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Shell - Sewaren Terminal

Parent Companies:
Shell Oil Company
EPA Facility ID:
100000055325
Other ID:
NJD002195220
Facility DUNS:
0
Parent Company DUNS:
4294737

Location:

Address:
111 State Street
Sewaren, NJ 07077
County:
MIDDLESEX
Lat / Long:
40.542, -74.258 (Get map)
Method:
Interpolation - Other
Description:
Administrative Building
Horizonal accuracy:
3 m
Horizontal reference datum:
World Geodetic System of 1984
Source map scale:

Owner/Operator:

Name:
Equilon Enterprises LLC
Phone:
(713) 767-5300
Address:
150 N. Dairy Ashford
Houston, TX 77079
Foreign Address:

Person responsible for RMP implementation:

Name:
Steve Kinnan
Title:
Facility Manager

Emergency contact:

Name:
Steve Kinnan
Title:
Facility Manager
Phone:
(832) 691-0736
24-hour phone:
(832) 691-0736
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Middlesex County LEPC
Full-Time Equivalent Employees:
65
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
BOP 080002
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Aug. 18, 2016
Inspecting Agency:
NJ DEP
Using Predictive Filing:
No

Processes:

Butane Blending
RMP ID:
1000074487
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Bulk Stations and Terminals (42471)
Chemical name
CAS#
Quantity (lbs.)
CBI
Butane
106-97-8
1,400,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Cocciardi and Associates, Inc.
Address:
4 Kacey Court
Mechanicsburg, PA 17055
Foreign Address:

Phone:
(717) 766-4500

Latest RMP Submission:

Date:
Aug. 22, 2016
Type:
Resubmission
Reason:
Voluntary update (not described by any of the above reasons)
Registered:
Yes
RMP ID:
1000059599

Deregistration:

Date:
Effective Date:
Reason:
Other Reason:

2. Toxics: Worst-case

None

3. Toxics: Alternative release

None

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 Butane Blending)
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 Butane Blending)
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

No Registered Accidents

7. Prevention: Program level 3

Butane Blending, Petroleum Bulk Stations and Terminals (42471)
Prevention Program ID:
1000062593
Safety Review Date
March 21, 2016, since latest RMP submission
PHA Update Date
Feb. 17, 2016, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
Sept. 15, 2017, since latest RMP submission
Training Review Date
Aug. 17, 2016, since latest RMP submission
Maintenance Review Date
Aug. 18, 2016, since latest RMP submission
Maintenance Inspection Date
Aug. 17, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 14, 2016
Management of Change Review Date
Dec. 10, 2008
Pre-startup Review Date
Aug. 18, 2016
Compliance Audit Date
None
Compliance Audit Change Completion Date
None
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Aug. 17, 2016
Hot Work Review Date
Aug. 17, 2016
Contractor Safety Review Date
Aug. 17, 2016, since latest RMP submission
Contractor Safety Eval. Date
None, since latest RMP submission

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:
Sept. 23, 2015
Local Response Agency:
Local Response Agency Phone:
(732) 727-8993
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
Yes
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

The Shell - Sewaren Terminal is an existing, onshore bulk storage fuel terminal located at 111 State Street, Sewaren, New Jersey 07077. The Terminal straddles State Street with most of its processing equipment and storage falling on the east side. The butane system is located on the west side. The Terminal is bounded on the east by the Arthur Kill Tidal Strait. The Terminal handles and stores various grades of unleaded gasoline, diesel, butane, ethanol, and petroleum additives for distribution to retail and commercial end-users in the vicinity of Sewaren, NJ.



Shell - Sewaren Terminal in Sewaren, NJ is committed to operating and maintaining processes in a safe, reliable and environmentally sound manner. Shell believes that excellent performance in health, safety, and the environment go hand in hand with operating reliably, and that outstanding HSE performance is of paramount importance.



The Sewaren Terminal is designed, operated and maintained in a manner that protects the environment, as well as the health and safety of its employees, contractors and the community. Shell promotes health, safety, and the environment through programs of awareness, compliance, prevention and protection. These programs include a combination of accidental release prevention and emergency response planning. This document provides a brief overview of the comprehensive risk management activities that Shell has designed and implemented, including:



A. A description of the facility and the use of regulated substances

B. An overview of the accidental release prevention programs

C. A five-year accident history for accidental releases of regulated chemicals

D. An overview of the emergency response program

E. An overview of planned changes to improve safety



A. STATIONARY SOURCE AND REGULATED SUBSTANCES



The primary function of the Sewaren Terminal, located in Sewaren, New Jersey is to act as a bulk storage fuel terminal. The Butane Railcar Offloading, Tank Blending, and Truck Loa
ding/Unloading System has been classified as Program level 3. No Program 1 or 2 processes containing regulated substances were identified. By virtue of the flammable effects associated with butane, it is necessary to observe certain safety precautions in handling butane to prevent unnecessary human exposure, to reduce the threat to employee health, and to minimize the threat and impact to nearby members of the community. Shell - Sewaren Terminal is strongly committed to employee, public, and environmental safety and health. Safety at the Facility depends upon the manner in which butane is handled as well as the various safety devices incorporated into the design of the process. Furthermore, comprehensive training is provided to employees, which reinforces the safety policies and procedures of the Sewaren Terminal.



The Sewaren Terminal has variable inventories of butane. The Butane Railcar Offloading, Tank Blending, and Truck Loading/Unloading System provides the Sewaren Terminal the capability to offload butane from railcars and trucks and blend the butane into gasoline tanks. In addition, it also allows for the direct transfer of butane from railcars to tanker trucks. The system consists of one (1) truck loading/offloading rack with three (3) bays, one (1) rail spur holding up to nine (9) butane railcars with two (2) rail offloading locations, one (1) air-eliminator, one (1) vapor removal pump, and associated piping and appurtenances. Butane can be offloaded from either tanker trucks at the three (3) loading rack bays or from railcars at the two (2) railcar offloading locations. The butane is then transferred to one of twelve above-ground, floating roof storage tanks for blending with gasoline. The System also provides the Sewaren Terminal the capability to transfer butane from railcars directly into tanker trucks. Truck loading can occur at Loading Rack Bays 2 and 3. Process safety controls include: "Smart Hose" (or equivalent) breakaway hoses at the truck offl
oading/loading stations, railcar excess flow valves, Snappy Joe Emergency Shutoff Valves, thermal/hydrostatic relief around all isolatable sections of piping, a pressure relief valve on the air eliminator, truck and railcar grounding devices at the offload stations, check valves, and pneumatic valves which fail closed. The supply lines to the pneumatic valves also incorporate low-melting point (<250?F) tubing for fire protection. Access to the Sewaren Terminal is restricted to authorized employees, management personnel and authorized contractors/visitors.



B. GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION MEASURES



The accidental release prevention programs and emergency planning and response programs help to effectively manage the hazards posed by the regulated substances to employees, the public, and the environment. The covered process is regulated by the EPA RMP regulation 40 CFR Part 68 and NJDEP TCPA Title 7, Chapter 31, as well as the OSHA Process Safety Management standard 29 CFR 1910.119. The following accident prevention program elements are in place at the Sewaren Terminal:



1) Employee Participation

2) Process Safety Information

3) Process Hazard Analysis (PHA) with Risk Assessments

4) Standard Operating Procedures

5) EHS Operator Training

6) Contractors

7) Pre-startup Safety Review

8) Mechanical Integrity with Preventive Maintenance

9) Work Permits

10) Management of Change

11) EHS Accident or Potential Catastrophic Event Investigation

12) Emergency Response

13) Compliance Audits

14) Trade Secrets



These fourteen (14) individual elements of the prevention program work together to prevent accidental chemical releases. The company and its employees are committed to the standards required by these management programs. In addition to the above elements, Sewaren Terminal also has specific prevention measures that are employed as part of the operating procedures and engineering and administrative controls to
help contain/control a release, quickly detect a release, and reduce the consequences of a release. These are briefly summarized as follows:



General Risk Reduction and Safety Measures



-Engineering and construction in accordance with recognized industry and company standards

-Equipment properly designed with protection from overpressure (pressure safety relief valves, etc.)

-Updated technical drawings, Piping & Instrument Diagrams and Process Flow Diagrams

-Operating systems monitored and controlled by trained Operators

-Computerized monitoring and control of process operation

-Redundant control systems

-Automatic and manual shutdown devices for critical systems

-Scheduled inspection and testing of instruments, analyzers, and safety devices

-Limited facility access

-Regular safety meetings and safety awareness programs

-Routinely scheduled safety inspections and audits

-Frequent unit surveillance by operators



General Release Mitigation



-Automatic and remotely operated shut-offs to limit release quantity

-Strategically located valves to isolate leaks

-Hydrocarbon detectors at key areas to warn of a chemical release



General Emergency Response



-Emergency alert system

-Periodic emergency training for employees

-Communication systems with local emergency responders and regulatory agencies

-Emergency drills with plant personnel, regulatory agencies, and community emergency responders to enhance response skills and coordination among agencies

-Participation with the Local Emergency Planning Committee (LEPC)



Further, the Sewaren Terminal complies with the American Petroleum Institute's Standard 2510 - Design and Construction of LPG Installations (API 2510-2001) requirements for LP Gas systems. In addition to the presence of appropriate controls to prevent possible releases of butane, if a release does occur, a Facility Response Plan (FRP) is in place for the Facility and response activities are coordinated with the Woodbridge Township F
ire Department and Middlesex County Office of Emergency Management.



C. FIVE YEAR ACCIDENT HISTORY



The Sewaren Terminal has an excellent record of accident prevention. The terminal keeps records for all significant accidental chemical releases that occur at our facility. This is a "new" Butane Railcar Offloading, Tank Blending, and Truck Loading/Unloading System process; consequently, there have been no accidents within the past five (5) years resulting from the chemical release of materials covered under the EPA RMP regulation.



D. EMERGENCY RESPONSE PROGRAM



Response actions are coordinated with the Woodbridge Township Fire Department. A Facility Response Plan (FRP) is in place to inform employees what to do in case of a release, fire, and to notify emergency responders when there is a need for a response.



Shell - Sewaren Terminal complies with the U.S. Environmental Protection Agency's (EPA) Accident Prevention Rules (40 CFR Part 68 Subpart D) NJDEP TCPA Title 7, Chapter 31, the Occupational Safety and Health Administration (OSHA) Process Safety Management (PSM) standard and associated 14 elements (29 CFR Part 1910.119), and all applicable state and local laws and regulations. The Butane Railcar Offloading, Tank Blending, and Truck Loading/Unloading System is designed, constructed, and maintained in accordance with API 2510.



In the event of an emergency involving the Sewaren Terminal Butane Railcar Offloading, Tank Blending, and Truck Loading/Unloading System, it is the policy of the Facility to initially contact the Woodbridge Township Fire Department and request their assistance. The Facility maintains a trained (annually) incipient fire capability. The Facility's emergency response plans are coordinated with the Woodbridge Township Fire Department and Middlesex County Office of Emergency Management. The Woodbridge Township Fire Department will participate in the initial PSM/RMP training session for this system.



Shell - Sewaren Terminal should
also maintain a relationship with the Woodbridge Township Fire Department. Tours and drills with members of local emergency response organizations are held routinely. These tours and drills enable the public emergency responders to become familiar with the hazards, equipment, resources and personnel in the terminal.



E. PLANNED CHANGES TO IMPROVE SAFETY



Shell is continually striving to make the Shell - Sewaren Terminal the safest and most reliable workplace possible for our employees, our neighbors and our community.



In an effort to improve and promote system safety, Shell looks for, and seeks employee input, on process safety improvements. The Woodbridge Township Fire Department is contacted regarding participation in site emergency response drills. Additionally, Shel will work cooperatively with the community to address any concerns.