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Delaware City Refining Company, LLC

Parent Companies:
PBF Holding Company, LLC
EPA Facility ID:
100000072841
Other ID:
19706TXCDL2000
Facility DUNS:
962406281
Parent Company DUNS:
962619206

Location:

Address:
4550 Wrangle Hill Road
Delaware City, DE 19706
County:
NEW CASTLE
Lat / Long:
39.587, -75.630 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Center of Facility
Horizonal accuracy:
10 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Delaware City Refining Company, LLC
Phone:
(302) 834-6000
Address:
4550 Wrangle Hill Road
Delaware City, DE 19706
Foreign Address:

Person responsible for RMP implementation:

Name:
Jose Dominguez
Title:
Refinery Manager

Emergency contact:

Name:
Rotating Assignment 24/7
Title:
Refinery Shift Superintendent
Phone:
(302) 834-6000
24-hour phone:
(302) 275-6045
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(302) 834-6200
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
New Castle LEPC
Full-Time Equivalent Employees:
600
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
AQM-003/00016
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Dec. 18, 2013
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Crude Unit
RMP ID:
1000049900
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
390,000
No
Public OCA Chemical
0
No
Fluid Coker
RMP ID:
1000049901
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
290,000
No
Public OCA Chemical
0
No
FCC & FCC G.P.
RMP ID:
1000049902
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
1,500,000
No
Public OCA Chemical
0
No
Polymerization/Alkylation
RMP ID:
1000049903
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
11,000,000
No
Public OCA Chemical
0
No
Aromex (CNHTU/Tetra/TR1)
RMP ID:
1000049904
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
360,000
No
Public OCA Chemical
0
No
Desulfurizer & Ether
RMP ID:
1000049905
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
660,000
No
Public OCA Chemical
0
No
Hydrocracker
RMP ID:
1000049906
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
88,000
No
Public OCA Chemical
0
No
CCR
RMP ID:
1000049907
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
61,000
No
Public OCA Chemical
0
No
Blending & Storage
RMP ID:
1000049908
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Propane
74-98-6
5,600,000
No
Butane
106-97-8
9,100,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Joe Greenfield
Address:
4550
4550 Wrangle Hill Road
Delaware City, DE 19706
Foreign Address:

Phone:
(302) 836-6510

Latest RMP Submission:

Date:
April 28, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000040463

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 Polymerization/Alkylation)
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 Blending & Storage)
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

Nov. 29, 2015 at 18:00
ID:
1000045460
NAICS:
Petroleum Refineries (32411)
Duration:
1 hours and 12 minutes
Chemicals involved:
  • Flammable Mixture
Release events:
Fire
Weather conditions at time of event
Wind speed:
4.0 miles/h NNE
Temperature:
43.00 ℉
Atmospheric stability:
B
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:
$1200000
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:
  • Improper procedure
Off-site responders notified:
Notified Only
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised training
  • Revised operating procedures
Aug. 21, 2015 at 13:05
ID:
1000045459
NAICS:
Petroleum Refineries (32411)
Duration:
2 hours and 17 minutes
Chemicals involved:
  • Flammable Mixture
  • Hydrogen sulfide
Release events:
Fire
Weather conditions at time of event
Wind speed:
8.0 miles/h NNW
Temperature:
84.00 ℉
Atmospheric stability:
C
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:
$20000000
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:
Off-site responders notified:
(b.) remained on standby
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised maintenance
  • Revised training
  • Revised operating procedures
  • New process controls
March 16, 2012 at 16:56
ID:
1000033032
NAICS:
Petroleum Refineries (32411)
Duration:
37 minutes
Chemicals involved:
  • Hydrogen
Release events:
Fire
Weather conditions at time of event
Wind speed:
4.0 miles/h W
Temperature:
58.00 ℉
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:
$2440000
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
Off-site responders notified:
Notified Only
Changes introduced as a result of the accident:
  • Revised maintenance
  • Revised operating procedures
  • New process controls

7. Prevention: Program level 3

Crude Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000043159
Safety Review Date
Dec. 13, 2011
PHA Update Date
Dec. 13, 2011
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Inhibitor Addition
  • Quench System
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
Procedure Review Date
Sept. 30, 2013
Training Review Date
Dec. 17, 2013
Maintenance Review Date
Nov. 11, 2012
Maintenance Inspection Date
April 2, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
April 16, 2014
Management of Change Review Date
April 17, 2012
Pre-startup Review Date
April 17, 2014
Compliance Audit Date
Dec. 18, 2013
Compliance Audit Change Completion Date
Dec. 18, 2013
Incident Investigation Date
Jan. 28, 2014
Incident Invest. Change Completion Date
April 30, 2014
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Nov. 23, 2013
Contractor Safety Review Date
Aug. 1, 2013
Contractor Safety Eval. Date
April 22, 2014
Fluid Coker, Petroleum Refineries (32411)
Prevention Program ID:
1000042840
Safety Review Date
Aug. 20, 2012
PHA Update Date
Aug. 20, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Inhibitor Addition
  • Rupture Disks
  • Quench System
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
Procedure Review Date
Feb. 25, 2014
Training Review Date
Dec. 17, 2013
Maintenance Review Date
Nov. 11, 2012
Maintenance Inspection Date
Feb. 12, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
April 16, 2014
Management of Change Review Date
April 17, 2012
Pre-startup Review Date
March 12, 2014
Compliance Audit Date
Dec. 18, 2013
Compliance Audit Change Completion Date
Dec. 18, 2013
Incident Investigation Date
Jan. 30, 2014
Incident Invest. Change Completion Date
April 30, 2014
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Nov. 23, 2013
Contractor Safety Review Date
Aug. 1, 2013
Contractor Safety Eval. Date
April 22, 2014
FCC & FCC G.P., Petroleum Refineries (32411)
Prevention Program ID:
1000042841
Safety Review Date
Oct. 9, 2012
PHA Update Date
Oct. 9, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Inhibitor Addition
  • Quench System
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
Procedure Review Date
May 9, 2013
Training Review Date
Dec. 17, 2013
Maintenance Review Date
Nov. 11, 2012
Maintenance Inspection Date
April 10, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
April 9, 2014
Management of Change Review Date
April 17, 2012
Pre-startup Review Date
April 9, 2014
Compliance Audit Date
Dec. 18, 2013
Compliance Audit Change Completion Date
Dec. 18, 2013
Incident Investigation Date
Feb. 23, 2014
Incident Invest. Change Completion Date
April 30, 2014
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Nov. 23, 2013
Contractor Safety Review Date
Aug. 1, 2013
Contractor Safety Eval. Date
April 22, 2014
Polymerization/Alkylation, Petroleum Refineries (32411)
Prevention Program ID:
1000042842
Safety Review Date
March 17, 2014
PHA Update Date
March 17, 2014
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
Mitigation Systems
  • Dikes
  • Deluge System
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
Procedure Review Date
March 17, 2014
Training Review Date
Dec. 17, 2013
Maintenance Review Date
Nov. 11, 2012
Maintenance Inspection Date
April 7, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
April 14, 2014
Management of Change Review Date
April 17, 2012
Pre-startup Review Date
April 21, 2014
Compliance Audit Date
Dec. 18, 2013
Compliance Audit Change Completion Date
Dec. 18, 2013
Incident Investigation Date
Jan. 7, 2014
Incident Invest. Change Completion Date
Oct. 31, 2014
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Nov. 23, 2013
Contractor Safety Review Date
Aug. 1, 2013
Contractor Safety Eval. Date
April 22, 2014
Aromex (CNHTU/Tetra/TR1), Petroleum Refineries (32411)
Prevention Program ID:
1000042843
Safety Review Date
March 25, 2013
PHA Update Date
March 25, 2013
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Quench System
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
Procedure Review Date
Feb. 21, 2014
Training Review Date
Dec. 17, 2013
Maintenance Review Date
Nov. 11, 2012
Maintenance Inspection Date
March 24, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
April 9, 2014
Management of Change Review Date
April 17, 2012
Pre-startup Review Date
April 9, 2014
Compliance Audit Date
Dec. 18, 2013
Compliance Audit Change Completion Date
Dec. 18, 2013
Incident Investigation Date
March 14, 2013
Incident Invest. Change Completion Date
March 27, 2013
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Nov. 23, 2013
Contractor Safety Review Date
Aug. 1, 2013
Contractor Safety Eval. Date
April 22, 2014
Desulfurizer & Ether, Petroleum Refineries (32411)
Prevention Program ID:
1000042844
Safety Review Date
April 24, 2013
PHA Update Date
April 24, 2013
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Rupture Disks
  • Quench System
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
Procedure Review Date
April 15, 2014
Training Review Date
Dec. 17, 2013
Maintenance Review Date
Nov. 11, 2012
Maintenance Inspection Date
April 21, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
April 15, 2014
Management of Change Review Date
April 17, 2012
Pre-startup Review Date
April 14, 2014
Compliance Audit Date
Dec. 18, 2013
Compliance Audit Change Completion Date
Dec. 18, 2013
Incident Investigation Date
Feb. 27, 2014
Incident Invest. Change Completion Date
March 6, 2014
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Nov. 23, 2013
Contractor Safety Review Date
Aug. 1, 2013
Contractor Safety Eval. Date
April 22, 2014
Hydrocracker, Petroleum Refineries (32411)
Prevention Program ID:
1000042845
Safety Review Date
June 4, 2012
PHA Update Date
June 4, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Rupture Disks
  • Quench System
  • Purge System
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
Procedure Review Date
Sept. 17, 2013
Training Review Date
Dec. 17, 2013
Maintenance Review Date
Nov. 11, 2012
Maintenance Inspection Date
Jan. 31, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
April 17, 2014
Management of Change Review Date
April 17, 2012
Pre-startup Review Date
April 14, 2014
Compliance Audit Date
Dec. 18, 2013
Compliance Audit Change Completion Date
Dec. 18, 2013
Incident Investigation Date
Sept. 8, 2013
Incident Invest. Change Completion Date
Nov. 22, 2013
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Nov. 23, 2013
Contractor Safety Review Date
Aug. 1, 2013
Contractor Safety Eval. Date
April 22, 2014
CCR, Petroleum Refineries (32411)
Prevention Program ID:
1000042846
Safety Review Date
June 17, 2011
PHA Update Date
June 17, 2011
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Quench System
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • Process Controls
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
Procedure Review Date
Feb. 13, 2014
Training Review Date
Dec. 17, 2013
Maintenance Review Date
Nov. 11, 2012
Maintenance Inspection Date
Jan. 31, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
April 17, 2014
Management of Change Review Date
April 17, 2012
Pre-startup Review Date
April 21, 2014
Compliance Audit Date
Dec. 18, 2013
Compliance Audit Change Completion Date
Dec. 18, 2013
Incident Investigation Date
Feb. 20, 2014
Incident Invest. Change Completion Date
May 31, 2014
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Nov. 23, 2013
Contractor Safety Review Date
Aug. 1, 2013
Contractor Safety Eval. Date
April 22, 2014
Blending & Storage, Petroleum Refineries (32411)
Prevention Program ID:
1000042847
Safety Review Date
May 31, 2011
PHA Update Date
May 31, 2011
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
Mitigation Systems
  • Deluge System
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
Procedure Review Date
June 28, 2013
Training Review Date
Dec. 17, 2013
Maintenance Review Date
Nov. 11, 2012
Maintenance Inspection Date
Feb. 12, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
March 20, 2013
Management of Change Review Date
April 17, 2012
Pre-startup Review Date
April 15, 2014
Compliance Audit Date
Dec. 18, 2013
Compliance Audit Change Completion Date
Dec. 18, 2013
Incident Investigation Date
Sept. 1, 2013
Incident Invest. Change Completion Date
March 31, 2014
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Nov. 23, 2013
Contractor Safety Review Date
Aug. 1, 2013
Contractor Safety Eval. Date
April 22, 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:
April 11, 2014
Local Response Agency:
Local Response Agency Phone:
(302) 395-3633
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

Executive Summary:



Corporate Policies Regarding Health, Safety and Accident Prevention



The Delaware City Refining Company, LLC is committed to protecting the health and safety of employees and others in our workplaces and protecting the environment and public wherever we conduct business activities. Our objective is to continuously improve our safety, health and environmental performance. The Company operates, maintains and designs improvements to the Delaware City Refinery to minimize environmental impact and to protect employees, contractors and the public from injury and illness. Safety, health and environmental performance are key factors in selecting and periodically evaluating contractors. The Company audits safety, health and environmental performance to assure compliance and improvement. The Company is prepared to respond quickly and effectively to any incidents involving the refinery, its equipment or products under its control. The refinery has had an active process safety management (PSM) program since 1989.



Employee participation is important in PSM. Refinery operators participate in every process hazards analysis (PHA) and PSM self-audit, contribute experience to updating procedures, evaluate jobs for hot work permits, and participate on incident investigation and emergency response teams. The refinery has two Health & Safety Representatives from the bargaining unit who contribute to overall refinery safety and PSM decisions. In addition, they coordinate the Triangle of Prevention (TOP) incident investigation program which investigates select incidents with trained investigators from both the bargaining unit and management. Additionally, in 2012, the Delaware City Refinery partnered with the United Steel Workers to establish a new "Process Safety Representative" position to improve process safety conditions for all employees in the refinery.



Refinery personnel have held local public meetings to discuss the Risk Management Plan (RM
P) program and the related refinery safety programs. The Company has also led or participated in Chemical Industry Council (CIC) and Local Emergency Planning Committee (LEPC) public meeting to explain the RMP program and accidental release prevention policies and preparedness practices.



Risk Management System



The Delaware City Refinery maintains up-to-date procedures to insure the proper control of hazardous materials. Procedures and systems include provisions for the periodic testing, review, and update of the emergency response programs. Employees are trained and periodically retrained in the methods of detection of hazardous material releases, the potential physical and health risks associated with the materials, and methods for protecting themselves, co-workers, and the public. The refinery investigates, corrects, and reports in writing all incidents involving hazardous materials having caused, or having the potential for causing, injury or loss.



The Refinery has developed a management system to oversee the implementation of the Risk Management Program in accordance with RMP, PSM and Delaware requirements. The management system identifies job functions by responsibility level as indicated below:



Refinery Manager

? Oversight of facility operation

? Facility Spokesperson

? Incident Commander for emergency response

? Management of emergency response activities (First aid, HAZMAT, Confined Space Rescue, fire)



Business Team Leaders

? Implementation of Process Safety Management Program

? Completion of Incident Investigations

? Monitor Compliance

? Oversee and document maintenance

? Management of Change, HAZOP and pre-startup safety reviews

? Department specific employee/ contractor safety training

? Compliance with facility policies/ procedures

? Development of operating procedures.



Refinery Shift Superintendents



? Incident Commander for emergency response

? Enforce compliance of HSE, operating, maintenance and inspection
procedures

? Ensure qualified personnel are present at each post



HSE Manager

? Oversight for RMP compliance

? Review and approve facility safety policies/ programs

? Development of facility emergency response plan

? Planning, executing, and analyzing emergency response drills





In addition, the Delaware City Refinery has implemented a standard for a multi-disciplinary risk management committee. The Risk Management Committee (RMC) composed of knowledgeable subject matter experts (SME) in various disciplines review any change, action or incident that has an unmitigated risk above a defined risk matrix level. Any of the following could come under the committee's review:



? Deviations from existing policies and procedures, deviations from design criteria, deferral of the inspection and/or testing of safety/critical components beyond their scheduled due date.

? Plans that involve a deferral of inspection, testing, or repairs.

? Deferral of mechanical integrity repairs beyond their recommended date.

? Issues outside of these categories if the requestor and RMC chair agree that there is value in the RMC assessing the potential risks and mitigation strategies developed.



Regulated Processes and Substances



The Delaware City Refinery is a complex facility consisting of 10 operating process areas, and the refinery Power Plant. Each area has its own staff, control system, operation building and process-specific procedures. These process areas contain unit operations that may be interconnected but can also work independently.



The refinery is designed and operated to process crude oil into fuels, including propane, butane, gasoline, home heating oil and diesel fuel. The process units may use heat pressure or catalysts to separate and recombine the hydrocarbons in crude oil to produce components for blending into fuel products.



There are no RMP toxic materials stored at the refinery in regulated quantities under the EPA RMP program. Hydrogen su
lfide is present in several processes but it is not stored and does not exist in sufficient quantity for inclusion in either the EPA RMP or PSM programs. Several regulated flammable substances, contained primarily in mixtures are present at refinery. There are nine process areas regulated under the EPA RMP program and one process regulated under the Delaware RMP program.



The Sulfur Recovery process area lacks sufficient quantities of EPA RMP regulated substances to be included in the EPA RMP program. The Sulfur Recovery area is registered for hydrogen sulfide with the Delaware program as a Program Level 3 process. Hydrogen sulfide is not stored but exists in piping between the Gas Plant where it is formed and the Sulfur Recovery area where it is converted to liquid sulfur product. Process areas with high flow rates of hydrogen sulfide have area monitors to provide early warning of possible leaks. Operators and emergency response personnel are trained in the use of fresh air breathing equipment when responding to a release. The Sulfur Recovery area consists of two trains. Each equipment train has a Claus sulfur plant and a tail gas treating unit.



The remaining nine refinery process areas described below are regulated under EPA RMP Program Level 3 because the worst-case release modeling of the flammable endpoint associated with a vapor cloud explosion may reach a public receptor (adjacent industrial facilities, intermittently used recreational area on refinery property) and the processes are regulated under PSM. Information on these nine process areas are reported as part of the EPA RMP submission.



The Crude Unit uses heat and vacuum to separate crude oil into components for further processing. Desalting units remove salts and sour water from crude oil. The Sour Water Stripping section removes hydrogen sulfide and ammonia form the refinery sour water.



The Fluid Coker process uses high temperature to crack heavy hydrocarbon molecules into mor
e useful gasoline and fuel oil components. Fluid coke is a byproduct from the process and is shipped off-site for use as a fuel.



The Fluid Catalytic Cracker and Gas Plant uses a circulating catalyst to break gas oils down into fuel oil, gasoline and light gases. The Gas Plant removes sulfur from light gases arriving from the Catalytic Cracker and other refinery processes and produces fuel gas for process heating and the refinery Power Plant.



The Polymerization and Alkylation process combines light gases into gasoline blending components by the use of catalysts. The Polymerization unit uses solid catalyst while the Alkylation catalyst uses sulfuric acid. Additional sections of this process area isomerize and separate hydrocarbon streams for gasoline blending.



The Naphtha Fractionation and Tetra Unit process separates reformed naphtha into gasoline blending components and product benzene using heat and solvent extraction. A unit in this process area adds hydrogen to raw gasoline to produce more stable material for product gasoline blending. Another unit in this process area removes sulfur from raw gasoline.



The Desulfurizer and Ether area processes use heat and catalyst to promote desirable chemical reactions. Four Desulfurizers Trains remove sulfur compounds from raw gasoline, kerosene and light fuel oils. The Ether Units produce the oxygenate gasoline components.



The Hydrocracker and Hydrogen process area includes a unit for converting high sulfur gas oil into heating oil and gasoline, as unit for producing hydrogen and a selective hydrogenation unit. The Hydrocracker uses high pressure and catalyst to crack heavy gas oils into lighter gasoline and fuel oils. It has alarms on all critical operating parameters and the capability to safely depressure the process unit to the flare system during an emergency. The hydrogen unit produces pure hydrogen by reforming methane from natural gas. The selective hydrogenation unit adds hydrogen to less
stable unsaturated molecules in raw gasoline to minimize gum formation.



The CCR uses a catalyst at high temperature to rearrange desulfurized naphtha molecules into high octane material for gasoline blending. Hydrogen is a byproduct of the reforming reaction. It is purified in an adsorption unit before being piped to other refinery processes.



The Blending and Storage area contains tanks of crude oil, blending component oils and finished petroleum products. Product propane and butane are stored as liquids under pressure. . These tanks are instrumented with temperature indicators and with level indicators and alarms. Their safety systems include pressure relief systems. Above ground propane and butane tanks have remotely-operated shutoff valves and water spray deluge systems.









Off-Site Hazard Assessment



The Refinery conducted an off-site consequence assessment consisting of an overall worst-case release and an alternative release scenario for flammable substance, as specified in the EPA RMP program requirements. In accordance with Homeland Security considerations, the release scenarios or the modeled consequences are not discussed in the Risk Management Plan Executive Summary. This information is, however, included in the RMP Data Elements. The worst-case release assessment for substances regulated only by the Delaware program are found within the Delaware RMP submittal document.



Prevention Program



The Delaware City Refinery has complied with the Delaware's PSM regulations since the Extremely Hazardous Risk Management Act was promulgated in 1989 as well as OSHA Process Safety Management (PSM) regulation 29 CFR 1910.119, promulgated in 1992. The refinery keeps updated process safety information including equipment data, piping and instrument drawings, and material safety data sheets (MSDS). The process equipment is regularly inspected and maintained. Each inspection is compared with previous inspections and to applicable Company
and industry standards to help plan maintenance and prevent accidental releases due to equipment failure. Changes to equipment, procedures or processes are evaluated and tracked in the computer based Management of Change (MOC) system. Operating procedures are updated as needed and reviewed annually. Operators receive thorough training to qualify for each position they work. Operator skills are maintained through documented refresher training every three years.



An initial process hazards analysis (PHA) was conducted for each process unit. Revalidation PHA studies are completed every five years. Recommendations from the PHA studies are tracked to their resolution in a computer-based system. The refinery performs a self-audit of PSM compliance every three years. Delaware's Accidental Release Prevention group has made PSM inspections. The refinery looks forward to these inspections as a means to continually improve activities and documentation that can help prevent incidents and accidental releases.



Five-year Accident History



Over the most recent five-years period, there have been no releases from a covered process involving a regulated substance held above its threshold quantity in process that resulted in on-site deaths or injuries, or known off-site deaths, injuries, evacuations, sheltering in place property damage or environmental damage. One process unit (Desulfurizer Train 4) experienced an event that resulted in exceeding the threshold for on-site property damage. This event is included in the refinery 5-year accident history in both the DNREC and EPA RMP reports.



Emergency Response Program



The Delaware City Refinery Emergency Response program is about prevention, control and countermeasure plans for refinery related events. It is based on the identification and understanding of credible exposures to people, property and the public inherently related to refinery operations.

The clear understanding of potential exposures provides
the basis for:

? Contingency planning for prevention, control and mitigation,

? Emergency response equipment design and readiness,

? Response personnel training and preparedness, and

? Collaboration with agencies and response organizations external to DCR



DCR has an Integrated Contingency Plan (ICP) at the core of its program. The ICP allows the refinery to comply with multiple federal and state emergency planning requirements while encompassing DCR specific response strategies. The strategies contained in the ICP are a combination of learnings, best practices and requirements from agencies (e.g. EPA, DOT, OSHA, US Coast Guard, FEMA, DEMA, etc.) and industry.







The DCR ICP contains:

? Facility Response Plan

? Emergency Response Action Plan (ERAP)

? Pre-Planning Information

? SPCC Plan

? Emergency Detection & Communication

? Emergency Response Categories and How to respond

? Emergency Response Equipment

? Severe Weather & Natural Disasters

? Security Action Plans



DCR emergency response teams (i.e. Fire, Hazmat, Oil Spill, Medical, Confined Space Rescue, High Angle Rescue and Emergency Operations Center) are trained by nationally and internationally-renowned providers of emergency training. These teams routinely conduct joint training, exercises and drills with industry, agencies and other support organizations. The emergency response teams are supported by modern fixed, portable and mobile response equipment designed specifically for responding to refinery related events.



The DCR Emergency Response program is integrated with the local, state and federal emergency management programs ensuring that appropriate and timely notification and interaction with agencies external to the refinery occurs. This provides for timely execution of external response plans by the responsible agencies.



Planne
d Changes to Improve Safety



The Delaware City Refinery is designed, maintained and operated in a manner to safeguard people, property and the public. DCR has organized its management systems to identify and address hazards and potential risks. The Refinery utilizes the "Plan, Do, Check, Act" philosophy to continuously improve occupational and process safety at the facility. The foundations of the refinery's continuous improvement process include:

? Employee and contract workforce engagement

? Equipment design, mechanical integrity and equipment reliability

? Organizational performance and improvement

? Occupational and process safety system structure

? Safe work and operational procedures and practices

? Inspection and auditing

? Incident Investigation,

? Employee and contract workforce training and education,

? Hazard Analysis,

? Leading and Lagging performance measurement,

? Contingency planning and Emergency Preparedness