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Valero Meraux Refinery

Parent Companies:
Valero Refining - Meraux LLC
EPA Facility ID:
100000064146
Other ID:
Facility DUNS:
0
Parent Company DUNS:
0

Location:

Address:
2500 St. Bernard Hwy.
Meraux, LA 70075
County:
ST. BERNARD
Lat / Long:
29.930, -89.944 (Get map)
Method:
Interpolation - Photo
Description:
Administrative Building
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
Valero Refining - Meraux LLC
Phone:
(504) 271-4141
Address:
1615 East Judge Perez Drive
Chalmette, LA 70043
Foreign Address:

Person responsible for RMP implementation:

Name:
Jack Merrill
Title:
Vice President and General Manager

Emergency contact:

Name:
Justin Stubbe
Title:
Manager Environmental
Phone:
(504) 271-4141
24-hour phone:
(210) 482-0953
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
St. Bernard Parish LEPC
Full-Time Equivalent Employees:
309
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
2500-00001-V12
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Aug. 26, 2014
Inspecting Agency:
EPA
Using Predictive Filing:
No

Processes:

MDH / ULSDHT
RMP ID:
1000071508
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
68,600
No
Public OCA Chemical
0
No
DHT / KHT
RMP ID:
1000071509
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
15,300
No
Public OCA Chemical
0
No
Crude/Vacuum Unit
RMP ID:
1000071510
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
111,600
No
Public OCA Chemical
0
No
ROSE Unit
RMP ID:
1000071511
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
798,900
No
Public OCA Chemical
0
No
Gas Con / Sats Gas
RMP ID:
1000071512
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
555,800
No
Public OCA Chemical
0
No
Platformer Unit
RMP ID:
1000071513
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
100,500
No
Public OCA Chemical
0
No
Hydrobon Unit
RMP ID:
1000071514
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
309,000
No
Public OCA Chemical
0
No
LPG Loading/Unloading
RMP ID:
1000071515
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
8,997,700
No
Public OCA Chemical
0
No
Hydrocracker/Hydrotreater
RMP ID:
1000071516
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
628,200
No
Public OCA Chemical
0
No
Benzene Reduction Unit
RMP ID:
1000071517
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
72,500
No
Public OCA Chemical
0
No
Flare System / Offsites
RMP ID:
1000071518
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
283,700
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
May 13, 2016
Type:
Resubmission
Reason:
Revised PHA / Hazard Review due to process change (40 CFR 68.190(b)(5))
Registered:
Yes
RMP ID:
1000057187

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 LPG Loading/Unloading)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
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 LPG Loading/Unloading)
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

MDH / ULSDHT, Petroleum Refineries (32411)
Prevention Program ID:
1000059795
Safety Review Date
March 9, 2016, since latest RMP submission
PHA Update Date
Feb. 8, 2013, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Quench System
  • Purge System
Mitigation Systems
  • Deluge System
  • Water Curtain
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Parameters
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 14, 2015, since latest RMP submission
Training Review Date
Feb. 25, 2016, since latest RMP submission
Maintenance Review Date
Aug. 3, 2015, since latest RMP submission
Maintenance Inspection Date
March 3, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 19, 2016
Management of Change Review Date
Dec. 18, 2013
Pre-startup Review Date
April 20, 2016
Compliance Audit Date
June 14, 2013
Compliance Audit Change Completion Date
March 31, 2015
Incident Investigation Date
March 31, 2016
Incident Invest. Change Completion Date
Oct. 31, 2016
Participation Plan Review Date
May 10, 2013
Hot Work Review Date
Jan. 29, 2015
Contractor Safety Review Date
Jan. 21, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 10, 2014, since latest RMP submission
DHT / KHT, Petroleum Refineries (32411)
Prevention Program ID:
1000059796
Safety Review Date
Dec. 2, 2015, since latest RMP submission
PHA Update Date
May 9, 2013, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Deluge System
  • Water Curtain
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
April 6, 2015, since latest RMP submission
Training Review Date
Feb. 25, 2016, since latest RMP submission
Maintenance Review Date
Aug. 3, 2015, since latest RMP submission
Maintenance Inspection Date
April 10, 2015, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Nov. 20, 2015
Management of Change Review Date
Dec. 18, 2013
Pre-startup Review Date
Jan. 4, 2016
Compliance Audit Date
June 14, 2013
Compliance Audit Change Completion Date
March 31, 2015
Incident Investigation Date
Feb. 20, 2013
Incident Invest. Change Completion Date
July 30, 2013
Participation Plan Review Date
May 10, 2013
Hot Work Review Date
Jan. 29, 2015
Contractor Safety Review Date
Jan. 21, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 10, 2014, since latest RMP submission
Crude/Vacuum Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000059797
Safety Review Date
April 13, 2016, since latest RMP submission
PHA Update Date
Jan. 23, 2015, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Purge System
Mitigation Systems
  • Deluge System
  • Water Curtain
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Parameters
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
March 16, 2016, since latest RMP submission
Training Review Date
Feb. 25, 2016, since latest RMP submission
Maintenance Review Date
Aug. 3, 2015, since latest RMP submission
Maintenance Inspection Date
April 10, 2015, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 18, 2016
Management of Change Review Date
Dec. 18, 2013
Pre-startup Review Date
March 7, 2016
Compliance Audit Date
June 14, 2013
Compliance Audit Change Completion Date
March 31, 2015
Incident Investigation Date
March 9, 2016
Incident Invest. Change Completion Date
Dec. 31, 2016
Participation Plan Review Date
May 10, 2013
Hot Work Review Date
Jan. 29, 2015
Contractor Safety Review Date
Jan. 21, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 10, 2014, since latest RMP submission
ROSE Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000059798
Safety Review Date
Jan. 27, 2016, since latest RMP submission
PHA Update Date
May 21, 2014, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Water Curtain
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Parameters
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 21, 2015, since latest RMP submission
Training Review Date
Feb. 25, 2016, since latest RMP submission
Maintenance Review Date
Aug. 3, 2015, since latest RMP submission
Maintenance Inspection Date
April 10, 2015, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Feb. 8, 2016
Management of Change Review Date
Dec. 18, 2013
Pre-startup Review Date
Jan. 26, 2016
Compliance Audit Date
June 14, 2013
Compliance Audit Change Completion Date
March 31, 2015
Incident Investigation Date
March 11, 2015
Incident Invest. Change Completion Date
Sept. 30, 2015
Participation Plan Review Date
May 10, 2013
Hot Work Review Date
Jan. 29, 2015
Contractor Safety Review Date
Jan. 21, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 10, 2014, since latest RMP submission
Gas Con / Sats Gas, Petroleum Refineries (32411)
Prevention Program ID:
1000059799
Safety Review Date
March 16, 2016, since latest RMP submission
PHA Update Date
May 14, 2014, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Purge System
Mitigation Systems
  • Deluge System
  • Water Curtain
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Parameters
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
April 19, 2016, since latest RMP submission
Training Review Date
Feb. 25, 2016, since latest RMP submission
Maintenance Review Date
Aug. 3, 2015, since latest RMP submission
Maintenance Inspection Date
Aug. 21, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 21, 2016
Management of Change Review Date
Dec. 18, 2013
Pre-startup Review Date
Dec. 18, 2015
Compliance Audit Date
June 14, 2013
Compliance Audit Change Completion Date
March 31, 2015
Incident Investigation Date
Feb. 11, 2016
Incident Invest. Change Completion Date
July 1, 2016
Participation Plan Review Date
May 10, 2013
Hot Work Review Date
Jan. 29, 2015
Contractor Safety Review Date
Jan. 21, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 10, 2014, since latest RMP submission
Platformer Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000059800
Safety Review Date
Feb. 26, 2016, since latest RMP submission
PHA Update Date
Oct. 9, 2015, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Deluge System
  • Water Curtain
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
March 16, 2016, since latest RMP submission
Training Review Date
Feb. 25, 2016, since latest RMP submission
Maintenance Review Date
Aug. 3, 2015, since latest RMP submission
Maintenance Inspection Date
March 31, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 4, 2016
Management of Change Review Date
Dec. 18, 2013
Pre-startup Review Date
Aug. 14, 2015
Compliance Audit Date
June 14, 2013
Compliance Audit Change Completion Date
March 31, 2015
Incident Investigation Date
Dec. 17, 2015
Incident Invest. Change Completion Date
March 31, 2017
Participation Plan Review Date
May 10, 2013
Hot Work Review Date
Jan. 29, 2015
Contractor Safety Review Date
Jan. 21, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 10, 2014, since latest RMP submission
Hydrobon Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000059801
Safety Review Date
April 25, 2016, since latest RMP submission
PHA Update Date
March 16, 2016, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • None
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Purge System
Mitigation Systems
  • Deluge System
  • Water Curtain
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
March 1, 2016, since latest RMP submission
Training Review Date
Feb. 25, 2016, since latest RMP submission
Maintenance Review Date
Aug. 3, 2015, since latest RMP submission
Maintenance Inspection Date
April 10, 2015, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 20, 2016
Management of Change Review Date
Dec. 18, 2013
Pre-startup Review Date
March 17, 2016
Compliance Audit Date
June 14, 2013
Compliance Audit Change Completion Date
March 31, 2015
Incident Investigation Date
April 14, 2016
Incident Invest. Change Completion Date
June 30, 2016
Participation Plan Review Date
May 10, 2013
Hot Work Review Date
Jan. 29, 2015
Contractor Safety Review Date
Jan. 21, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 10, 2014, since latest RMP submission
LPG Loading/Unloading, Petroleum Refineries (32411)
Prevention Program ID:
1000059802
Safety Review Date
Jan. 5, 2016, since latest RMP submission
PHA Update Date
Feb. 20, 2013, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Grounding Equipment
Mitigation Systems
  • Water Curtain
Monitoring Systems
  • None
Changes since PHA
  • Process Controls
  • Perimeter Monitoring
  • Mitigation Systems
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
March 31, 2016, since latest RMP submission
Training Review Date
Feb. 25, 2016, since latest RMP submission
Maintenance Review Date
Aug. 3, 2015, since latest RMP submission
Maintenance Inspection Date
Jan. 25, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 23, 2016
Management of Change Review Date
Dec. 18, 2013
Pre-startup Review Date
Oct. 23, 2015
Compliance Audit Date
June 14, 2013
Compliance Audit Change Completion Date
March 31, 2015
Incident Investigation Date
Jan. 10, 2015
Incident Invest. Change Completion Date
Sept. 30, 2015
Participation Plan Review Date
May 10, 2013
Hot Work Review Date
Jan. 29, 2015
Contractor Safety Review Date
Jan. 21, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 10, 2014, since latest RMP submission
Hydrocracker/Hydrotreater, Petroleum Refineries (32411)
Prevention Program ID:
1000059803
Safety Review Date
March 22, 2016, since latest RMP submission
PHA Update Date
March 5, 2012, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Quench System
  • Purge System
Mitigation Systems
  • Deluge System
  • Water Curtain
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Parameters
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
April 15, 2016, since latest RMP submission
Training Review Date
Feb. 25, 2016, since latest RMP submission
Maintenance Review Date
Oct. 7, 2015, since latest RMP submission
Maintenance Inspection Date
June 18, 2015, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 20, 2016
Management of Change Review Date
Dec. 18, 2013
Pre-startup Review Date
Feb. 26, 2016
Compliance Audit Date
June 14, 2013
Compliance Audit Change Completion Date
March 31, 2015
Incident Investigation Date
March 17, 2016
Incident Invest. Change Completion Date
July 31, 2016
Participation Plan Review Date
May 10, 2013
Hot Work Review Date
Jan. 29, 2015
Contractor Safety Review Date
Jan. 21, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 10, 2014, since latest RMP submission
Benzene Reduction Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000059804
Safety Review Date
March 11, 2016, since latest RMP submission
PHA Update Date
Oct. 18, 2013, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Sprinkler System
  • Deluge System
  • Water Curtain
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Parameters
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
April 15, 2016, since latest RMP submission
Training Review Date
Feb. 25, 2016, since latest RMP submission
Maintenance Review Date
Aug. 3, 2015, since latest RMP submission
Maintenance Inspection Date
March 4, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 11, 2016
Management of Change Review Date
Dec. 18, 2013
Pre-startup Review Date
March 8, 2016
Compliance Audit Date
June 14, 2013
Compliance Audit Change Completion Date
March 31, 2015
Incident Investigation Date
June 2, 2015
Incident Invest. Change Completion Date
July 31, 2015
Participation Plan Review Date
May 10, 2013
Hot Work Review Date
Jan. 29, 2015
Contractor Safety Review Date
Jan. 21, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 10, 2014, since latest RMP submission
Flare System / Offsites, Petroleum Refineries (32411)
Prevention Program ID:
1000059805
Safety Review Date
March 8, 2016, since latest RMP submission
PHA Update Date
Sept. 15, 2015, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Dikes
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
March 30, 2016, since latest RMP submission
Training Review Date
Feb. 25, 2016, since latest RMP submission
Maintenance Review Date
Aug. 3, 2015, since latest RMP submission
Maintenance Inspection Date
Jan. 5, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 23, 2016
Management of Change Review Date
Dec. 18, 2013
Pre-startup Review Date
March 10, 2016
Compliance Audit Date
June 14, 2013
Compliance Audit Change Completion Date
March 31, 2015
Incident Investigation Date
Jan. 8, 2016
Incident Invest. Change Completion Date
June 30, 2016
Participation Plan Review Date
May 10, 2013
Hot Work Review Date
Jan. 29, 2015
Contractor Safety Review Date
Jan. 21, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 10, 2014, 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:
May 3, 2016
Local Response Agency:
Local Response Agency Phone:
(504) 278-4275
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

ACCIDENTAL RELEASE PREVENTION AND RESPONSE POLICIES



The Meraux 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 monitor and contain the release.





DESCRIPTION OF THE STATIONARY SOURCE AND REGULATED SUBSTANCES



The Meraux Refinery, located in Meraux, Louisiana, operates a variety of processes to produce petroleum products (e.g., propane, butane, diesel fuels and gasoline) from raw crude oil. The refinery contains Part 68-regulated Flammable Mixtures (which contain variable combinations of propane, butane, propylene, isobutane, isopentane, pentane, ethane, methane, and hydrogen). A variety of flammable mixtures classified as Rating 4 (highly flammable) per the National Fire Protection Association (NFPA) system with different compositions are also present at the refinery.





GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM STEPS



The following is a summary of the general accident prevention program in place at the Meraux Refinery. Because processes at the refinery that are regulated by the EPA RMP rule are also subject to the OSHA PSM standard, this summary addresses each of the OSHA PSM elements and describes the management system in place to implement the accident prevention program.





Employee Participation



The Meraux Refinery 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 cr
eated 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. In addition, the refinery has a number of initiatives under way that address process safety and employee safety issues. These initiatives include forming teams to promote both process and personal safety. The teams typically have members from various areas of the plant, including operations, maintenance, engineering, and plant management.





Process Safety Information



The Meraux Refinery keeps a variety of technical documents that are used to help maintain 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 (MSDSs). This information is supplemented by documents that specifically address known corrosion concerns and any known hazards associated with the inadvertent mixing of chemicals. The refinery has documented safety-related limits for specific process parameters (e.g., temperature, level, composition) in the operating procedures for each process. 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 mater
ials of construction, design pressure and temperature ratings, electrical rating 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 monitor that safety features in the process are not compromised.





Process Hazard Analysis



The Meraux Refinery 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 the controls that are in place to manage these hazards.



The Meraux Refinery primarily uses the hazard and operability (HAZOP) analysis technique to perform these evaluations. 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 the refinery leadership team 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 attention first. All approved mitigation options being implemented in response to PHA team findings are tracked until they are complete. The final resolution of each finding is documented and retained.



To verify that the process controls and/or process hazards do not eventually deviate significantly from the original design safety features, the Meraux Refinery periodically updates a
nd 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



The Meraux 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 and annually certified as current and accurate. The procedures are maintained current and accurate by revising them as necessary to reflect changes made through the management of change process.



In addition, the operating procedures at the Meraux Refinery provide guidance on how to prevent or respond to exceedances beyond upper or lower limits specified 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 Meraux Refinery has implemented a thorough 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 ad
equate 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 operating procedures to verify that their skills and knowledge are maintained at an acceptable level. This refresher training is conducted at least every 3 years. All of this training is documented for each operator, including the means used to verify that the operator understood the training.





Contractors



The Meraux Refinery uses contractors to supplement its workforce. Because some contractors work on or near process equipment, 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 Meraux 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.





Pre-startup Safety Reviews (PSSRs)



The Meraux Refinery conducts a PSSR for any 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 construction is in accordance with the design specifications and that all supporting sys
tems 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 Meraux 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., adequate wall thickness for pressure vessels). If a deficiency is identified, employees will correct the deficiency before placing the equipment back into service, or a management of change (MOC) team 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. The Meraux Refinery incorporates quality assurance measures into equipment purchases and repairs. This verifies 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 Meraux Refinery has long-standing safe work practices in place to manage worker and process safety. Examples of these include (1) monitoring the entry/presence/exit of support personnel, (2) a lockout/tagout procedure that requires 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 monitor activities that might produce ignition sources (i.e., hot work) in areas where flammable materials could be present, and (5) a permit and procedure that require 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 that promotes the safe performance of operations and maintenance activities.





Management of Change



The Meraux Refinery has a comprehensive system to manage changes to process equipment, chemicals, technology (including process operating conditions), and procedures, as well as other facility changes that could affect covered processes. This system requires that changes be properly reviewed and authorized before being implemented. Changes are reviewed to verify that (1) adequate controls are in place to manage any new hazards and (2) 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 appropriate training on the change.





Incident Investigation



The Meraux Refinery promptly investigates all incidents that resulted in, or reasonably could have resulted in, a fire, explosion, or toxic gas release, that caused major property damage, environmental loss, or pers
onal injury. The goal of each investigation is to determine the facts and develop corrective actions to prevent a recurrence of that incident or a similar incident. The investigation team documents its findings, develops recommendations to prevent a recurrence, and forwards these results to the refinery leadership team 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 and 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 verify that the accident prevention program is functioning properly, the Meraux Refinery periodically conducts an audit to determine whether the procedures and practices required by the accident prevention program are being implemented. Compliance audits are conducted at least every 3 years. Both hourly and management personnel participate as audit team members. 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 Meraux Refinery have hazards that must be managed to ensure continued safe operation. The accident prevention program summarized previously is applied to all EPA RMP-covered processes at the Meraux 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, the Mera
ux Refinery has safety features on many units to help (1) contain and control a release, (2) quickly detect a release, and (3) reduce the consequences of a release. The following types of safety features are used in various processes:



Release Detection



* Process area ambient air analyzers with alarms



Release Containment and Control



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

* Scrubber to neutralize chemical releases

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

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

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

* Curbing or diking to contain liquid releases

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

* Atmospheric relief devices



Release Mitigation



* Fire suppression and extinguishing systems

* Deluge system for specific equipment

* Trained emergency response personnel

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

* Blast-resistant buildings to help protect control systems and personnel





FIVE-YEAR ACCIDENT HISTORY



The Meraux Refinery has an excellent record of accident prevention over the past 5 years, with no RMP accidents.



EMERGENCY RESPONSE PROGRAM INFORMATION



The Meraux 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 pers
onnel after an evacuation, notification of local emergency response agencies and the public if a release occurs, and post-incident cleanup and decontamination requirements. In addition, the Meraux 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 Meraux Refinery is coordinated with the St. Bernard Parish Office of Emergency Preparedness, the fire department, and the sheriff's office. This coordination includes periodic meetings of the committee, which includes local emergency response officials, local government officials, and industry representatives. The Meraux Refinery has around-the-clock communications capability with appropriate community officials and emergency response organizations (e.g., the fire department). This provides a means of facilitating quick response to an incident, as well as notifying the public of an incident if necessary. In addition to periodic local emergency planning committee (LEPC) meetings, the Meraux Refinery conducts periodic emergency drills that involve the LEPC and other emergency response organizations.



From knowledge gained from the Katrina event, the Meraux Refinery has also developed a comprehensive hurricane preparedness plan intended to insure the safety of the facility in a major storm.





PLANNED CHANGES TO IMPROVE SAFETY



The Meraux Refinery has recently implemented a number of changes to improve the safety of the facility and the surrounding community.



The Meraux Refinery has recently completed a revamp which included the decommissioning of its Fluid Catalytic Cracking (FCC)U
nit and the Hydrofluoric (HF) Acid Alkylation Unit. As a result of this change, the Meraux Refinery no longer holds a Part 68-regulated toxic material above a threshold quantity and no longer has a toxic worst-case scenario or an alternative release scenario with offsite impacts.



To increase equipment reliability and operator response, the Meraux Refinery has recently enhanced its refinery process control systems by upgrading its computerized distributed control system (DCS), implemented refinery-wide. The system is operated from a blast-resistant Central Control Building.



The Meraux Refinery Emergency Response Team employees continue to receive firefighting, HAZMAT, and incident command refresher training. The training consists of: chemistry of hazardous materials; incident command; dry chemical fire extinguishers; LPG fire suppression; flammable liquids fire suppression; firefighting foam applications; Level "A" HAZMAT simulated leak response; and fire truck water hydraulics. The refinery provides industrial firefighting and rescue training for members of the St. Bernard Fire Department as well.