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This story was co-published with The Desert Sun, a member of the ProPublica Local Reporting Network.

In May 2019, workers in California’s Central Valley struggled to seal a broken oil well. It was one of thousands of aging wells that crowd the dusty foothills three hours from the coast, where Chevron and other companies inject steam at high pressure to loosen up heavy crude. Suddenly, oil shot out of the bare ground nearby.

Chevron corralled the oil in a dry streambed, and within days the flow petered out. But it resumed with a vengeance a month later. By July, a sticky, shimmering stream of crude and brine oozed through the steep ravine.

Workers and wildlife rescuers couldn’t immediately approach the site — it was 400 degrees underground, and if the earth exploded or gave way, they might be scalded or drown in boiling fluids. Dizzying, potentially toxic fumes filled the scorching summer air. Lights strobed through the night and propane cannons fired to ward off rare burrowing owls, tiny San Joaquin kit foxes, antelope squirrels and other wildlife.

An aerial view of the Chevron spill in the Cymric field on July 13, 2019. (Obtained by ProPublica and The Desert Sun via a Public Records Act request)

Over four months, more than 1.2 million gallons of oil and wastewater ran down the gully.

California had declared these dangerous inland spills illegal that spring. They are known as “surface expressions,” and the Cymric field was a hot spot. Half a dozen spills and a massive well blowout had occurred there since 1999. This time, faced with news headlines and a visit by Gov. Gavin Newsom to the site, officials with the California Geologic Energy Management Division, or CalGEM — the main state agency overseeing the petroleum industry — ordered Chevron to stop the flow. Regulators later levied a $2.7 million fine on the company.

Instead, Chevron profited.

Amid the noise and heat, trucks arrived daily to vacuum out the oil from a safe distance. It was refined, sold and shipped to corner gas stations, bringing the company $399,000, according to state records. Chevron appealed the fine, saying while “we fully accept — and take responsibility for — our actions,” it does not believe the spill, known as Cymric 1Y, posed a threat to human health. The company has yet to pay, and CalGEM has not moved forward with an appeal hearing.

Along with being a global leader on addressing climate change, California is the seventh-largest producer of oil in the nation. And across some of its largest oil fields, companies have for decades turned spills into profits, garnering millions of dollars from surface expressions that can foul sensitive habitats and endanger workers, an investigation by The Desert Sun and ProPublica has found.

California Oil Spills Earn Companies Millions

For years, companies have corralled spilling oil in four large fields and sold it.

Shoshana Gordon/ProPublica. Source: California Department of Conservation

Since the new regulations outlawed surface expressions last year, more than two dozen have occurred in Kern County, the heart of the state’s oil industry. In the Cymric field, three spills are still running, state officials say, including one that’s spilled nearly twice as much as the one for which Chevron was fined.

Dozens of older spills have also flowed for years, the investigation found. The largest, just around the bend from Cymric 1Y, started in 2003. The site, also operated by Chevron and dubbed GS-5, has since produced more than 16.8 million gallons of oil and about 70 million gallons of wastewater, a company spokeswoman said. That tops the amount of oil spilled by the Exxon Valdez, the infamous tanker that ran aground in Alaska in 1989. In the last three years alone, the crude collected from GS-5 has generated an estimated $11.6 million, according to an analysis of production data provided by the state.

Chevron and state regulators say they’re trying to shut down GS-5 and they have reduced the flow by 90%. It was spilling approximately 15,000 to 23,000 gallons of fluid a day in early February, the latest date for which the state provided detailed data. Ten to 15% of that was oil, officials said.

“We take our responsibility to operate safely and in a manner that protects public health, the communities where we operate and the environment very seriously,” company spokeswoman Veronica Flores-Paniagua said. “We remain committed to stopping and preventing seeps consistent with the updated state regulations.”

But a close review of the state’s new rules shows they contain several large loopholes that keep oil from surface expressions flowing — the result of years of lobbying and pushback by the energy industry.

Vacuum trucks suck thousands of gallons of oil and wastewater a day out of the GS-5 spill, near McKittrick. GS-5 is one of the largest and longest-running surface expressions. (Jay Calderon/The Desert Sun)

For example, over stiff opposition from environmentalists, state officials explicitly allowed high-pressure “steam fracking,” a controversial extraction technique that has been linked to surface expressions. And when spills break out, there is nothing stopping producers from turning them into moneymakers. In a practice known as “containment,” companies can corral the spills with dirt berms, netting, pipes or drains; vacuum out the crude; refine it and sell it. The 2019 regulations spell out steps companies must take to try to halt the spills — mainly temporarily ceasing steam injection — but there are no deadlines for stopping them and restoring the sites.

The new rules also largely exempt “low energy” surface expressions related to oil production. According to a review of state and local records, the exemption appears to cover more than 70 older spills that are still revenue generators.

A cache of internal documents, photos and video obtained by The Desert Sun and ProPublica shows that over the past quarter century, CalGEM has routinely allowed oil companies to contain and commercialize surface expressions, despite warnings by staffers about environmental and human harm. The agency acknowledges that more than 160 containment structures have been built to corral spills since the late 1990s.

The inland spills typically draw little attention, unlike major marine events that garner national headlines.

But hundreds of them have occurred, records show. Geysers of oil, rock and mud have shot skyward 100 feet, and slopes have collapsed under smoking waterfalls of crude and wastewater. In one case, a worker died; in another, an employee had to wrench his ankle away from a sudden sinkhole; and a third had to abandon his truck as a dark stain of oil mushroomed beneath it.

A Berry Petroleum Co. surface expression in the Midway-Sunset Oil Field in August 2011. (Obtained by ProPublica and The Desert Sun via a Public Records Act request)

“Keep in mind that these eruptions are not at well sites,” wrote then-Oil and Gas Supervisor Elena Miller in a 2011 email to her boss. “These are locations where the earth opens up and spews fluids, solids and gases.”

Oil company representatives defend their practices, saying surface expressions mirror natural seeps of crude and come with harvesting a product that provides thousands of well-paying jobs and fuels car-centric California. Containing the spills, they added, also costs money. Chevron, for instance, told lawmakers this year that it had spent $9 million to try to halt spills in the Cymric field.

Environmentalists who fought for the regulations are furious about the loopholes and the continued spills.

“It’s completely obscene that oil companies can cause an oil spill and then profit off it,” said Hollin Kretzmann, an attorney with the Center for Biological Diversity, an environmental nonprofit organization.

CalGEM could not provide a full accounting of how much oil has spilled from surface expressions, even though the 2019 regulations explicitly require that oil companies report production numbers. The agency also declined to provide spill maps and plans mandated by the new rules, citing, in part, “multiple ongoing legal investigations,” including a departmental probe of the Cymric spills and ongoing litigation between Chevron and another company involving the field where the worker died.

“We are greatly reducing the problem. We continue to make progress, but more work is needed,” state Oil and Gas Supervisor Uduak-Joe Ntuk said in a statement. He noted that the practices had developed over decades, and that the new regulations were crafted under his predecessor and then-Gov. Jerry Brown.

“This Administration has made it clear that surface expressions are unacceptable and will not be tolerated as the cost of doing business,” he said.

After visiting Chevron’s Cymric 1Y spill site last year, Newsom pledged to “tighten things up.” In November, his administration placed a statewide moratorium on new permits for steam fracking, a suspected root cause of many surface expressions, and hired scientists with the Lawrence Livermore National Laboratory to study whether the method can be used safely.

Ntuk said that while that review is in progress, the agency is cracking down. He has the power to fine companies $25,000 a day for ongoing spills. But other than the one, unpaid fine against Chevron, he has not imposed any financial penalties for surface expressions, instead issuing “notices of violation” — citations that Ntuk has compared to “parking tickets.” He said that approach is working; many spills have stopped and some companies are working proactively to seal abandoned, often damaged wells to prevent future spills.

Companies with existing permits, however, are free to keep steam fracking — and to scoop up any oil that cracks the surface.

Some experts say the current reality is reminiscent of the 19th-century oil rush.

“It reminds me of the industry back when you’re watching ‘There Will Be Blood’ and they used to let this stuff explode out of the ground and collect it,” said Deborah Gordon, a Brown University senior fellow, who researched California’s Midway-Sunset field, where many surface spills occur. Her group concluded it emitted more greenhouse gases than any oil field in the nation. “This is not where this industry needs to be.”

After 150 Years, California’s Oil Gets Harder to Extract

Oil production in California began in the 1850s, just as its famous gold rush was petering out. Tantalized by visible natural “seeps,” companies large and small drilled wells across the state, hoping to hit paydirt. While profits could be big, so could the spills.

In 1910, a Kern County wellhead blew out. Oil skyrocketed from the ground. Over 18 months, the Lakeview Gusher spilled 395 million gallons, creating a pool so deep and wide that men rowed boats across it. It still holds the record for the largest oil spill in U.S. history, dwarfing BP’s Deepwater Horizon disaster, which leaked 210 million gallons into the Gulf of Mexico.

Top, the Lakeview Gusher in 1910. Above, men row on the lake of oil created by the spill. (San Joaquin Geological Society)

The California Division of Oil and Gas — the precursor to today’s CalGEM — was formed in 1915. Until this year, the agency’s primary mission was clear: Maximize the production of petroleum and other energy resources. That included helping companies relocate water that interfered with oil, both freshwater supplies and the briny waste that gushes from wells along with crude.

After decades of extraction, pumping California’s increasingly tarry reserves became tougher. Much of it was locked underground in diatomites — tightly packed layers of ancient, tiny sea skeletons whose algal innards compressed over milleniums into gooey crude. (Cat litter is made of diatomaceous earth scraped off Kern County hillsides.) By the 1960s, researchers discovered that flooding the subterranean reservoirs with steam or injecting it in cycles, through a process known as “huff and puff,” worked well.

The huff phase involves injecting scalding steam down wellbores, then letting the heat melt the tar. The puff portion refers to softened crude, thin as heated maple syrup, rising up through production wells. When the flow slows, another steam cycle begins. The technique is called “cyclic steaming.”

By the late 1990s, companies were using a supercharged version of it: steam fracking. Producers injected steam down well bores at pressures high enough to crack brittle underground formations so oil could ooze upward. Nearly half of the oil in the state is produced from cyclic steaming, according to a University of California, Berkeley, report issued in April.

How Cyclic Steaming Can Create Pools of Boiling Oil

This example is modified from a model of a geographical cross section of the Midway-Sunset Oil Field by Ahinoam Pollack, Stanford University, published in a March 2020 study. (Lucas Waldron/ProPublica)

But blasting old, often damaged wells with steam had an unintended side effect: surface expressions. Like underground tea kettles blowing their tops, seeps of gas, mud, oil and rock erupted in a dozen oil fields. Five companies reported scores of spills over more than 20 years. Chevron alone logged 64 surface expressions between 1997 and 2010, according to a report it sent to CalGEM.

Typically, CalGEM has told oil field operators to “shut in” wells near a surface expression, meaning temporarily cease nearby steam injection or drilling. Usually, the spill would stop or slow within days. If it didn’t, the agency has ordered them to stop steaming in an ever-larger radius. But some spots sprang leaks again and again or spilled large amounts for years. With CalGEM’s approval, companies turned these into de facto — but permanent — production sites, even in creeks and ravines supposedly protected by environmental laws.

CalGEM got revenue too — the agency is completely funded by the industry it regulates, and this year will receive 67 cents for every barrel of oil produced.

“The Earth Had Literally Cracked Open”

U.S. House Minority Leader Kevin McCarthy, a Republican whose district includes Kern County oil fields, once called Sandy Creek a “ditch” and claimed it hadn’t rained there in 30 years. The creek, which in the 1800s ran miles from the Temblor Mountains to the then-vast Buena Vista Lake, is now dry most of the year.

But when winter rains fall, the creek flows. State biologists documented sections that are home to breeding western toads, cliff swallows, California quail, kildeer and other birds passing through on long migrations.

In 1998, near Sandy Creek’s headwaters, Aera Energy and two other companies began injecting steam into wells in the soft dirt. A web of surface expressions quickly developed, with continuous oil pools forming in the streambed. They’re still flowing 22 years later.

Rather than shutting down production, Aera reshaped the landscape. It installed a 400-foot-long metal pipe, diverting rainwater from its natural path so the crude could continue to flow into the creekbed. Although the spills were still running, they were considered contained; the oil was confined to open-air pools. Nets were slung over them to prevent birds from flying in.

Aera and TRC, another oil company that leased adjoining property, periodically pumped out the oil and sold it. State oil regulators later said in an internal report that Aera was producing about 3,000 gallons of crude and waste a day from Sandy Creek.

Under state laws, it’s illegal to discharge any hazardous substance into a creek or streambed, dry or not. The California Department of Fish and Wildlife, which enforces those laws, said it can issue temporary permits for cleanup activities, but not for permanent alterations of a streambed. “The Department sees oil spills as emergencies, and its role is to respond to minimize harm to wildlife and clean up ASAP,” a spokesman told The Desert Sun and ProPublica. The department did not respond to questions about whether it has ever cited or fined companies that have spilled oil and altered the streambed in Sandy Creek.

TRC did not respond to requests for comment. Aera, which has since sold its Sandy Creek leases, declined to comment on past surface expressions there, but it said in a statement that the company “uses a combination of innovation, engineering, and technology to ensure that we are producing California’s energy under the most environmentally responsible and safe conditions in the world.”

The containment approach wasn’t foolproof.

In fall 2010, heavy rains sparked flash floods, dismembering the metal culvert. Days before Christmas, rains fell again. The creek reclaimed its natural channel, shoving crude and wastewater 10 miles downstream, through the town of Taft and out the other end.

The aftermath of flash floods in Sandy Creek, where Aera had installed a metal culvert to divert rainwater from its natural path. (Obtained by ProPublica and The Desert Sun via a Public Records Act request)

Bruce Joab, a California Fish and Wildlife senior scientist who assesses the environmental damage wreaked by oil spills, still recalls Sandy Creek after the storms.

“I was actually shocked at how torn up that upper end of the watershed was,” Joab said. Rusted pipes, steam manifolds and other heavy debris littered the bed. “It was hard to distinguish where the creek began and the oil operation began.”

Field warden colleagues who’d seen many surface expressions warned him to watch his step.

“There were places where the earth had literally cracked open and oil was spilling out,” he recalled.

When spills occur, CalGEM employees work side by side with oil companies to investigate the causes. Chevron officials, for instance, were part of the team that responded to and probed the causes of last summer’s Cymric 1Y spill. Ntuk said that approach is required by state law.

In Sandy Creek, a CalGEM staffer documented the flood damage and spills with dozens of photographs and said in a lengthy report to supervisors that the surface expressions there were caused by steam operations. CalGEM, however, did not include Sandy Creek in a tally of surface expressions it provided to The Desert Sun and ProPublica, saying the situation is “still under evaluation and has not yet been categorized.” CalGEM provided no evidence it has ever cited or fined companies for damage after the 2010 floods or after more oily floods in 2016.

Sandy Creek is just one place where companies have constructed elaborate containment structures.

They can carry a heavy cost.