (QQQ) 7/25/2022 Arrival Time: 2:30 PM CT Departure Time: 5:00 PM CT 7/26/2022 Arrival Time: 8:30 AM CT Departure Time: 5:00 PM CT 7/27/2022 Arrival Time: 8:00 AM CT Departure Time: 5:30 PM CT 7/28/2022 Arrival Time: 8:30 AM CT Departure Time: 11:30 AM CT Inspection Type: Unannounced Inspection Announced Inspection OPENING CONFERENCE Presented Credentials Stated authority and purpose of inspection Small Business Resource Information Sheet not provided. Reason: Not a small business Provided CBI warning to facility The following information was obtained verbally from employees at Flint Hills Resources Pine Bend Refinery (Flint Hills) unless otherwise noted. Page 2 of 8 Process Description: Flint Hills is a fuels refinery. The facility receives heavy and light crude oil from Canada and North Dakota and produces approximately 350,000 barrels of refined product per day. In addition, the refinery produces asphalt, molten sulfur, and ammonia bisulfate (fertilizer) as byproducts. There are three (3) crude units that run in parallel, three (3) coke units, three (3) hydro processing units to remove sulfur to sell as elemental sulfur, four (4) flares, a wastewater treatment plant, and numerous miscellaneous units. The North Flare is steam-assisted, the East and West Flares are air-assisted, and the Utility Flare has no assist and is used only for emergency flaring. Wastewater treatment plant (WWTP) Wastewater is collected around the facility in the oily water sewer, one of seven major sumps or one of the many minor sumps that feed the major sumps. The BWON controlled system consists of the sumps, underground API (OWS API), Siemens API, tanks 205/206, vessel 49, equalization basins 7A/B, Dissolved Nitrogen Floatation (DNF) A/B, old Dissolved Air Floatation (DAF), new DAF, sludge storage basins 2A/B/C, tank 336, vessel 26, tanks 63/64 and the aeration/biological treatments basins 3A/B/C. The system becomes uncontrolled when the wastewater hits the splitter box and clarifiers. The closed vent system feeds one of two thermal oxidizer (TO) units, H1 and H3; H3 is only used for back-up. Staff Interview: Flint Hills conducts monthly visual inspections for equipment subject to QQQ; all carbon canisters including those associated with the wastewater treatment system sumps are monitored daily, and breakthrough is considered at 100 ppm. Quarterly gap seal inspections are conducted on equalization basins 7A/B, subject to Subpart Kb, as well as quarterly visual inspections for BWON. Flint Hills uses a contractor (HydroChemPSC) to perform the bulk of the annual EPA Method 21 LDAR - Determination of Volatile Organic Compound (VOC) Leaks - monitoring on equipment subject to BWON. Flint Hills reported approximately 376 Mg Total Annual Benzene in 2021 and the quantity of benzene that was considered not controlled and therefore counted under BWON was 0.0187 Mg. Flint Hills has therefore been exempt from treating benzene in the waste streams. The facility's target flow into the DNFs is 1350 gallon/minute. TO unit H1 was replaced approximately 15 years ago; TO unit H3 has not changed in approximately 22 years but is only used for back-up. Facility representatives mentioned that low-emission valves are most commonly used on site. Flint Hills closed out their former Consent Decree in 2018. Tanks 205/206 are controlled with internal floating roofs (IFRs). TOUR INFORMATION EPA Tour of the Facility: Yes Page 3 of 8 Data Collected and Observations: EPA conducted leak detection and repair (LDAR) monitoring using Toxic Vapor Analyzer Model 2020 (TVA 2020) flame ionization detectors (FID) on Flint Hills's BWON controlled sewer system components, which are required to be designed to operate with no detectable emissions (NDE), as indicated by an instrument reading of less than 500 ppm (see Appendix B). EPA also monitored the primary and secondary carbon canisters used to control benzene emissions for breakthrough. Flint Hills uses a photoionization detector (PID) to conduct this breakthrough monitoring. EPA observed that the PID was not detecting concentrations as high as EPA's FID, and in many Flint Hills was not detecting breakthrough at 100 ppm whereas EPA was above 100 ppm. (see Appendix B) In addition, EPA visually inspected drain hubs and other QQQ affected equipment. EPA took 20 forward looking infrared radiation (FLIR) videos to detect leaks. EPA observed VOCs venting from rain caps on equalization basin 7A (see MOV_0437.mp4 and MOV_0438.mp4). EPA was informed by Jim Bean that the rain caps regularly open straight to atmosphere and vent benzene and VOCs. EPA also observed leaks from the seals on tank 63, tank 64 and vessel 49 (see MOV_0430.mp4, MOV_0432.mp4, MOV_0440.mp4, and MOV_0441.mp4). EPA observed excess dirt from foam spills from aeration/biological treatments basins 3A/B on sludge basins 2A/B/C (see IMG_0157.JPG and IMG_0158.JPG). EPA also observed that the hatch on T205 was open. EPA inspected 31 drains in the hydrocracker unit (Unit 29). The table below summarizes the observations from the visual inspections: Inspection Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Component ID 29DC1014OWS 29DC1015OWS 29DC1016OWS 29DC1017OWS 29DC1018OWS 29DC1019OWS 29DC1020OWS 29DC1021OWS 29DC1022OWS 29DC1023OWS 29DC1024OWS 29DC1025OWS 29DC1034OWS 29DC1035OWS 29DC1036OWS 29DC1037OWS Observation Oil/water mix Oil Dust, couldn't see Oil Water Water and oil Oil Oil Oil Oil Oil Oil Water with debris Oil Water Water and oil liquid Page 4 of 8 17 29DC1038OWS Water with debris 18 29DC1039OWS Water 19 29DC1040OWS Oil 20 29DC1041OWS Water 21 29DC1042OWS Water 22 29DC1043OWS Water 23 29DC1044OWS Oil 24 29DC1045OWS Water 25 29DC1046OWS Water 26 29DC1047OWS Oil 27 29DC1048OWS Oil 28 29DC1049OWS Oil 29 29DC1052OWS Oil 30 29DC1061OWS Oil 31 29DC1062OWS Water with debris 31 29DC2001OWS Gaps and dirt at seams where bolts are EPA inspected 5 junction boxes in the hydrocracker unit (Unit 29) and naphtha unit (Unit 28). The table below summarizes the observations from the visual inspections: Inspection Number 1 Unit Naphtha unit 2 Naphtha unit 3 Naphtha unit 4 Naphtha unit 5 Hydrocracker Component ID /Description 28SB5191OWS 28SB5202OWS 28SB5210OWS South Battery limits 37SB4354OWS Observation Cracks and broken seal (IMG_0166.JPG) Cracks in seal (IMG_0165.JPG) No cracks or gaps No cracks or gaps No cracks or gaps Photos and/or Videos: were taken during the inspection. Field Measurements: were taken during this inspection. RECORDS REVIEW Process flow diagram CLOSING CONFERENCE Provided U.S. EPA point of contact to the facility Page 5 of 8 Requested documents: Temperature of H1 & H3 TO (hourly) for the past 3 years Most recent performance tests for H1 and H3 Destruction efficiency for H1 and H3 (if not included in the most recent performance tests) Inspection reports for equipment subject to QQQ and FF for the past 3 years, including visual observations and LDAR monitoring Standard procedures for BWON and Subpart QQQ visual inspections Corrective action for foam events, for the past 3 years Semi-annual Subpart QQQ reports for 2019, 2020, and 2021 Quarterly BWON reports for 2019, 2020 and 2021 Records of carbon canister monitoring for 2022 End-of Line BWON sampling reports at the biobasins for the past 2 years Engineer design for equipment to show that it will be compliant with BWON Evidence of correction/repairs that took place as a result of the EPA inspection Concerns: 1. EPA identified concerns that numerous QQQ drains had oil in them instead of water seal. 2. EPA identified concerns that the visual inspections for QQQ are not being completed properly because Flint Hills is checking for liquid rather than water, as indicated by Flint Hills operations personnel. 3. EPA identified detectable emissions above 500 pm at sumps, underground API (OWS API) inlet, Siemens API, and 7A/B inlet/outlet boxes. 4. EPA identified concerns that the visual inspections for BWON are not being completed properly or at all, since numerous locations where EPA identified detectable emissions above 500 ppm had visible leaks and cracks. 5. EPA identified concerns with leaks observed from V49, 7A/B and tank 63/64 with the FLIR. V49 recently had a seal inspection. 6. EPA identified the concern that the controlled WWTP may not be designed to operate below NDE as required by BWON. 7. EPA identified concern with the concentration of VOCs that was measured in the exhaust vent stream of numerous carbon canisters and the discrepancy between concentrations measured with EPA/Flint Hills' TVA and Flint Hills' photo ionization detectors. 8. EPA identified concern with the substantial amount of dried caulk on the top of the old DAF/new DAF. 9. EPA identified concern with the dirt on 2A/B/C basins as it impedes BWON visual observations. 10. EPA identified concern that the refinery's may not be meeting its current 2 Mg compliance option. 11. EPA identified concern with the hatch on T205 being open when not in use instead of being bolted, as T205 is subject to Subpart Kb. Page 6 of 8 DIGITAL SIGNATURES Digitally signed by Brittany Cobb Date: 2022.09.19 Brittany Cobb Report Author: __________________09_:4_3:_46_-0_5'_00_' ________ Section Supervisor: SARAH Digitally signed by SARAH MARSHALL ____M__A_R__S_H__A_L_L___10_:0_1:_10_-0_5_'00_' __________ Date: 2022.09.19 Page 7 of 8 APPENDICES AND ATTACHMENTS 1. Digital Image Log 2. FLIR video log 3. Field Measurement data Page 8 of 8 Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 APPENDIX 1: PHOTO LOG 1. Inspector(s) Name: Brittany Cobb and Tess Russell 2. Archival Record Location: EPA's OneDrive folder and Electronic Records System (ERC) Image Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 File Name IMG_0072.JPG IMG_0073.JPG IMG_0074.JPG IMG_0075.JPG IMG_0076.JPG IMG_0077.JPG IMG_0078.JPG IMG_0079.JPG IMG_0080.JPG IMG_0081.JPG IMG_0082.JPG IMG_0083.JPG IMG_0084.JPG IMG_0085.JPG IMG_0086.JPG IMG_0087.JPG IMG_0088.JPG IMG_0089.JPG IMG_0090.JPG IMG_0091.JPG Date and Time (Central Time) YYYY:MM:DD Time 2022:07:26 10:38:24 2022:07:26 10:41:21 2022:07:26 10:42:35 2022:07:26 10:51:17 2022:07:26 10:55:41 2022:07:26 11:00:55 2022:07:26 11:05:12 2022:07:26 11:13:16 2022:07:26 11:26:13 2022:07:26 11:32:05 2022:07:26 11:40:52 2022:07:26 11:57:38 2022:07:26 11:57:44 2022:07:26 12:02:16 2022:07:26 12:06:50 2022:07:26 12:10:14 2022:07:26 12:16:15 2022:07:26 12:16:47 2022:07:26 12:17:32 2022:07:26 12:18:30 Description of Image Crack in southwest corner of forebay inlet detectable emission measured East side of forebay inlet, pealing caulk and visible leak - detectable emissions with TVA Crack on southwest corner of forebay inlet detectable emissions with TVA Crack on east side of trash rack - detectable emissions with TVA Crack in caulk on east side of forebay detectable emissions with TVA Crack and 8th and 9th bolts on west side of trash rack - detectable emissions with TVA Crack on east side of trash rack - detectable emissions with TVA Crack in northeast side of trash rack detectable emissions with TVA Crack in caulk, north side of trash rack detectable emissions with TVA Crack in caulk - detectable emissions with TVA Caulk on ground - detectable emissions with TVA Caulk west of walkway - detectable emissions with TVA Duplicate photo Loose caulk seal north of walkway, forebay detectable emissions with TVA Third bolt southwest of walkway over forebay, visible leak - detectable emissions with TVA Second bolt southwest of walkway over forebay, detectable emissions with TVA Oil spill on the underground API Rain cap on underground API Caulk on the roof of API South half of API - oil spills visible Appendices Page 1 of 13 Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 21 IMG_0092.JPG 2022:07:26 12:23:57 North plate of underground API, a lot of caulking and very high detectable emissions with TVA 22 IMG_0093.JPG 2022:07:26 12:25:05 North plate of underground API, a lot of caulking and very high emissions detected with TVA 23 IMG_0094.JPG 2022:07:26 12:27:32 South plate with caulk 24 IMG_0095.JPG 2022:07:26 12:32:06 5th rain cap from walkway on south side of roof on API, visible oil 25 IMG_0096.JPG 2022:07:26 12:33:07 Oil spill on south side of underground API roof 26 IMG_0097.JPG 2022:07:26 12:33:50 Caulk on south side of underground API roof 27 IMG_0098.JPG 2022:07:26 12:34:36 Oil spills on 10th and 11th section of API roof (south side) 28 IMG_0099.JPG 2022:07:26 12:35:22 Oil spill and caulking on south roof of underground API 29 IMG_0100.JPG 2022:07:26 12:37:35 Caulk on skim sump, equipment 94 S2 30 IMG_0101.JPG 2022:07:26 12:38:36 Caulk on bolt - skim sump, equipment 94 S2 31 IMG_0102.JPG 2022:07:26 12:47:01 Cracks in the north face of north side of API roof, next to skim sump, equipment 94 S2 32 IMG_0103.JPG 2022:07:26 12:50:01 Eighth panel of north roof, crack in cement with caulking - detectable emissions with TVA 33 IMG_0104.JPG 2022:07:26 12:51:39 Bolt on skim sump, equipment 94 S2 - detectable emissions with TVA 34 IMG_0105.JPG 2022:07:26 12:54:37 Warped cap with caulk, west side of skim sump, equipment 94 S2 - detectable emissions with TVA 35 IMG_0106.JPG 2022:07:26 13:01:32 Third bolt east, north side of skim sump, equipment 94 S2 - detectable emissions with TVA 36 IMG_0107.JPG 2022:07:26 15:14:41 First bolt on northwest corner of skim sump 94 S2 - detectable emissions with TVA 37 IMG_0108.JPG 2022:07:26 15:18:34 North roof of underground API - visible oil 38 IMG_0109.JPG 2022:07:26 15:18:43 North roof of underground API - visible oil 39 IMG_0110.JPG 2022:07:26 15:19:35 North roof of underground API, rain caps with visible leaks 40 IMG_0111.JPG 2022:07:26 15:20:05 Northeast side of underground API roof 41 IMG_0112.JPG 2022:07:26 15:24:09 Entrance to east sump area (aft bay), elevated readings on TVA 42 IMG_0113.JPG 2022:07:26 15:26:19 Northwest corner of afterbay - detectable emissions with TVA 43 IMG_0114.JPG 2022:07:26 15:26:36 Caulk around bolt on aft bay Appendices Page 2 of 13 Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 44 IMG_0115.JPG 2022:07:26 15:28:47 Northeast corner of aft bay, visible leaks in bolt and caulking - detectable emissions with TVA 45 IMG_0116.JPG 2022:07:26 15:33:34 Caulking along the eastern middle part of underground API (north end) 46 IMG_0117.JPG 2022:07:26 15:35:33 Caulking along the eastern middle part of underground API (south side) 47 IMG_0118.JPG 2022:07:26 15:38:08 South end of aft bay plate - visible leaks in caulking 48 IMG_0119.JPG 2022:07:26 15:40:41 Location where grease is added for bearings - south end of aft bay 49 IMG_0120.JPG 2022:07:26 15:46:55 P-tray on Siemens tank 50 IMG_0121.JPG 2022:07:26 16:46:03 Top of Siemens tank (94-ME-259A) - visual leak around bolt, TVA measured 120 ppm 51 IMG_0122.JPG 2022:07:26 16:56:32 Caulk on pressure relief hatch on Siemens 259A - detectable emissions with TVA 52 IMG_0123.JPG 2022:07:26 16:56:37 Caulk on pressure relief hatch on Siemens 259A - detectable emissions with TVA 53 IMG_0124.JPG 2022:07:26 17:05:57 Caulk and visible leaks on pressure relief hatch on Siemens B - detectable emissions with TVA 54 IMG_0125.JPG 2022:07:26 17:08:13 Pressure relief hatch (Siemens A) 55 IMG_0126.JPG 2022:07:26 17:08:27 Pressure relief hatch (Siemens A) 56 IMG_0127.JPG 2022:07:27 10:10:49 Crack in inlet box on west side of tank 7B - detectable emissions with TVA 57 IMG_0128.JPG 2022:07:27 10:24:19 Visible oil on top of tank 7B 58 IMG_0129.JPG 2022:07:27 10:30:15 Equipment 94S12, visible leak around caulk - detectable emissions with TVA 59 IMG_0130.JPG 2022:07:27 10:33:02 Equipment 94S12, visible leak and loose caulk - detectable emissions with TVA 60 IMG_0131.JPG 2022:07:27 10:39:22 Southwest corner of equipment 94S12, seam of level indicator - detectable emissions with TVA 61 IMG_0132.JPG 2022:07:27 10:39:33 West end of equipment 94S12, caulking peeling - detectable emissions with TVA 62 IMG_0133.JPG 2022:07:27 10:45:24 West plate of equipment 94S12, large gap in plate - detectable emissions with TVA 63 IMG_0134.JPG 2022:07:27 10:49:16 Hole in metal plate - equipment 94S12 64 IMG_0135.JPG 2022:07:27 10:52:10 Seam in plate cover, west side of equipment 94S12 65 IMG_0136.JPG 2022:07:27 10:54:04 Equipment 94S12 - spray painted areas where detectable emissions were detected with TVA Appendices Page 3 of 13 Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 66 IMG_0137.JPG 2022:07:27 11:04:09 Outbox hatch on equipment 94S12 - detectable emissions with TVA 67 IMG_0138.JPG 2022:07:27 11:08:04 West side of equipment 94S12 68 IMG_0139.JPG 2022:07:27 11:08:39 Middle of equipment 94S12 - detectable emissions with TVA 69 IMG_0140.JPG 2022:07:27 11:10:42 Equipment 94S12, gap in seal of plate 70 IMG_0141.JPG 2022:07:27 11:14:14 Outlet box of tank 7A - detectable emissions with TVA 71 IMG_0142.JPG 2022:07:27 11:16:38 Waterman gate lift on equipment 95S12 72 IMG_0143.JPG 2022:07:27 11:22:30 Northeast corner of 7A 73 IMG_0144.JPG 2022:07:27 11:50:29 Caulking on DNF A - 94-ME-430A 74 IMG_0145.JPG 2022:07:27 11:55:57 Hatch/connector on DNF A with method 21 tags 75 IMG_0146.JPG 2022:07:27 11:56:45 Northeast corner of 94-ME-430B - detectable emissions with TVA 76 IMG_0147.JPG 2022:07:27 12:11:45 Northwest corner of east hatch, equipment 94- ME-430B - detectable emissions with TVA 77 IMG_0148.JPG 2022:07:27 12:14:45 Caulk on north side corner of equipment 94- ME-430A (DNFA) 78 IMG_0149.JPG 2022:07:27 12:19:52 New DAF - Equipment 94V21 79 IMG_0150.JPG 2022:07:27 12:21:46 Caulk on south side of new DAF 80 IMG_0151.JPG 2022:07:27 12:26:18 Caulk and oil on top of 94-V21 - north side of equipment 81 IMG_0152.JPG 2022:07:27 12:45:04 Southeast corner of the top of DAF-94-V4 82 IMG_0153.JPG 2022:07:27 12:45:15 South side of the top of DAF-94-V4 83 IMG_0154.JPG 2022:07:27 12:47:02 Top of DAF-94-V4 84 IMG_0155.JPG 2022:07:27 14:33:29 Roof of vessel 2C 85 IMG_0156.JPG 2022:07:27 14:35:42 Conservation vent over sludge with caulk and cracks (in between 2C and 2B) 86 IMG_0157.JPG 2022:07:27 14:40:49 Dirt from foam event on top of sludge basin, in between 2B and 2A 87 IMG_0158.JPG 2022:07:27 14:41:00 Dirt from foam event on top of sludge basin, in between 2B and 2C 88 IMG_0159.JPG 2022:07:27 14:43:39 Wood on top of sludge basin, in between 2B and 2A 89 IMG_0160.JPG 2022:07:27 15:12:08 Caulk on all of the drill/nail locations - tank 2A 90 IMG_0161.JPG 2022:07:27 15:15:05 No caulk on drill/nail locations - vessel 2B 91 IMG_0162.JPG 2022:07:27 15:17:49 Crack in viewing window of vessel 2A 92 IMG_0163.JPG 2022:07:27 15:23:23 Vessel 2A, trans pump area, caulk on handles 93 IMG_0164.JPG 2022:07:27 15:27:33 Vessel 2A, crack and caulk in viewing window 94 IMG_0165.JPG 2022:07:28 11:00:50 28SB5202OWS Junction Box Appendices Page 4 of 13 Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 95 IMG_0166.JPG 2022:07:28 11:02:55 28SB5191OWS Junction Box 96 DC_0444.JPG 2022:07:28 10:32:40 LDSN Sensor No. DC444 Appendices Page 5 of 13 Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 APPENDIX 2: FLIR VIDEO LOG Video Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 File Name MOV_0423.mp4 MOV_0424.mp4 MOV_0425.mp4 MOV_0426.mp4 MOV_0428.mp4 MOV_0429.mp4 MOV_0430.mp4 MOV_0431.mp4 MOV_0432.mp4 MOV_0433.mp4 MOV_0434.mp4 MOV_0435.mp4 MOV_0436.mp4 MOV_0437.mp4 MOV_0438.mp4 MOV_0439.mp4 MOV_0440.mp4 MOV_0441.mp4 MOV_0442.mp4 MOV_0443.mp4 Date and Time YYYY:MM:DD Time (Central Time) 7/26/2022 11:58 7/26/2022 12:10 7/26/2022 15:56 7/26/2022 16:31 7/26/2022 16:49 7/26/2022 17:00 7/27/2022 10:11 7/27/2022 10:14 7/27/2022 10:18 7/27/2022 10:21 7/27/2022 10:31 7/27/2022 10:43 7/27/2022 10:52 7/27/2022 11:05 7/27/2022 11:10 7/27/2022 11:14 7/27/2022 11:34 7/27/2022 11:43 7/27/2022 11:49 7/27/2022 12:25 Description of Image API external roof Rain cap on API external roof Aft Bay seam on east side plate between the second and third bolt from the North; sample collection. Tank 205 conservation vents OWS API gap check ERROR V49 - west seal V49 - north PRV V49 - south seal V49 - south slotted guide pole V49 - south/middle slotted guide pole 7B - Southeast corner of mixer hatch West of hatch on 71806 7A rain cap - middle row, 4th from middle wall 7A rain cap 7A - base of inlet box West seal on tank 63 West seal on tank 64 S12 Sump ME121 Location where EPA summa canister taken Appendices Page 6 of 13 Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 APPENDIX 3: FIELD MEASUREMENT DATA The table below summarizes EPA's TVA 2020 monitoring results: Number Component ID TVA - SL1555 Equipment EPA's Type Reading (ppm) 1 94 B1 Underground 1000 sump leading into the API forebay 2 94 B1 Underground 860 sump leading into the API forebay 3 94 B1 Underground 770 sump leading into the API forebay 4 94 B1 Underground 6800 sump leading into the API forebay 5 94 B1 Underground 998 sump leading into the API forebay 6 94 B1 Underground 1600 sump leading into the API forebay 7 94 B1 Underground 770 sump leading into the API forebay 8 - West of walkway 578 over inground API 9 - West of walkway 1031 over inground API 10 - West of walkway 700 over inground API 11 Third bolt on the 1520 - west side of walkway over inground API 12 Second bolt on the 717 - west side of walkway over inground API Flint Hills' Confirmation Reading (ppm) 1640 Additional Notes At caulk seal 5079 1020 42000 16555 10000 1189 572 787 833 1699 Crack in cement Crack in cement Crack in caulk seal Crack in cement Crack in cement Crack in cement Caulk seal Caulk seal Caulk seal - Appendices Page 7 of 13 Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 13 94 S2 Bolt 7000 2002 14 94 S2 Corner of cement 750 15 259A First pressure 10000 Siemens relief hatch 16 259A First pressure 600 Siemens relief hatch 17 259A Second pressure 763 Siemens relief hatch 18 Gasket 1200 - 19 - Inlet box for 7B 3795 20 94 S12 Sump 20000 1386 2500 667 535 1779 3200 1283 21 94 S12 Sump 4000 10000 22 94 S12 Sump 700 604 23 94 S12 Sump 530 1100 24 94 S12 Sump 1085 1305 25 94 S12 - Sump 1300 3000 446A 26 7A Outlet box hatch 3800 5191 27 7A Outlet box hatch 760 1200 28 - Primary carbon 4000 - can next to 94 S12 29 - Secondary carbon 1031 - can next to 94 S12 30 Primary carbon 2800 800 - can near parking lot - sewer system Secondary carbon 2800 2500 - can near parking 31 lot - sewer system 39ME12B - Primary carbon 2050 4569 32 49B can for sump 39ME12B - Secondary carbon - 31 33 49B can for sump 39ME12B - Primary carbon 180 283 34 49D can for sump Appendices Page 8 of 13 Crack in caulk seal around bolt in NW corner Near third pressure relief hatch Crack in cement Crack in caulk next to fire extinguisher Gap in sheet metal cover Northeast corner of 446C Between 446C and 446 A East of 446A Caulk on ground Flint Hills' PID read 57 ppm Flint Hills' PID read 0 ppm Flint Hills' PID read 0 ppm Flint Hills' PID read 0 ppm Flint Hills' PID read 186 ppm Flint Hills' PID read 0 ppm Flint Hills' PID read 5 ppm Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 39ME12B - Secondary carbon 76 35 49D can for sump 18ME133 - Primary carbon 252 36 50 can for sump 18ME133 - Secondary carbon 55 37 50 can for sump 45ME245 - Primary carbon 4 38 62B can for sump 45ME245 - Secondary carbon 4 39 62B can for sump 45ME245 - Primary carbon 79 40 62A can for sump 45ME245 - Secondary carbon 164 41 62A can for sump 33ME91A - Primary carbon 174 42 60 can for sump 33ME91A - Secondary carbon 14 43 60 can for sump TVA - A56575 44 94ME176 4th bolt cement 3500 45 94ME176 SW corner cement 10,000 46 94ME176 8th bolt North on 2800 west side 47 94ME176 Crack in cement 785 between 6th and 7th bolt on west side 48 94ME176 Crack in cement 1850 by 15th bolt on west side 49 Inlet chamber and 5600 trash racks to API - forebay; Seam running N-S crack between cover plates 50 Inlet chamber and 43000 trash racks to API - forebay; North wall corner cement foundation by 8th bolt east 51 Forebay rain cap 1547 - on NW floating roof API 27 260 11 4 4 24 649 267 12 586 6500 19568 1435 3211 19008 7606 2145 Appendices Page 9 of 13 Flint Hills' PID read 0 ppm Flint Hills' PID read 87 ppm Flint Hills' PID read 7 ppm Flint Hills' PID read 0 ppm Flint Hills' PID read 0 ppm Flint Hills' PID read 0 ppm Flint Hills' PID read 0 ppm Flint Hills' PID read 0 ppm Flint Hills' PID read 0 ppm Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 52 - Forebay out of 131 service auger 53 Forebay top 13500 - corner of API roof north wall 54 - Forebay seal of 2600 SW API roof 55 Sump 9452 North wall API 680 crack on sump wall 56 Sump 9452 Bolt on west side 10300 57 Sump 9452 Bolt on west side 6800 58 Sump 9452 Seam on west side 26900 11399 2599 1827 13130 33110 - 59 Sump 9452 Seam on west side 722 1200 60 - Aft Bay plate 973 1140 (NW corner) 61 - Aft Bay plate (N 1015 1901 side) 62 - Aft Bay plate (E 22,000 30,000 side) 63 - Aft Bay wall (S 8000 20551 side) where external API roof meets Aft Bay 64 - Aft Bay seam in 3800 670 concrete where external API roof meets Aft Bay 65 - Aft Bay wall (N 800 727 side) where external API roof meets Aft Bay 66 - Aft Bay wall (SW 1988 5325 corner) where external API roof meets Aft Bay 67 - Prong on top of 2081 2217 metal plate (SW corner) Appendices Page 10 of 13 Pump turned off before a confirmatory reading could be done by company Location where summa canisters were taken by EPA Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 68 94512 Outlet box to 7A 1015 and 7B; SW corner plate 69 94512 Outlet box to 7A 636 and 7B; plate near base level gage (ID 71805) 70 94512 Outlet box to 7A 1.10% and 7B; W side plate 71 94512 Outlet box to 7A 4096 and 7B; W side plate 72 94512 Outlet box to 7A 2.42% and 7B; NW side plate 73 Outlet box to 7A 7056 - and 7B S12; North plate (near tag ID #94P446B) 74 Outlet box to 7A 682 - and 7B S12; base of tag ID #71797) 75 Outlet box to 7A 3.5% - and 7B S12; seam between North and South plate 76 Outlet box to 7A 2036 - and 7B S12; seam of plate 77 Outlet box to 7A 968 - and 7B S12; seam of plate 78 94ME430B DNF B west hatch 659 (NE corner) 79 94ME430B DNF B west hatch 1336 (NE corner) 80 94ME430B DNF B east hatch 680 (NW corner) 81 39 Unit Carbon canister 1370 Major Sump- primary 49A 82 39 Unit Carbon canister 124 Major Sump- secondary 49A 1440 884 605 3001 45000 2465 40901 682 5300 555 1000 934 1803 77 Appendices Page 11 of 13 Company unable to confirm Company PID measured 34 Company PID measured 0 Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 83 39 Unit Carbon canister 1211 Major Sump- primary 49C 84 39 Unit Carbon canister 83 Major Sump- secondary 49C 85 18ME130-51 Carbon canister 223 primary 86 18ME130-51 Carbon canister 3558 secondary 87 17ME270-52 Carbon canister 41 primary 88 17ME270-52 Carbon canister 3 secondary 89 45ME25- Carbon canister 4 61A primary 90 45ME25- Carbon canister 3 61A secondary 91 45ME25- Carbon canister 4 61B primary 92 45ME25- Carbon canister 4 61B secondary 1219 39 11000 3100 86 6 - Company PID measured 26 Company PID measured 0 Company PID measured 76; EPA TVA flamed out Company PID measured 0 Company PID measured 0 Company PID measured 0 Company PID measured 0 Company PID measured 0 Company PID measured 0 Company PID measured 0 Calibration and Instrument Information EPA used two ThermoFisher Toxic Vapor Analyzers 2020 (TVA2020). The EPA TVA2020 response times are about 4 seconds. 7/26/2022 Calibration 8:41 average calibration reading, 500 ppm gas 13:43 bump check reading, 500 ppm gas A56575 497 ppm 501 ppm SL1555 492 ppm 498 ppm 7/27/2022 Calibration 8:25 average calibration reading, 500 ppm gas 13:05 bump check reading, 500 ppm gas A56575 517 ppm 499 ppm SL1555 496 ppm 498 ppm Appendices Page 12 of 13 Facility Name: Flint Hills Resources Pine Bend Refinery Facility Location: 13775 Clark Rd, Rosemount, MN 55068 Date of Inspection: 7/25/2022 - 7/28/2022 Calibration Gas Information EPA calibration gases Composition Manufacturer CALGAZ Air zero grade THC <1 ppm GASCO Methane in air 500 ppm GASCO Methane in air 1960 ppm GASCO Methane in air 10,000 ppm Lot # 1486172 304-402110297-2 304-402110299-1 304-402110296-1 Expiration May 2026 May 2025 May 2025 May 2025 Appendices Page 13 of 13