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Chevron Phillips Chemical Co. - PA Plant

Parent Companies:
Chevron Phillips Chemical Company LP
EPA Facility ID:
100000092142
Other ID:
77640CHVRN2001S
Facility DUNS:
879914232
Parent Company DUNS:
152975665

Location:

Address:
2001 S. Gulfway Drive
Port Arthur, TX 77641
County:
JEFFERSON
Lat / Long:
29.852, -93.977 (Get map)
Method:
Interpolation - Photo
Description:
Administrative Building
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
2400

Owner/Operator:

Name:
Chevron Phillips Chemical Co. LP
Phone:
(409) 985-0700
Address:
P. O. Box 1547
Port Arthur, TX 77641 -1547
Foreign Address:

Person responsible for RMP implementation:

Name:
Mark Hickey
Title:
EHS&S Manager

Emergency contact:

Name:
Christopher Gonzales
Title:
Emergency Preparedness & Sec Coordn
Phone:
(409) 985-0782
24-hour phone:
(409) 460-0236
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(409) 985-0708
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Jefferson County LEPC
Full-Time Equivalent Employees:
274
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
O-1235
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Oct. 1, 2014
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Ethylene Unit 1544
RMP ID:
1000059676
CBI claimed:
No
Program Level:
3
NAICS:
Petrochemical Manufacturing (32511)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
14,000,000
No
Public OCA Chemical
0
No
Cyclohexane Unit 1741
RMP ID:
1000059677
CBI claimed:
No
Program Level:
3
NAICS:
Petrochemical Manufacturing (32511)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
22,000
No
Public OCA Chemical
0
No
CFPU 1740
RMP ID:
1000059678
CBI claimed:
No
Program Level:
3
NAICS:
Petrochemical Manufacturing (32511)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
633,235
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Phil Cuevas
Address:
2001 S. Gulfway Drive
Port Arthur, TX 77641 -1547
Foreign Address:

Phone:
(409) 985-0781

Latest RMP Submission:

Date:
Jan. 2, 2015
Type:
Resubmission
Reason:
Voluntary update (not described by any of the above reasons)
Registered:
Yes
RMP ID:
1000047822

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 Ethylene Unit 1544)
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 Ethylene Unit 1544)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

July 7, 2014 at 20:08
ID:
1000036832
NAICS:
Petrochemical Manufacturing (32511)
Duration:
7 hours and 30 minutes
Chemicals involved:
  • Propane
  • Ethane
Release events:
Fire
Weather conditions at time of event
Wind speed:
5.0 miles/h SSW
Temperature:
85.00 ℉
Atmospheric stability:
F
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:
2
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$58000000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Unknown
Contributing factors:
  • Process design failure
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised training
  • Revised operating procedures
  • New process controls

7. Prevention: Program level 3

Ethylene Unit 1544, Petrochemical Manufacturing (32511)
Prevention Program ID:
1000049703
Safety Review Date
Aug. 21, 2014
PHA Update Date
Aug. 21, 2014
PHA Techniques
  • None
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Polymerization
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
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
  • Rupture Disks
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
  • Process Parameters
  • Process Controls
  • Process Detection
Training Type
  • None
Competency Testing
  • None
Procedure Review Date
Dec. 5, 2014
Training Review Date
June 12, 2014
Maintenance Review Date
April 9, 2014
Maintenance Inspection Date
Oct. 1, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
Sept. 18, 2014
Management of Change Review Date
Oct. 16, 2014
Pre-startup Review Date
Sept. 18, 2014
Compliance Audit Date
March 29, 2013
Compliance Audit Change Completion Date
July 1, 2016
Incident Investigation Date
Aug. 3, 2014
Incident Invest. Change Completion Date
Jan. 11, 2015
Participation Plan Review Date
June 15, 2010
Hot Work Review Date
Aug. 12, 2014
Contractor Safety Review Date
Oct. 3, 2014
Contractor Safety Eval. Date
Oct. 21, 2014
Cyclohexane Unit 1741, Petrochemical Manufacturing (32511)
Prevention Program ID:
1000049704
Safety Review Date
June 30, 2010
PHA Update Date
June 30, 2010
PHA Techniques
  • None
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Polymerization
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
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
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • Process Parameters
  • Process Controls
Training Type
  • None
Competency Testing
  • None
Procedure Review Date
Dec. 5, 2014
Training Review Date
March 27, 2014
Maintenance Review Date
April 9, 2014
Maintenance Inspection Date
April 23, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
Oct. 22, 2014
Management of Change Review Date
Oct. 16, 2014
Pre-startup Review Date
Oct. 22, 2014
Compliance Audit Date
March 29, 2013
Compliance Audit Change Completion Date
July 1, 2016
Incident Investigation Date
July 10, 2014
Incident Invest. Change Completion Date
July 13, 2014
Participation Plan Review Date
June 15, 2010
Hot Work Review Date
Aug. 12, 2014
Contractor Safety Review Date
Oct. 3, 2014
Contractor Safety Eval. Date
Oct. 21, 2014
CFPU 1740, Petrochemical Manufacturing (32511)
Prevention Program ID:
1000049705
Safety Review Date
March 24, 2010
PHA Update Date
March 24, 2010
PHA Techniques
  • None
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Polymerization
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
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
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
  • Process Parameters
  • Process Controls
Training Type
  • None
Competency Testing
  • None
Procedure Review Date
Dec. 5, 2014
Training Review Date
March 27, 2014
Maintenance Review Date
April 9, 2014
Maintenance Inspection Date
Oct. 6, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
Sept. 30, 2014
Management of Change Review Date
Oct. 16, 2014
Pre-startup Review Date
Sept. 30, 2014
Compliance Audit Date
March 29, 2013
Compliance Audit Change Completion Date
July 1, 2016
Incident Investigation Date
Jan. 14, 2013
Incident Invest. Change Completion Date
Dec. 15, 2014
Participation Plan Review Date
June 15, 2010
Hot Work Review Date
Aug. 12, 2014
Contractor Safety Review Date
Oct. 3, 2014
Contractor Safety Eval. Date
Oct. 21, 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:
March 20, 2014
Local Response Agency:
Local Response Agency Phone:
(409) 835-8757
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

PORT ARTHUR: CHEMICAL MANUFACTURING PLANT

RMP EXECUTIVE SUMMARY



Chevron Phillips Chemical Company LP is an indirect wholly-owned subsidiary of Chevron Phillips Chemical Company LLC, one of the world's top producers of olefins and polyolefins and a leading supplier of aromatics, alpha olefins, styrenics, specialty chemicals, plastic piping and polymer resins. With approximately 5,000 employees, the LLC and its affiliates own more than $10.5 billion in assets, including 37 manufacturing and research facilities in eight countries. Chevron Phillips Chemical Company LLC is equally owned by Chevron U.S.A. Inc., an indirect wholly-owned subsidiary of Chevron Corporation, and by wholly-owned subsidiaries of Phillips 66, and is headquartered in The Woodlands, Texas.



The Port Arthur Plant employs approximately 274 full time equivalent employees. This facility is managed by Michael P. Nemeth, Plant Manager. Mr. Mark Hickey, EHS Manager, is responsible for RMP implementation for this site.



The Port Arthur Plant has developed an Integrated Contingency Plan to guide responses to various types of emergencies and events. This ICP includes procedures for coordination with on- and off-site responders. Jefferson County Local Emergency Planning Committee (409-835-8757) is the primary organization responsible for coordinating emergency response operations for this area. The Port Arthur Plant is an active member of this organization and we are also a member of Sabine Neches Chiefs Association, a mutual assistance emergency response organization dedicated to providing fire protection and safety management resources to the petrochemical industry of Jefferson County. In the event of a major release of any hazardous substance, or a fire, the Port Arthur Plant would coordinate emergency response with these groups as well as the appropriate governmental agencies as needed. The plant has an internal plant wide alarm system for fires and emergencies. In addition, the plant
can activate the (community) alarm system in the event of incidents with potential offsite consequences. The plant also maintains a volunteer Emergency Response Team.



This facility uses light hydrocarbon feedstocks purchased from refineries to make the following products: Cyclohexane, Ethylene, Propylene, 1,3-Butadiene and RPG. This facility consists of three process units designed to make these products. Greater than threshold quantities of regulated flammable mixtures are found in this plant, which includes: methane, hydrogen, ethylene, ethane, propylene, propane, butenes, butanes, 1,3-butadiene, pentenes, and pentanes.



This facility includes (3) RMP covered processes, that we have identified as the Ethylene Unit (EU-1544), Cyclohexane Unit (CU-1741), and the Cumene Feed Prep Unit (CFPU-1740). The (3) processes contain mixtures of flammable regulated substances in greater than threshold quantities and are classified as Prevention Program 3 facilities.



Various safety measures are in place to prevent the release of flammable chemicals. Some examples of these measures include: (pressure relief valves, hydrocarbon area detectors, remote valves to isolate the process, administrative controls, operating procedures, Safety Instrumented Systems, etc,).



This facility is covered by OSHA Process Safety Management regulations and we are in substantial compliance with these PSM regulations. This facility is also covered by numerous EPA and Texas Commission on Environmental Quality regulatory requirements designed to limit the impact on the environment and we are in substantial compliance with these regulations.



Accidents with On-Site Effects:

The plant had (1) accident with on-site effects in the last five years involving chemicals that are on the 40 CFR PART 68.130 List of Substances and meeting the RMP criteria for accidents.



Accidents with Off-Site Effects:

The plant had (0) accidents with off-site effects in the last five years involv
ing chemicals that are on the 40 CFR PART 68.130 List of Substances.



The Port Arthur Plant is continually reviewing our plant's physical facilities and operations to maintain a safe place for our employees to work, and to minimize environmental impacts. The plant manages all aspects of process safety through employee participation at all levels in the organization. Each element of the PSM and RMP standards is assigned to a responsible organizational position to maintain the systems that ensure compliance with regulatory requirements and management of that aspect of process safety. We have adopted a program of continuous improvement which can involve changes to plant design, operating procedures, or safety systems. The facility continually uses the MOC / PSSR and PHA processes, to implement and evaluate changes to the equipment and chemical processes, and to determine if change will occur to the Alternative or Worst Case Release scenarios that have been previously identified. The facility also uses extensive facility siting procedures / requirements, to continuously evaluate personnel safety and process hazards.