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Coffeyville Resources Refining & Marketing, LLC

Parent Companies:
CVR Refining, LP
EPA Facility ID:
100000146175
Other ID:
Facility DUNS:
144266660
Parent Company DUNS:
142905293

Location:

Address:
400 North Linden Street
Coffeyville, KS 67337
County:
MONTGOMERY
Lat / Long:
37.051, -95.602 (Get map)
Method:
Interpolation - Map
Description:
Plant Entrance (General)
Horizonal accuracy:
40 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
48000

Owner/Operator:

Name:
CRRM, LLC
Phone:
(620) 251-4000
Address:
P.O. Box 1566
Coffeyville, KS 67337 -1566
Foreign Address:

Person responsible for RMP implementation:

Name:
Darin Rains
Title:
VP and General Manager Refining
Email:

Emergency contact:

Name:
Steven Lafferty
Title:
Safety Manager
Phone:
(620) 252-4670
24-hour phone:
(620) 251-4000
Ext or PIN:
4200

Other contacts:

Facility (or company) email:
Facility phone:
(620) 251-4000
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Montgomery County LEPC
Full-Time Equivalent Employees:
369
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
1250003
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
July 30, 2014
Inspecting Agency:
OSHA
Using Predictive Filing:
No

Processes:

Alky Feed Treater Systems
RMP ID:
1000060730
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
59,000
No
Public OCA Chemical
0
No
Propane Storage & Loading
RMP ID:
1000060731
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Propane
74-98-6
1,700,000
No
Public OCA Chemical
0
No
Sat Gas South Unit
RMP ID:
1000060732
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
77,000
No
Public OCA Chemical
0
No
Coker Unit
RMP ID:
1000060733
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
77,000
No
Public OCA Chemical
0
No
HF Alky Unit
RMP ID:
1000060734
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
200,000
No
Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
7664-39-3
190,000
No
Propane
74-98-6
30,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Sat Gas North Unit
RMP ID:
1000060735
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
64,000
No
Public OCA Chemical
0
No
FCC Unit
RMP ID:
1000060736
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
240,000
No
Public OCA Chemical
0
No
Isomerization Unit
RMP ID:
1000060737
CBI claimed:
No
Program Level:
1
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
51,000
No
Public OCA Chemical
0
No
Butanes and NFPA4 Storage
RMP ID:
1000060738
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Butane
106-97-8
1,700,000
No
Isobutane [Propane, 2-methyl]
75-28-5
4,800,000
No
Flammable Mixture
00-11-11
1,600,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
CCR Unit
RMP ID:
1000060739
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
270,000
No
Public OCA Chemical
0
No
Hydrobon Unit
RMP ID:
1000060740
CBI claimed:
No
Program Level:
1
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
43,000
No
Public OCA Chemical
0
No
ULSG Unit
RMP ID:
1000060741
CBI claimed:
No
Program Level:
1
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
17,000
No
Public OCA Chemical
0
No
#1 Crude Unit
RMP ID:
1000060794
CBI claimed:
No
Program Level:
1
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
39,000
No
Public OCA Chemical
0
No
#2 Crude Unit
RMP ID:
1000060795
CBI claimed:
No
Program Level:
1
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
19,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Sage Environmental Consulting, L.P.
Address:
720 West Araphao
Richardson, TX 77080
Foreign Address:

Phone:
(972) 480-9800

Latest RMP Submission:

Date:
Jan. 29, 2015
Type:
Resubmission
Reason:
Regulated substance present above TQ in new (or previously not covered) process (40 CFR 68.190(b)(4))
Registered:
Yes
RMP ID:
1000048494

Deregistration:

Date:
Effective Date:
Reason:
Other Reason:

2. Toxics: Worst-case

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

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

Public OCA Chemical (in HF Alky Unit)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
10.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps

3. Toxics: Alternative release

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

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

Public OCA Chemical (in HF Alky Unit)
CBI claimed:
No
Percent weight:
90.0
Physical state:
Gas
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • Dikes
  • Enclosures
  • Drains
  • Sumps
not considered:
  • Berms
Active mitigation
considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Flares
  • Emergency shutdown
not considered:
  • Excess flow valve
  • Scrubbers

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 Propane Storage & Loading)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Blast walls
Public OCA Chemical (in Isomerization Unit)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
Passive mitigation
considered:
  • None
not considered:
  • Blast walls
Public OCA Chemical (in Butanes and NFPA4 Storage)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Blast walls
Public OCA Chemical (in Hydrobon Unit)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
Passive mitigation
considered:
  • None
not considered:
  • Blast walls
Public OCA Chemical (in ULSG Unit)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
Passive mitigation
considered:
  • None
not considered:
  • Blast walls
Public OCA Chemical (in #1 Crude Unit)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
Passive mitigation
considered:
  • None
not considered:
  • Blast walls
Public OCA Chemical (in #2 Crude Unit)
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 Sat Gas South Unit)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • Dikes
not considered:
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

July 29, 2014 at 00:20
ID:
1000037389
NAICS:
Petroleum Refineries (32411)
Duration:
30 minutes
Chemicals involved:
  • Flammable Mixture
Release events:
Liquid spills/evaporation
Fire
Weather conditions at time of event
Wind speed:
0.100000001 miles/h ENE
Temperature:
67.00 ℉
Atmospheric stability:
F
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
1
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
3
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$6300000
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 and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • New process controls
Dec. 28, 2010 at 04:00
ID:
1000037387
NAICS:
Petroleum Refineries (32411)
Duration:
47 minutes
Chemicals involved:
  • Sulfur dioxide (anhydrous)
Release events:
Gas release
Fire
Weather conditions at time of event
Wind speed:
4.0 miles/h S
Temperature:
28.00 ℉
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:
0
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$5000000
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:
  • Human error
  • Management error
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Enforce procedures and evaluate instrumentation

7. Prevention: Program level 3

Alky Feed Treater Systems, Petroleum Refineries (32411)
Prevention Program ID:
1000050509
Safety Review Date
June 7, 2011
PHA Update Date
May 12, 2010
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
Feb. 24, 2014
Training Review Date
May 21, 2014
Maintenance Review Date
June 23, 2014
Maintenance Inspection Date
Oct. 1, 2011
Equipment Tested
Yes
Management of Change Most Recent Date
Sept. 24, 2014
Management of Change Review Date
May 6, 2014
Pre-startup Review Date
Aug. 14, 2014
Compliance Audit Date
Aug. 4, 2014
Compliance Audit Change Completion Date
Aug. 4, 2015
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
May 1, 2014
Hot Work Review Date
July 16, 2014
Contractor Safety Review Date
July 31, 2014
Contractor Safety Eval. Date
Nov. 3, 2014
Propane Storage & Loading, Petroleum Refineries (32411)
Prevention Program ID:
1000050510
Safety Review Date
June 30, 2007
PHA Update Date
June 17, 2013
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • Process Detection
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
May 30, 2014
Training Review Date
Aug. 6, 2010
Maintenance Review Date
June 23, 2014
Maintenance Inspection Date
Sept. 1, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 30, 2014
Management of Change Review Date
May 6, 2014
Pre-startup Review Date
Jan. 12, 2015
Compliance Audit Date
Aug. 4, 2014
Compliance Audit Change Completion Date
Aug. 4, 2015
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
May 1, 2014
Hot Work Review Date
July 16, 2014
Contractor Safety Review Date
July 31, 2014
Contractor Safety Eval. Date
Nov. 3, 2014
Sat Gas South Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000050511
Safety Review Date
May 31, 2011
PHA Update Date
Feb. 15, 2011
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
May 21, 2014
Training Review Date
Aug. 26, 2010
Maintenance Review Date
June 23, 2014
Maintenance Inspection Date
Oct. 1, 2011
Equipment Tested
Yes
Management of Change Most Recent Date
March 26, 2014
Management of Change Review Date
Oct. 9, 2009
Pre-startup Review Date
Aug. 27, 2014
Compliance Audit Date
Aug. 4, 2014
Compliance Audit Change Completion Date
Aug. 4, 2015
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
May 1, 2014
Hot Work Review Date
July 16, 2014
Contractor Safety Review Date
July 31, 2014
Contractor Safety Eval. Date
Nov. 3, 2014
Coker Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000050512
Safety Review Date
June 10, 2011
PHA Update Date
April 23, 2010
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Excess Flow Device
  • Quench System
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
May 21, 2014
Training Review Date
June 20, 2014
Maintenance Review Date
June 23, 2014
Maintenance Inspection Date
Dec. 1, 2011
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 14, 2015
Management of Change Review Date
Oct. 9, 2009
Pre-startup Review Date
Jan. 12, 2015
Compliance Audit Date
Aug. 4, 2014
Compliance Audit Change Completion Date
Aug. 4, 2015
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
May 1, 2014
Hot Work Review Date
July 16, 2014
Contractor Safety Review Date
July 31, 2014
Contractor Safety Eval. Date
Nov. 3, 2014
HF Alky Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000050513
Safety Review Date
May 21, 2012
PHA Update Date
May 21, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Process Detection
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
May 29, 2014
Training Review Date
June 11, 2013
Maintenance Review Date
June 23, 2014
Maintenance Inspection Date
Aug. 1, 2013
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 7, 2015
Management of Change Review Date
Oct. 9, 2009
Pre-startup Review Date
Nov. 3, 2014
Compliance Audit Date
Aug. 4, 2014
Compliance Audit Change Completion Date
Aug. 4, 2015
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
May 1, 2014
Hot Work Review Date
July 16, 2014
Contractor Safety Review Date
July 31, 2014
Contractor Safety Eval. Date
Nov. 3, 2014
Sat Gas North Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000050514
Safety Review Date
Dec. 8, 2009
PHA Update Date
June 15, 2011
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
May 29, 2014
Training Review Date
July 31, 2013
Maintenance Review Date
June 23, 2014
Maintenance Inspection Date
Nov. 1, 2011
Equipment Tested
Yes
Management of Change Most Recent Date
March 26, 2014
Management of Change Review Date
Oct. 9, 2009
Pre-startup Review Date
Aug. 27, 2014
Compliance Audit Date
Aug. 4, 2014
Compliance Audit Change Completion Date
Aug. 4, 2015
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
May 1, 2014
Hot Work Review Date
July 16, 2014
Contractor Safety Review Date
July 31, 2014
Contractor Safety Eval. Date
Nov. 3, 2014
FCC Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000050515
Safety Review Date
June 10, 2011
PHA Update Date
Nov. 19, 2014
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
May 29, 2014
Training Review Date
June 12, 2013
Maintenance Review Date
June 23, 2014
Maintenance Inspection Date
Dec. 1, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 22, 2015
Management of Change Review Date
Oct. 9, 2009
Pre-startup Review Date
Jan. 8, 2015
Compliance Audit Date
Aug. 4, 2014
Compliance Audit Change Completion Date
Aug. 4, 2015
Incident Investigation Date
Dec. 28, 2010
Incident Invest. Change Completion Date
Jan. 27, 2011
Participation Plan Review Date
May 1, 2014
Hot Work Review Date
July 16, 2014
Contractor Safety Review Date
July 31, 2014
Contractor Safety Eval. Date
Nov. 3, 2014
Butanes and NFPA4 Storage, Petroleum Refineries (32411)
Prevention Program ID:
1000050517
Safety Review Date
July 8, 2008
PHA Update Date
May 21, 2012
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
May 30, 2014
Training Review Date
Aug. 19, 2010
Maintenance Review Date
June 23, 2014
Maintenance Inspection Date
Sept. 1, 2012
Equipment Tested
Yes
Management of Change Most Recent Date
July 18, 2014
Management of Change Review Date
Oct. 9, 2009
Pre-startup Review Date
Sept. 8, 2014
Compliance Audit Date
Aug. 4, 2014
Compliance Audit Change Completion Date
Aug. 4, 2015
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
May 1, 2014
Hot Work Review Date
July 16, 2014
Contractor Safety Review Date
July 31, 2014
Contractor Safety Eval. Date
Nov. 3, 2014
CCR Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000050518
Safety Review Date
May 24, 2011
PHA Update Date
June 6, 2011
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
Jan. 8, 2015
Training Review Date
Aug. 1, 2013
Maintenance Review Date
June 23, 2014
Maintenance Inspection Date
Oct. 1, 2011
Equipment Tested
Yes
Management of Change Most Recent Date
Oct. 8, 2014
Management of Change Review Date
Oct. 9, 2009
Pre-startup Review Date
Oct. 28, 2014
Compliance Audit Date
Aug. 4, 2014
Compliance Audit Change Completion Date
Aug. 4, 2015
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
May 1, 2014
Hot Work Review Date
July 16, 2014
Contractor Safety Review Date
July 31, 2014
Contractor Safety Eval. Date
Nov. 3, 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:
Oct. 29, 2014
Local Response Agency:
Local Response Agency Phone:
(620) 330-1260
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



ACCIDENTAL RELEASE PREVENTION AND RESPONSE POLICIES



Coffeyville Resources Refining & Marketing, LLC (CRRM) has a long-standing commitment to worker and public safety and protecting the environment. This commitment is demonstrated by the resources invested in accident prevention, such as personnel training and consideration of safety in the design, installation, operation, and maintenance of our processes. The objective of risk management and our policy is to implement effective controls to prevent releases of regulated substances. However, if a release does occur, CRRM's trained personnel will respond to control, contain, and mitigate the release.



DESCRIPTION OF THE STATIONARY SOURCE AND REGULATED SUBSTANCES



CRRM's Coffeyville Refinery (Refinery), located near Coffeyville, KS, operates a variety of processes to produce petroleum products (e.g., propane, butane, gasoline, diesel fuels and coke) from crude oil. Several regulated flammable substances and flammable mixtures and one toxic substance, hydrofluoric acid, are contained in processes above threshold quantities.



Processes included in the plan are subject to the U.S. EPA's Accidental Release Prevention Risk Management Program (RMP). Some processes at the Refinery are also subject to the Occupational Safety and Health Administration (OSHA) Process Safety Management (PSM) regulation.



GENERAL ACCIDENT PREVENTION PROGRAM STEPS



The following is a summary of the general accident prevention program in place at the Refinery. This section addresses the following elements: Process Safety Information, Process Hazard Analysis, Operating Procedures, Training, Mechanical Integrity, Management of Change, Pre-startup Review, Compliance Audits, Incident Investigation, Employee Participation, Hot Work Permit and Contractors. The accident prevention program at the Refinery equally covers all individually listed regulated substances, flammable mixtures, and toxic substance.



Proces
s Safety Information



CRRM maintains a variety of technical documents and standard operating procedures that are used to help maintain safe operation of the processes. These documents address chemical properties and associated hazards, safe 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 inadvertent mixing of chemicals. This information addresses any known hazards associated with the use and handling of chemicals. Safe operating limits and consequences of deviation have been established for processes. The Refinery ensures that processes are maintained within these safe operating limits using computerized process controls and monitoring instruments, highly trained personnel and protective systems (e.g., automated shutdown systems, alarm systems, pressure relieving systems).



The Refinery also maintains numerous technical documents that provide information about the design and construction of process equipment. These documents include materials 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 ensure that safety features in the process are not compromised.



Process Hazard Analysis



The Refinery has a comprehensive program to help ensure that hazards associated with the various processes are identi
fied and controlled. Within this program, each process is systematically examined to identify hazards and ensure that adequate controls are in place to manage these hazards. The refinery primarily uses the Hazard and Operability (HAZOP) technique to perform Process Hazard Analysis (PHA). The analyses are conducted using a team of people who have operating experience and engineering expertise on the process evaluated. The PHA 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.



To ensure that the process controls are consistent with the design safety features, the Refinery periodically updates and revalidates the hazard analysis results. Hazard reviews are also performed during the design stage of new facilities and for facilities undergoing significant modification.



Operating Procedures



The Refinery maintains written procedures that address various modes of process operations, such as:

(1) initial startup;

(2) normal operations;

(3) temporary operations;

(4) emergency shutdown;

(5) emergency operations;

(6) normal shutdown; and,

(7) startup following a turnaround or after an emergency shutdown.



These procedures are used as a reference by experienced operators and provide a consistent basis for training of new operators. The procedures are maintained current and accurate by revising them as necessary to reflect changes made through the management of change process. These procedures are reviewed and certified annually as current and accurate.



Training



To complement the written procedures for process operations, the Refinery has implemented a comprehensive training program for all employees involved in operating a process. New employees are classified as trainees and receive basic training in refinery operations, policies and safe work practices. The tra
inee then completes curriculum specific training to their assigned area to obtain Operator 3 level certification under the guidance of the area trainer. The trainee will also learn and perform process-specific duties and tasks under the guidance of senior operators. After operators demonstrate (e.g., through tests, skills demonstration) having adequate knowledge to perform the duties and tasks in a safe manner on their own, they can independently perform all job tasks of an Operator 3. Operators will progress through subsequent job levels in the same manner. In addition, all operators periodically receive refresher training on the operating procedures to ensure that their skills and knowledge are maintained at an acceptable level. This refresher training is conducted at least every 3 years. All training is documented for each operator, including the means used to verify that the operator understood the training.



Mechanical Integrity



The 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 processes;

(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 equ
ipment 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, the deficiency will be corrected before placing the equipment back into service or the equipment use will be reviewed to determine necessary actions to ensure the continued safe operation of the equipment.



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



Management of Change



The Refinery has a comprehensive system to manage changes to processes. This system requires that changes to items such as process equipment, chemicals, technology, procedures, and other facility changes be properly reviewed and authorized before implementation. Changes are reviewed to (1) ensure that adequate controls are in place to manage any new hazards, and (2) verify that existing controls have not been compromised by the change.



Affected chemical hazard information, process operating limits, and equipment information, as well as procedures, are updated to incorporate these changes. In addition, operating and maintenance personnel are provided any necessary training on the change.



Pre-startup Review



The Refinery conducts a pre-startup review for any new facility or facility modification that requires a change in the process safety information. The purpose of the pre-startup review 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 an additional check to ensure construction is in accordance with the design specifications and that all supporting systems are operationally ready. The pre-startup review tea
m uses checklists to verify all aspects of readiness. A pre-startup review involves field verification of the construction and serves a quality assurance function by requiring verification that accident prevention program requirements are properly implemented.



Compliance Audits



To help ensure that the accident prevention program is functioning properly, the Refinery conducts a compliance audit at least every three years to determine whether the procedures and practices required by the accident prevention program are being implemented. 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 resolution of each finding is documented, and the two most recent audit reports are retained.



Incident Investigation



The Refinery promptly investigates all incidents that resulted in, or reasonably could have resulted in a fire/explosion or toxic gas release that could lead to personal injury, severe environmental impact, or major property damage. The goal of each investigation is to determine the cause(s) and develop corrective actions to prevent a recurrence of the incident or a similar incident. The investigation team documents its findings, develops recommendations to prevent a recurrence, and forwards these results to Refinery management for resolution. Corrective actions taken in response to the investigation team's findings and recommendations are tracked until they are complete. The 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, and are reviewed during PHAs and PHA revalidations.



Employee Participation



The Refinery encourages employees to participate in all aspects of process safety management and accident preven
tion. 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 also form the Emergency Response Team (ERT). Employees have access to information created as part of the Refinery accident prevention program, which is documented in an employee participation plan that is maintained at the Refinery.



Hot Work Permit



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



Contractors



The Refinery uses contractors to supplement its workforce during periods of increased maintenance or construction activities. Contractors are to adhere to all safety rules and practices applicable to CRRM employees. 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 the
ir 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 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.



SPECIFIC ACCIDENT PREVENTION PROGRAM MEASURES



The processes at the Refinery have hazards that must be managed to ensure continued safe operation. The accident prevention program summarized in the previous section is applied to all processes at the refinery. Collectively, these prevention program activities help prevent potential accident scenarios that could be caused by equipment failures and human errors.



In addition to the accident prevention program activities, the Refinery has safety features on many units to help to:

(1) contain/control a release;

(2) quickly detect a release; and,

(3) reduce the consequences of or mitigate a release.



The following risk reduction and safety measures are used by CRRM in various processes:



1. Release Prevention

(a) Operating systems monitored and controlled 24/7 by trained operating personnel

(b) Alarms to provide early indication of approaching operating limits for operator intervention

(c) Redundant equipment and instrumentation (e.g., uninterruptable power supply for process control system)

(d) Routine inspection and testing of instruments, analyzers and safety interlocks

(e) Vehicular traffic prohibited from critical areas

(f) Limited facility access and 24/7 security



2. Release Detection

(a) Hydrocarbon detectors with alarms

(b) Hydrogen sulfide (H2S) detectors with alarms

(c) Hydrofluoric acid (HF) detectors with alarms

(d) TV surveillance cameras

(e) Operator surveillance



3. Release Containme
nt/Control

(a) Pressure control devices

(b) Process relief valves protecting equipment from overpressure discharge to flare

(c) Automated shutdown systems for specific process parameters

(d) Valves to isolate the process (manual or automated)

(e) Dikes and curbing to contain liquid releases



4. Mitigation

(a) Fire suppression and extinguishing systems

(b) Deluge system for specific equipment

(c) Trained on-site Emergency Response Team

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

(e) Blast resistant buildings to help protect personnel and control systems

(f) Emergency drills with plant personnel, and community emergency responders including LEPC and Mutual Aid Teams



FIVE-YEAR ACCIDENT HISTORY



The Refinery had two RMP-reportable incidents in the five-year period ending January 2015. An incident occurred on December 28, 2010 when loss of containment of gas oil from the FCCU Fractionator resulted in a fire. On-site impacts resulted from the incident, but there were no off-site impacts. The incident was investigated and corrective actions developed to improve safety and prevent recurrence.



An incident occurred on July 29, 2014. A pump seal failed, releasing hydrocarbon to the atmosphere and resulting in a fire. The process was safely shut down and the fire was extinguished. On-site impacts resulted from the incident, but there were no off-site impacts. The incident was investigated and corrective actions developed to improve safety and prevent recurrence.



EMERGENCY RESPONSE PROGRAM INFORMATION



The Refinery maintains a written Emergency Response Plan, 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-a
id and medical treatment for exposures, evacuation plans and accounting for personnel after an evacuation, notification of local emergency response agencies and the public if a release occurs, and post incident cleanup and decontamination requirements. In addition, the 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 Refinery interfaces with plans developed by other local emergency response organizations. This coordination includes periodic meetings that include local emergency response officials, local government officials, industry representatives and the local media. The Refinery has around-the-clock communications capability with emergency response organizations (e.g., fire department, police, and media). This provides a means of notifying the public of an incident, if necessary, as well as facilitating quick response to an incident. In addition to participating in Montgomery County Local Emergency Planning Committee (LEPC) meetings, the Refinery conducts periodic emergency drills that involve the LEPC and emergency response organizations. The Refinery provides periodic refresher training to local emergency responders regarding the hazards of regulated substances that are present in the refinery.



PLANNED CHANGES TO IMPROVE SAFETY



Several changes have resulted from the implementation of the various elements of the accidental release prevention programs. All of the programs covered in this submittal are designed to facilitate change of unsafe situations, and to ensure that when changes are performed to the processes in
the facility that they do not compromise safety, environment, equipment, or product quality. Additional detection and mitigation in the HF Alkylation unit is planned. CRRM continues to evaluate and install isolation valves to reduce the potential for loss of containment. Process parameter alarms are being evaluated for prioritization and management to improve alarm acknowledgement and response.