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Pasadena Refinery

Parent Companies:
Pasadena Refining Systems, Inc.
EPA Facility ID:
100000038274
Other ID:
77506crwnc111re
Facility DUNS:
0
Parent Company DUNS:
184166325

Location:

Address:
111 Red Bluff Road
Pasadena, TX 77506
County:
HARRIS
Lat / Long:
29.724, -95.206 (Get map)
Method:
Classical Surveying Techniques
Description:
SW Corner of Land Parcel
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Pasadena Refining Systems, Inc.
Phone:
(713) 472-2461
Address:
111 Red Bluff Road
Pasadena, TX 77506
Foreign Address:

Person responsible for RMP implementation:

Name:
Karthick Poosekar
Title:
Process Safety Engineer

Emergency contact:

Name:
Ron Sommers
Title:
Emergency Res. & Sec. Coordinator
Phone:
(713) 920-3946
24-hour phone:
(281) 745-7482
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(713) 920-1310
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Pasadena LEPC
Full-Time Equivalent Employees:
345
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
O1544
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
July 7, 2014
Inspecting Agency:
EPA
Using Predictive Filing:
No

Processes:

Petroleum Refining
RMP ID:
1000077465
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ethane
74-84-0
880
No
2-Butene-trans [2-Butene, (E)]
624-64-6
33,000
No
Ethylene [Ethene]
74-85-1
400
No
Hydrogen
1333-74-0
3,600
No
Isobutane [Propane, 2-methyl]
75-28-5
5,400,000
No
Isopentane [Butane, 2-methyl-]
78-78-4
250,000
No
Methane
74-82-8
2,300
No
Pentane
109-66-0
138,000
No
1-Pentene
109-67-1
93,000
No
Propane
74-98-6
540,000
No
Propylene [1-Propene]
115-07-1
1,200,000
No
Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
7664-39-3
230,000
No
Chlorine
7782-50-5
20,000
No
1,3-Butadiene
106-99-0
1,300
No
Butane
106-97-8
5,900,000
No
1-Butene
106-98-9
120,000
No
Butene
25167-67-3
24,000
No
2-Butene-cis
590-18-1
26,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Karthick Poosekar
Address:
111 Red Bluff Road
Pasadena, TX 77506
Foreign Address:

Phone:
(832) 616-9244

Latest RMP Submission:

Date:
Jan. 17, 2017
Type:
Resubmission
Reason:
Voluntary update (not described by any of the above reasons)
Registered:
Yes
RMP ID:
1000061838

Deregistration:

Date:
Effective Date:
Reason:
Other Reason:

2. Toxics: Worst-case

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Petroleum Refining)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
10.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps

3. Toxics: Alternative release

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Petroleum Refining)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • Deluge systems
  • Excess flow valve
not considered:
  • Sprinkler systems
  • Water curtain
  • Neutralization
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Petroleum Refining)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Petroleum Refining)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Petroleum Refining)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown

4. Flammables: Worst-case

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Petroleum Refining)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Blast walls

5. Flammables: Alternative release

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Petroleum Refining)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

July 25, 2016 at 14:54
ID:
1000047642
NAICS:
Petroleum Refineries (32411)
Duration:
153 hours and 5 minutes
Chemicals involved:
  • Sulfur dioxide (anhydrous)
  • Propylene [1-Propene]
  • Ethylene [Ethene]
  • Propane
  • Butane
  • Butene
  • 1,3-Butadiene
  • Pentane
  • Hydrogen sulfide
Release events:
Gas release
Weather conditions at time of event
Wind speed:
5.0 miles/h S
Temperature:
88.00 ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
0
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$0
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
11113
Property damage:
$0
Environmental damage:
Initiating event:
Natural (weather conditions, earthquake)
Contributing factors:
  • Equipment failure
Off-site responders notified:
EPA, TCEQ, Harris County
Changes introduced as a result of the accident:
  • None
March 5, 2016 at 10:27
ID:
1000047641
NAICS:
Petroleum Refineries (32411)
Duration:
8 hours and 33 minutes
Chemicals involved:
  • Hydrogen sulfide
  • Sulfur dioxide (anhydrous)
  • Butane
  • Butene
  • Ethylene [Ethene]
  • Propane
  • Propylene [1-Propene]
  • Pentane
  • 1-Pentene
Release events:
Fire
Weather conditions at time of event
Wind speed:
7.0 miles/h NNW
Temperature:
75.00 ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
1
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$18000000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Equipment failure
  • Human error
  • Improper procedure
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised MOC procedure

7. Prevention: Program level 3

Petroleum Refining, Petroleum Refineries (32411)
Prevention Program ID:
1000065131
Safety Review Date
Nov. 12, 2012
PHA Update Date
Nov. 12, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
Process Controls
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Alarms
Mitigation Systems
  • Dikes
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 30, 2013
Training Review Date
Dec. 30, 2013
Maintenance Review Date
Jan. 1, 2005
Maintenance Inspection Date
Aug. 30, 2012
Equipment Tested
Yes
Management of Change Most Recent Date
None
Management of Change Review Date
May 1, 2012
Pre-startup Review Date
None
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Feb. 1, 2014
Hot Work Review Date
March 31, 2009
Contractor Safety Review Date
April 1, 2009
Contractor Safety Eval. Date
April 30, 2014
Petroleum Refining, Petroleum Refineries (32411)
Prevention Program ID:
1000065132
Safety Review Date
June 18, 2013
PHA Update Date
June 18, 2013
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Corrosion
  • Equipment failure
  • Cooling loss
Process Controls
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
Mitigation Systems
  • Sprinkler System
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 17, 2013
Training Review Date
Dec. 17, 2013
Maintenance Review Date
Jan. 1, 2005
Maintenance Inspection Date
March 11, 2013
Equipment Tested
Yes
Management of Change Most Recent Date
April 14, 2014
Management of Change Review Date
May 1, 2012
Pre-startup Review Date
March 4, 2014
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
Sept. 6, 2013
Incident Invest. Change Completion Date
Nov. 7, 2013
Participation Plan Review Date
Feb. 1, 2014
Hot Work Review Date
March 31, 2009
Contractor Safety Review Date
April 1, 2009
Contractor Safety Eval. Date
April 30, 2014
Petroleum Refining, Petroleum Refineries (32411)
Prevention Program ID:
1000065133
Safety Review Date
Oct. 20, 2009
PHA Update Date
Oct. 20, 2009
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Equipment failure
  • Cooling loss
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Alarms
  • Backup Pump
  • Grounding Equipment
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 19, 2013
Training Review Date
Dec. 19, 2013
Maintenance Review Date
Jan. 1, 2005
Maintenance Inspection Date
Sept. 5, 2013
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 16, 2013
Management of Change Review Date
May 1, 2012
Pre-startup Review Date
July 31, 2009
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Feb. 1, 2014
Hot Work Review Date
March 31, 2009
Contractor Safety Review Date
April 1, 2009
Contractor Safety Eval. Date
April 30, 2014
Petroleum Refining, Petroleum Refineries (32411)
Prevention Program ID:
1000065134
Safety Review Date
Dec. 7, 2011
PHA Update Date
Dec. 7, 2011
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Overfilling
  • Equipment failure
  • Cooling loss
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Feb. 4, 2009
Training Review Date
Feb. 4, 2009
Maintenance Review Date
Jan. 1, 2005
Maintenance Inspection Date
Feb. 12, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
June 20, 2014
Management of Change Review Date
May 1, 2012
Pre-startup Review Date
May 17, 2010
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Feb. 1, 2014
Hot Work Review Date
March 31, 2009
Contractor Safety Review Date
April 1, 2009
Contractor Safety Eval. Date
April 30, 2014
Petroleum Refining, Petroleum Refineries (32411)
Prevention Program ID:
1000065135
Safety Review Date
Oct. 22, 2012
PHA Update Date
Oct. 22, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Explosion
Process Controls
  • Relief Valves
  • Automatic Shutoffs
  • Alarms
  • Inhibitor Addition
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 11, 2013
Training Review Date
Dec. 11, 2013
Maintenance Review Date
Jan. 1, 2005
Maintenance Inspection Date
March 1, 2013
Equipment Tested
Yes
Management of Change Most Recent Date
None
Management of Change Review Date
May 1, 2012
Pre-startup Review Date
May 7, 2011
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
April 28, 2010
Incident Invest. Change Completion Date
Aug. 31, 2010
Participation Plan Review Date
Feb. 1, 2014
Hot Work Review Date
March 31, 2009
Contractor Safety Review Date
April 1, 2009
Contractor Safety Eval. Date
April 30, 2014
Petroleum Refining, Petroleum Refineries (32411)
Prevention Program ID:
1000065136
Safety Review Date
Oct. 22, 2009
PHA Update Date
Oct. 22, 2009
PHA Techniques
  • HAZOP
Hazards Identified
  • Overpressurization
  • Corrosion
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Grounding Equipment
Mitigation Systems
  • Dikes
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 30, 2013
Training Review Date
Dec. 30, 2013
Maintenance Review Date
Jan. 1, 2005
Maintenance Inspection Date
Jan. 29, 2013
Equipment Tested
Yes
Management of Change Most Recent Date
April 30, 2013
Management of Change Review Date
May 1, 2012
Pre-startup Review Date
May 10, 2013
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
Jan. 20, 2014
Incident Invest. Change Completion Date
Sept. 1, 2014
Participation Plan Review Date
Feb. 1, 2014
Hot Work Review Date
March 31, 2009
Contractor Safety Review Date
April 1, 2009
Contractor Safety Eval. Date
April 30, 2014
Petroleum Refining, Petroleum Refineries (32411)
Prevention Program ID:
1000065137
Safety Review Date
April 27, 2011
PHA Update Date
April 27, 2011
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Overpressurization
  • Cooling loss
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Automatic Shutoffs
  • Alarms
  • Rupture Disks
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Oct. 24, 2013
Training Review Date
Oct. 24, 2013
Maintenance Review Date
Jan. 1, 2005
Maintenance Inspection Date
April 25, 2013
Equipment Tested
Yes
Management of Change Most Recent Date
June 20, 2014
Management of Change Review Date
May 1, 2012
Pre-startup Review Date
May 15, 2010
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
Oct. 7, 2013
Incident Invest. Change Completion Date
Jan. 1, 2016
Participation Plan Review Date
Feb. 1, 2014
Hot Work Review Date
March 31, 2009
Contractor Safety Review Date
April 1, 2009
Contractor Safety Eval. Date
April 30, 2014
Petroleum Refining, Petroleum Refineries (32411)
Prevention Program ID:
1000065138
Safety Review Date
Dec. 7, 2011
PHA Update Date
Dec. 7, 2011
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Overpressurization
  • Equipment failure
  • Cooling loss
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 24, 2013
Training Review Date
Dec. 24, 2013
Maintenance Review Date
Jan. 1, 2005
Maintenance Inspection Date
March 1, 2008
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 13, 2009
Management of Change Review Date
May 1, 2012
Pre-startup Review Date
None
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Feb. 1, 2014
Hot Work Review Date
March 31, 2009
Contractor Safety Review Date
April 1, 2009
Contractor Safety Eval. Date
April 30, 2014
Petroleum Refining, Petroleum Refineries (32411)
Prevention Program ID:
1000065139
Safety Review Date
Dec. 18, 2012
PHA Update Date
Dec. 18, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Equipment failure
  • Cooling loss
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Purge System
Mitigation Systems
  • Sprinkler System
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 20, 2013
Training Review Date
Dec. 20, 2013
Maintenance Review Date
Jan. 1, 2005
Maintenance Inspection Date
March 10, 2013
Equipment Tested
Yes
Management of Change Most Recent Date
May 22, 2014
Management of Change Review Date
May 1, 2012
Pre-startup Review Date
March 30, 2012
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
Sept. 25, 2013
Incident Invest. Change Completion Date
March 10, 2014
Participation Plan Review Date
Feb. 1, 2014
Hot Work Review Date
March 31, 2009
Contractor Safety Review Date
April 1, 2009
Contractor Safety Eval. Date
April 30, 2014
Petroleum Refining, Petroleum Refineries (32411)
Prevention Program ID:
1000065140
Safety Review Date
Oct. 17, 2012
PHA Update Date
Oct. 17, 2012
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Overpressurization
Process Controls
  • Relief Valves
  • Automatic Shutoffs
  • Alarms
  • Inhibitor Addition
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 17, 2013
Training Review Date
Dec. 17, 2013
Maintenance Review Date
Jan. 1, 2005
Maintenance Inspection Date
Jan. 30, 2013
Equipment Tested
Yes
Management of Change Most Recent Date
June 23, 2014
Management of Change Review Date
May 1, 2012
Pre-startup Review Date
Oct. 24, 2012
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
May 14, 2012
Incident Invest. Change Completion Date
Oct. 14, 2013
Participation Plan Review Date
Feb. 1, 2014
Hot Work Review Date
March 31, 2009
Contractor Safety Review Date
April 1, 2009
Contractor Safety Eval. Date
April 30, 2014
Petroleum Refining, Petroleum Refineries (32411)
Prevention Program ID:
1000065141
Safety Review Date
July 26, 2012
PHA Update Date
July 26, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Equipment failure
  • Cooling loss
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Sprinkler System
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 11, 2013
Training Review Date
Dec. 11, 2013
Maintenance Review Date
Jan. 1, 2005
Maintenance Inspection Date
Feb. 23, 2012
Equipment Tested
Yes
Management of Change Most Recent Date
March 25, 2014
Management of Change Review Date
May 1, 2012
Pre-startup Review Date
Dec. 4, 2013
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
Oct. 4, 2012
Incident Invest. Change Completion Date
Feb. 20, 2014
Participation Plan Review Date
Feb. 1, 2014
Hot Work Review Date
March 31, 2009
Contractor Safety Review Date
April 1, 2009
Contractor Safety Eval. Date
April 30, 2014

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
Yes
Facility Own Response Plan:
No
Specific Facility Response Plan:
Yes
Inform. Procedures in Response Plan:
No
Emergency Care in Response Plan:
Yes
Plan Review Date:
Response Training Date:
June 23, 2014
Local Response Agency:
Local Response Agency Phone:
(713) 473-2273
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
No
Subject To - OPA:
No
Subject To - State EPCRA:
No
Subject To - Other:

Executive Summary

ACCIDENTAL RELEASE PREVENTION AND RESPONSE POLICIES



The Pasadena Refining Systems, Inc. (PRSI) Pasadena refinery has a long standing commitment to worker and public safety. This commitment is demonstrated by the resources invested in accident prevention, such as training personnel and considering safety in the design, installation, operation, and maintenance of our processes. Our policy is to implement reasonable controls to prevent foreseeable releases of regulated substances. However, if a release does occur, our trained personnel will respond to control and contain the release.



DESCRIPTION OF THE STATIONARY SOURCE AND REGULATED SUBSTANCES



PRSI's refinery, located in Pasadena, Texas, operates a variety of processes to produce petroleum products (e.g., refinery grade propylene, gasoline, fuel oil, and coke) from raw crude oil. The refinery has several regulated flammables, such as hydrogen, methane, ethanes, propanes, butanes, and pentanes. In addition, the refinery uses chlorine for algae control in cooling towers and hydrogen fluoride in the making of gasoline, which are also regulated substances.



FIVE-YEAR ACCIDENT HISTORY



The Pasadena refinery has an excellent record of accident prevention over the past 5 years; the frequency of accidental releases has decreased. None of the incidents that have occurred have resulted in offsite consequences. Over the last five years PRSI have had two incidents that qualifies for reporting through EPA's Risk Management Program. We investigate every incident very carefully to determine ways to prevent similar incidents from occurring.



GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM STEPS



The following is a summary of the general accident prevention program in place at PRSI's refinery. Because processes at the refinery that are regulated by the EPA RMP regulation are also subject to the OSHA PSM standard, this summary addresses each of the OSHA PSM elements and describes the management system in place t
o implement the accident prevention program.



Employee Participation



PRSI encourages employees to participate in all facets of process safety management and accident prevention. Examples of employee participation range from updating and compiling technical documents and chemical information to participating as a member of a process hazard analysis (PHA) team. Employees have access to all information created as part of the refinery accident prevention program. Specific ways that employees can be involved in the accident prevention program are documented in an employee participation plan that is maintained at the refinery and addresses each accident prevention program element.



Process Safety Information



PRSI maintains and updates a variety of technical documents that are used to ensure safe operation of the processes. These documents address chemical properties and associated hazards, limits for key process parameters and specific chemical inventories, and equipment design basis/configuration information. Specific departments within the refinery are assigned responsibility for maintaining up-to-date process safety information.



Chemical-specific information, including exposure hazards and emergency response/exposure treatment considerations, is provided in material safety data sheets (MSDS). For specific process areas, the refinery has documented safety-related limits for certain process parameters, such as , temperature, level, and composition, in its Unit Operating Procedures manuals. The refinery ensures that the process is maintained within these limits using process controls and monitoring instruments, highly trained personnel, and protective instrument systems (e.g., automated shutdown systems).



The refinery also maintains numerous technical documents that provide information about the design and construction of process equipment. This information includes materials of construction, design pressure and temperature ratings, electrical rati
ng of equipment, etc. This information, in combination with written procedures and trained personnel, provides a basis for establishing inspection and maintenance activities, as well as for evaluating proposed process and facility changes to ensure that safety features in the process are not compromised.



Employees involved with operating a process are trained to make them familiar with all of the process safety information. Any time that changes or updates are made to the process safety information, all such employees are informed and familiarized.



Process Hazard Analysis (PHA)



PRSI has a comprehensive program to help ensure that hazards associated with the various processes are identified and controlled. Within this program, each process is systematically examined to identify hazards and ensure that adequate controls are in place to manage these hazards.



PRSI's refinery primarily uses the hazard and operability (HAZOP) analysis technique to perform these evaluations, which is part of the OSHA Process Hazard Analysis program. HAZOP analysis is recognized as one of the most systematic and thorough hazard evaluation techniques. The analyses are conducted using a team of people who have operating and maintenance experience as well as engineering expertise. This team identifies and evaluates hazards of the process as well as accident prevention and mitigation measures, and makes suggestions for additional prevention and/or mitigation measures when the team believes such measures are necessary.



The PHA team findings are forwarded to management for resolution. Implementation of mitigation options in response to PHA findings is based on a relative risk ranking assigned by the PHA team. This ranking helps ensure that potential accident scenarios assigned the highest risk receive immediate attention. All approved mitigation options being implemented in response to PHA team findings are tracked until they are completed. The final resolution of each
finding is documented and retained.



To help ensure that the process controls and/or process hazards do not eventually deviate significantly from the original design safety features, PRSI's refinery periodically updates and revalidates the hazard analysis results. These periodic reviews are conducted at least every 5 years and will be conducted at this frequency until the process is no longer operating. The results and findings from these updates are documented and retained. Once again, the team findings are forwarded to management for consideration and the final resolution of the findings is documented and retained.



Operating Procedures



PRSI's refinery maintains written procedures that address various modes of process operations, such as (1) unit startup, (2) normal operations, (3) temporary operations, (4) emergency shutdown, (5) normal shutdown, and (6) initial startup of a new process. These procedures can be used as a reference by experienced operators and provide a basis for consistent training of new operators. These procedures are periodically reviewed to insure that they are current and accurate. These procedures are also updated whenever a change is implemented that affects the process chemicals, technology, or equipment in an operating process.



In addition, PRSI's refinery maintains in its Unit Operating Procedures Manuals procedures that provide guidance on how to respond to upper or lower limit exceedances for specific process or equipment parameters. This information, along with written operating procedures is readily available to operators in the process unit and for other personnel to use as necessary to safely perform their job tasks.



Training



To complement the written procedures for process operations, the Pasadena refinery has implemented a comprehensive training program for all employees involved in operating a process. New employees receive basic training in refinery operations if they are not already familiar with such
operations. After successfully completing this training, a new operator is paired with a senior operator to learn process-specific duties and tasks. After operators demonstrate (e.g., through tests, skills demonstration) having adequate knowledge to perform the duties and tasks in a safe manner on their own, they can work independently. In addition, all operators periodically receive refresher training on the emergency operating procedures to ensure that their skills and knowledge are maintained at an acceptable level. This refresher training is conducted at least every 2 years. All of this training is documented for each operator, including the means used to verify that the operator understood the training.



Contractors



The refinery has procedures in place to ensure that contractors (1) perform their work in a safe manner, (2) have the appropriate knowledge and skills, (3) are aware of the hazards in their workplace, (4) understand what they should do in the event of an emergency, (5) understand and follow site safety rules, and (6) inform refinery personnel of any hazards that they find during their work. This is accomplished by providing contractors with (1) a process overview, (2) information about safety and health hazards, (3) emergency response plan requirements, and (4) safe work practices prior to their beginning work. In addition, the Pasadena refinery evaluates contractor safety programs and performance during the selection of a contractor. Refinery personnel periodically monitor contractor performance to ensure that contractors are fulfilling their safety obligations. The company has formed a Partnership for Safety program which is a safety effort involving representatives from all of the contract companies doing work in the refinery. This group meets regularly to discuss safety performance and make suggestions to improve safety practices in the refinery. The Partnership for Safety program is in addition to the company's monthly management
safety meeting.



Pre-startup Safety Reviews (PSSRs)



The Pasadena refinery conducts a PSSR for any new facility or significant facility modification that requires a change in the process safety information. The purpose of the PSSR is to ensure that safety features, procedures, personnel, and the equipment are appropriately prepared for startup prior to placing the equipment into service. This review provides one additional check to make sure that any change is in accordance with the design specifications and that all supporting systems are operationally ready. The PSSR review team uses checklists to verify all aspects of readiness. A PSSR involves field verification of the construction and serves a quality assurance function by requiring verification that accident prevention program requirements are properly implemented.



Mechanical Integrity



The Pasadena refinery has well-established practices and procedures to maintain pressure vessels, piping systems, relief and vent systems, controls, pumps and compressors, and emergency shutdown systems in a safe operating condition. The basic aspects of this program include: (1) conducting training, (2) developing written procedures, (3) performing inspections and tests, (4) correcting identified deficiencies, and (5) applying quality assurance measures. In combination, these activities form a system that maintains the mechanical integrity of the process equipment.



Maintenance personnel receive training on (1) an overview of the process, (2) safety and health hazards, (3) applicable maintenance procedures, (4) emergency response plans, and (5) applicable safe work practices to help ensure that they can perform their job in a safe manner. Written procedures help ensure that work is performed in a consistent manner and provide a basis for training. Inspections and tests are performed to help ensure that equipment functions as intended, and to verify that equipment is within acceptable limits (e.g., adequ
ate wall thickness for pressure vessels). Inspections are performed both "on-line" and when the equipment is scheduled down for inspection and repairs. If a deficiency is identified, employees will correct the deficiency before placing the equipment back into service (if the equipment has not exceeded its useful life), or a Management of Change team organized pursuant to OSHA's PSM program, will review the use of the equipment and determine what actions are necessary to ensure the safe operation of the equipment.



Another integral part of the mechanical integrity program is quality assurance. PRSI's refinery incorporates quality assurance measures into equipment purchases and repairs. This helps ensure that new equipment is suitable for its intended use and that proper materials and spare parts are used when repairs are made.



Safe Work Practices



The Pasadena refinery has long-standing safe work practices in place to help ensure worker and process safety. Examples of these include (1) control of the entry/presence/exit of support personnel, (2) a lockout/tagout procedure to ensure isolation of energy sources for equipment undergoing maintenance, (3) a procedure for safe removal of hazardous materials before process piping or equipment is opened, (4) a permit and procedure to control spark-producing activities (i.e., hot work), and (5) a permit and procedure to ensure that adequate precautions are in place before entry into a confined space. These procedures (and others), along with training of affected personnel, form a system to help ensure that operations and maintenance activities are performed safely.



Management of Change



The Pasadena refinery has a comprehensive system to manage changes to processes. This system requires that changes to items such as process equipment, chemicals, technology (including process operating conditions), procedures, and other facility changes are properly reviewed and authorized before being implemented. Changes
are reviewed to (1) ensure that adequate controls are in place to manage any new hazards and (2) verify that existing controls have not been compromised by the change. Affected chemical hazard information, process operating limits, and equipment information, as well as procedures, are updated to incorporate these changes. In addition, operating and maintenance personnel are provided any necessary training on the change.



Incident Investigation



PRSI promptly investigates all incidents that resulted in, or reasonably could have resulted in, a fire/explosion, toxic gas release, major property damage, environmental loss, or personal injury. The goal of each investigation is to determine the facts and develop corrective actions to prevent a recurrence of the incident or a similar incident. The investigation team documents its findings, develops recommendations to prevent a recurrence, and forwards these results to refinery management for resolution. Corrective actions taken in response to the investigation team's findings and recommendations are tracked until they are complete. The final resolution of each finding or recommendation is documented, and the investigation results are reviewed with all employees (including contractors) who could be affected by the findings. Incident investigation reports are retained for at least 5 years so that the reports can be reviewed during future PHAs and PHA revalidations.



Compliance Audits



To help ensure that the accident prevention program is functioning properly, PRSI periodically conducts an audit to determine whether the procedures and practices required by the accident prevention program are being implemented. Both hourly and management personnel participate in the audit function. The audit team develops findings that are forwarded to refinery management for resolution. Corrective actions taken in response to the audit team's findings are tracked until they are complete. The final resolution of each finding
is documented, and the two most recent audit reports are retained.



CHEMICAL SPECIFIC PREVENTION STEPS



The processes at the Pasadena refinery have hazards that must be managed to ensure continued safe operation. The accident prevention program summarized previously is applied to all Program 3 EPA RMP-covered processes at the Pasadena refinery. Collectively, these prevention program activities help prevent potential accident scenarios that could be caused by (1) equipment failures and (2) human errors.



In addition to the accident prevention program activities, PRSI has safety features on many units to help (1) quickly detect a release, (2) contain/control a release, and (3) reduce the consequences of (mitigate) a release. The following types of safety features are used in various processes:



Release Detection



1.Hydrocarbon detectors with alarms



2.Hydrofluoric acid leak detectors with warning mechanisms



3.Hydrogen sulfide leak detectors with warning mechanisms



4.Video camera surveillance



Release Containment/Control



1.Process relief valves that discharge to a flare to capture and incinerate episodic releases



2.Scrubber to neutralize chemical releases



3.Valves to permit isolation of the process (manual or automated)



4.Automated shutdown systems for specific process parameters (e.g., high level, high temperature)



5.Vessel to permit partial removal of the process inventory in the event of a release (e.g., dump tank)



6.Curbing or diking to contain liquid releases



7.Redundant equipment and instrumentation (e.g., uninterruptible power supply for process control system, backup firewater pump)



8.Atmospheric relief devices



Release Mitigation



1.Fire suppression and extinguishing systems



2.Water spray system for specific equipment



3.Trained emergency response personnel



4.Personal protective equipment (e.g., protective clothing, self-contained breathing apparatus)



EMERGENCY RESPONSE PROGRAM INFORMATION



T
he Pasadena refinery maintains a written emergency response program, which is in place to protect worker and public safety as well as the environment. The program consists of procedures for responding to a release of a regulated substance, including the possibility of a fire or explosion if a flammable substance is accidentally released. The procedures address all aspects of emergency response, including proper first-aid and medical treatment for exposures, evacuation plans and accounting for personnel after an evacuation, notification of local emergency response agencies and the public if a release occurs, and post-incident cleanup and decontamination. In addition, PRSI' s refinery has procedures that address maintenance, inspection, and testing of emergency response equipment, as well as instructions that address the use of emergency response equipment. Employees receive training in these procedures as necessary to perform their specific emergency response duties. The emergency response program is updated when necessary based on modifications made to refinery processes or other refinery facilities.



The overall emergency response program for the Pasadena refinery is coordinated with the Pasadena, Texas, Local Emergency Planning Committee (LEPC). This coordination includes periodic meetings of the committee, which includes local emergency response officials, local government officials, and industry representatives. PRSI's refinery has around-the-clock communications capability with appropriate LEPC officials and emergency response organizations such as the Channel Industries Mutual Aid (CIMA) organization. CIMA consists of approximately 110 industries and local fire departments which stand ready to provide emergency response teams in the event they are needed. This provides a means of notifying the public of an incident, if necessary, as well as facilitating quick response to an incident. In addition to periodic LEPC meetings, the Pasadena refinery con
ducts periodic emergency drills that involve the LEPC and emergency response organizations, and the refinery provides refresher training to local emergency responders regarding the hazards of regulated substances in the refinery.



PLANNED CHANGES TO IMPROVE SAFETY



The PRSI refinery resolves all findings from PHAs, some of which result in modifications to the process. The following types of changes are planned:

Revised process instrumentation and/or controls

Revisions to personnel training programs

Revise written operating procedures

Additional use of "carsealing" on isolation valves in the path of the pressure relief systems

Drug and Alcohol training for supervisors and managers

HF Acid safety awareness

Forklift training to train the trainer

Front end loader train the trainer

Aerial lift train the trainer

Chemical Hygiene Plan training for lab personnel