Damon Shodrock, CSPSafety & Security Supervisor

Calumet San Antonio Refinery

5S + Safety Finds a New Home at an Old Refinery

Company OverviewCalumet Specialty Products Partners, L.P. is a leading independent producer of high-quality, specialty hydrocarbon products. Our product lines include both naphthenic and paraffinic oils, aliphatic solvents, synthetic lubricants, asphalt, fuels, white mineral oils, waxes, petrolatums and hydrocarbon gels.

NASDAQ: CLMTHQ: Indianapolis, INFortune 500 Company: 2014 & 2015

Calumet San Antonio Refinery (CSAR) Past• Built by Howell Hydrocarbons in the 1950s

• Legacy of the AGE Ownership

• Calumet Spills April & May 2014

CSAR 2015 SAFETY IMPROVEMENT PLANSTRATEGIES TACTICSPromote Operational Excellence

1. Author and collaborate on well written procedures.2. Conduct Root Cause Analysis for significant events and drive completion of CAPA.

Foster Professional & Technical Competence

1. Deliver top quality training.2. All Operators fully trained on Emergency Response Team

(ERT).3. Launch 10 computer training center in the break room.4. Develop leadership path within the ERT.

Develop Outstanding Safety Culture

1. Launch Behavior and Conditions Observation Program.2. Launch “STOP Card” Program.

Fatality & Severe Loss Prevention

1. Conduct operational discipline gap assessment against top 10 OSHA serious violations.

2. Routinely audit facilities for vulnerabilities.

CSAR 2015 SAFETY IMPROVEMENT PLAN

CSAR Future

• High-grade solvents

• Strengthen our Community Advisory Panel (CAP)

• Continue building relationships local first responders.

• Continue building relationships w/ neighborhood groups.

April 5, 2015. San Antonio Express News. Business Section.

CSAR Future

February 15, 2016. KSAT News. 10 PM. Tim Gerber, Reporter“South Side oil refinery opens up to show off upgrades”

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Why 5S?Company Image. Increase Employee Morale. “Customers” Demand It.

(Direct Customers, ISO & VPP Auditors, etc.)Less for Regulators to Observe.Eliminates Waste/ Better Time Management. Improves Quality.

le.

The 5S's –an English “Translation”

Sort: Clear the work area

Set in Order: Designate locations

Shine: Cleanliness & workplace appearance

Standardize: Everyone doing things the same way

Sustain: Ingraining the 5S’s into the culture

Baseline Findings

Crane leaking hydraulic fluid.

Faded labels and rusty tank .

Evidence of tank overfilling.

Broken X-Ray Machine Tossed in the Control

Room Hallway.

Abandoned Chairs or Trashy Chairs?

Access to Electrical Panel Blocked.

Baseline Findings

Why 5S?Before–Hazardous Waste Storage Room

Why 5S?After–Hazardous Waste Storage Room

First Attempts @ 5S at Calumet …• Refinery PPE Cabinets• LOTO Locks and Lock Box Cabinets• Loading Rack Spill Response Supplies

Photo: William Luther /San Antonio Express-News

SORT

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Sort = only what is needed in the work area. Applies to all work areas.

Set in OrderEXAMPLE: First Aid cabinet after SORT and SET IN ORDER.

ShineMore than making the work area spic and span.Shine Objectives: 1. Getting the workplace clean, 2. Maintaining its appearance, and 3. Using preventive measures to keep it clean.

Before Sort, Set in Order, and Shine

After Sort, Set in Order, and Shine

Standardize• Must Have Clear Roles and Responsibilities.

• Train Personnel to Consistently Apply 5S Techniques.

StandardizeExpectations for All Employees:•No leaks, spills, or liquids found on floors. •Leaks reported and repaired.

StandardizeExpectations for All Employees:•No items stored on or around equipment.•Consolidate supplies & parts to prevent unnecessary stock.

StandardizeExpectations for All Employees:•Items not part of a ongoing job (48 hour rule) should be cleaned up and properly stored.•Every item stored should have a designated location (ex. floor marking, shelf label.)•Stored items should be stored neatly.

SustainAudit Weekly

Track Progress by Owner

Maxim Integrated Products5S Board

SustainAudit Weekly

Track Progress by Owner

Calumet San Antonio Refinery5S + Safety Checklist & Progress Board

LOCATION DATE SCORE # OF ACTIONS DATE SCORE # OF ACTIONSHazardous Waste Cage 2/18/201610.2 ± 3.1 4Rail Loading 7/22/201619.2 ± 5.0 5ULSD Unit 9/23/201619.4 ± 4.3 2Flare Safety Area 10/28/201617.5 ± 3.1 0JPTS Tank Farm 7/29/201610.4 ± 2.9 1RO Unit 11/4/201615.0 ± 2.8 1Crude Unit 10/21/201614.6 ± 3.5 2ASU Unit 10/14/201620.5 ± 3.9 3Refinery Warehouse 9/16/201611.3 ± 7.5 0300 Tank Farm 10/28/201620.6 ± 2.4 2Drum Dock 4/6/20169.8 ± 3.1 6200 Tank Farm 11/11/201620.3 ± 3.0 0Elmendorf Terminal 12/16/201619.5 ± 2.1 3400 Tank Farm 12/2/201610.7 ± 2.0 2Brooks Shop & Backlot 8/12/201615.4 ± 7.0 2South 40 9/2/20165.0 ± 4.7 4100 Tank Farm 9/9/20167.5 ± 3.5 2Cooling Towers 7/15/20167.0 ± 1.8 4SFU Unit 11/4/201622.0 ± 1.4 1Staging Lot & 430 Tanks 11/18/201615.0 ± 1.0 3Brooks Warehouse 1/6/201720.2 ± 4.2 1Brooks Lab 1/13/201718.5 ± 2.4 4Brooks Bunker Room 1/20/201712.7 ± 4.3 2Brooks Office 1/20/201711.9 ± 4.6 5Control Room 1/27/20179.3 ± 2.1 1Truck Loading Rack Office 1/27/20178.7 ± 2.3 1

Sustain = Audit & Track Action Items to Closure

Showing Pride in Our Facility Through HousekeepingSSustain = Leader Reminder & Support

Before: Refinery Drum Dock Random Vehicle Parking

After: Refinery Drum Dock Accessible

Before: Heavy Equipment Parking

After: Heavy Equipment Parking

Before: Refinery Drum Dock Storage

After: Refinery Drum Dock Storage

After: Refinery Drum Dock Storage

Before: Tank 431 Curved Stair Treads

After: Tank 431 Curved Stair Treads

Before: 200 Tank Farm Walkway

After: 200 Tank Farm Walkway

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Before: Brooks Lab Chemical Storage Canopy

After: Brooks Lab Chemical Storage Canopy and Satellite Waste Accumulation Area

Before: Safety Zone Marking

After: Safety Zone Marking

After: Safety Zone Marking

Before: Standardization of Swing Gates

After: Standardization of Swing Gates

Before: Accumulator Row Platform

After: Accumulator Row Platform

Before: Unit Work Permits

After: Unit Work Permits

Before: Vehicle Bollard Protection

General Information

Incident Short Description: Silver Ford pickup ran through truck rack fence

Detailed Description:

at approx. 0400 hrs. a silver ford pickup truck ran through truck rack fence. As I pulled up to the loading rack I saw a silver ford pickup leaving out of the truck rack. I asked the operators what happened and they told me he just ran through the fence on the NE side of the truck rack. I called the duty manager and he called the on duty safety rep and I called SAPD Case # SAPD16120003 Officer M. Hollenbeck #370

Initial Corrective Action: called Duty Manager

Location Details

Site: San Antonio Refining

Unit:

Shift: Shift D

Area where incident took place: Truck Rack NE fence

Before: Vehicle Bollard Protection

After: Vehicle Bollard Protection

5S + Safety Can Be Fun!

Sustain: Overview of Roles and ResponsibilitiesEveryone: 5S becomes part of culture and is entrenched in our everyday work

Owners, Supervisors & Managers: Perform weekly audits of areas and enter action items into RegAction.

Damon Shodrock, CSPDamon.Shodrock@CLMT.com