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Lima Refining Company

Parent Companies:
Husky Energy Corporation
EPA Facility ID:
100000148681
Other ID:
45804SHLCM1150
Facility DUNS:
620060632
Parent Company DUNS:
801450573

Location:

Address:
1150 S. Metcalf Street
Lima, OH 45804
County:
ALLEN
Lat / Long:
40.717, -84.125 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Center of Facility
Horizonal accuracy:
47 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Husky Energy Corporation
Phone:
(403) 298-6111
Address:
707 8th Avenue S.W.
Box 6525, Station D
Calgary,
Foreign Address:
Alberta, CA T2P 3G7

Person responsible for RMP implementation:

Name:
Rick S. Kennedy
Title:
Refinery PSM Manager

Emergency contact:

Name:
W. Doug Litsey
Title:
Emergency Response Coordiinator
Phone:
(419) 226-2551
24-hour phone:
(419) 226-2555
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Allen County LEPC
Full-Time Equivalent Employees:
457
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
0302020012
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
June 30, 2015
Inspecting Agency:
OSHA
Using Predictive Filing:
No

Processes:

OM&S Butane
RMP ID:
1000066385
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Butane
106-97-8
12,000,000
No
Isobutane [Propane, 2-methyl]
75-28-5
6,100,000
No
Flammable Mixture
00-11-11
5,900,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
OM&S Propane
RMP ID:
1000066386
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Propane
74-98-6
750,000
No
Flammable Mixture
00-11-11
59,000,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Isocracker IV Unit
RMP ID:
1000066387
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
620,000
No
Public OCA Chemical
0
No
OM&S Propylene
RMP ID:
1000066388
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
13,000,000
No
Flammable Mixture
00-11-11
5,300,000
No
Flammable Mixture
00-11-11
520,000
No
Flammable Mixture
00-11-11
120,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Coker Unit
RMP ID:
1000066389
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
230,000
No
Public OCA Chemical
0
No
Crude II Unit
RMP ID:
1000066390
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
520,000
No
Public OCA Chemical
0
No
Fluid Cat Cracker Unit
RMP ID:
1000066391
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
280,000
No
Public OCA Chemical
0
No
Isomerization Unit
RMP ID:
1000066393
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
180,000
No
Public OCA Chemical
0
No
LIU Amine Unit
RMP ID:
1000066394
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
32,000
No
Public OCA Chemical
0
No
Naphtha HDS Unit
RMP ID:
1000066395
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
66,000
No
Public OCA Chemical
0
No
Propylene Splitter Unit
RMP ID:
1000066396
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
340,000
No
Public OCA Chemical
0
No
Saturated Gas Plant
RMP ID:
1000066397
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
870,000
No
Public OCA Chemical
0
No
SRU Amine Unit
RMP ID:
1000066398
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
23,000
No
Public OCA Chemical
0
No
Tetra Unit
RMP ID:
1000066399
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
320,000
No
Public OCA Chemical
0
No
Ultraformer Unit
RMP ID:
1000066400
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
670,000
No
Public OCA Chemical
0
No
Butane-Butylene Treater
RMP ID:
1000066401
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
40,000
No
Public OCA Chemical
0
No
Gasoline De-Sulfurization
RMP ID:
1000066402
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
330,000
No
Public OCA Chemical
0
No
Diesel Hydrotreater Unit
RMP ID:
1000066403
CBI claimed:
No
Program Level:
3
NAICS:
Petroleum Refineries (32411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
630,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
March 15, 2016
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000052717

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 OM&S Butane)
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 OM&S Butane)
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

Jan. 10, 2015 at 06:04
ID:
1000040837
NAICS:
Petroleum Refineries (32411)
Duration:
1 minutes
Chemicals involved:
  • Flammable Mixture
Release events:
Fire
Explosion
Weather conditions at time of event
Wind speed:
3.0 miles/h WSW
Temperature:
-1.00 ℉
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:
$60000000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$350000
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

7. Prevention: Program level 3

OM&S Butane, Petroleum Refineries (32411)
Prevention Program ID:
1000055231
Safety Review Date
Dec. 21, 2015
PHA Update Date
Jan. 20, 2015
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Emergency Air Supply
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • Dikes
  • Deluge System
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Nov. 23, 2015
Training Review Date
Nov. 6, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
Nov. 13, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 18, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Dec. 18, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Nov. 27, 2013
Incident Invest. Change Completion Date
Nov. 27, 2013
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
OM&S Propane, Petroleum Refineries (32411)
Prevention Program ID:
1000055232
Safety Review Date
Sept. 15, 2015
PHA Update Date
June 24, 2015
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Overfilling
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • 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
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Nov. 23, 2015
Training Review Date
Aug. 20, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
Oct. 15, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 28, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Dec. 28, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Oct. 5, 2014
Incident Invest. Change Completion Date
Oct. 29, 2014
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Isocracker IV Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055233
Safety Review Date
Nov. 2, 2015
PHA Update Date
Sept. 17, 2015
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • 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
  • Quench System
  • Purge System
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Nov. 17, 2015
Training Review Date
Dec. 7, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
Aug. 12, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 21, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Dec. 21, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Sept. 2, 2015
Incident Invest. Change Completion Date
Sept. 11, 2015
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
OM&S Propylene, Petroleum Refineries (32411)
Prevention Program ID:
1000055234
Safety Review Date
July 20, 2015
PHA Update Date
June 25, 2015
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Overfilling
  • Equipment failure
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Emergency Air Supply
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Nov. 23, 2015
Training Review Date
Aug. 20, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
Oct. 15, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Nov. 9, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Nov. 9, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
March 14, 2014
Incident Invest. Change Completion Date
Jan. 2, 2015
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Coker Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055235
Safety Review Date
Oct. 29, 2015
PHA Update Date
March 31, 2013
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Rupture Disks
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 15, 2015
Training Review Date
Dec. 15, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
Sept. 27, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Oct. 7, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Oct. 7, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Oct. 14, 2015
Incident Invest. Change Completion Date
Oct. 14, 2015
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Crude II Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055236
Safety Review Date
Sept. 29, 2015
PHA Update Date
Jan. 20, 2014
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • 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
  • Rupture Disks
Mitigation Systems
  • Dikes
  • Deluge System
  • Water Curtain
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 7, 2015
Training Review Date
Nov. 20, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
Dec. 15, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 17, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Dec. 17, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Nov. 5, 2015
Incident Invest. Change Completion Date
Nov. 10, 2015
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Fluid Cat Cracker Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055237
Safety Review Date
Oct. 7, 2015
PHA Update Date
Jan. 6, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
Mitigation Systems
  • Deluge System
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 15, 2015
Training Review Date
Dec. 15, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
Aug. 4, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Nov. 19, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Nov. 19, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Nov. 10, 2015
Incident Invest. Change Completion Date
Nov. 11, 2015
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Isomerization Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055239
Safety Review Date
May 8, 2015
PHA Update Date
June 4, 2013
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Rupture Disks
  • Purge System
Mitigation Systems
  • Dikes
  • Deluge System
  • Neutralization
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 21, 2015
Training Review Date
Aug. 27, 2013
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
Feb. 26, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Nov. 18, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Nov. 18, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Oct. 1, 2012
Incident Invest. Change Completion Date
Oct. 3, 2012
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
LIU Amine Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055240
Safety Review Date
Dec. 21, 2015
PHA Update Date
Nov. 13, 2013
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Corrosion
  • Equipment failure
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 8, 2015
Training Review Date
Oct. 23, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
June 19, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 8, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Dec. 8, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Jan. 20, 2012
Incident Invest. Change Completion Date
March 15, 2012
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Naphtha HDS Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055241
Safety Review Date
April 4, 2014
PHA Update Date
Aug. 5, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Equipment failure
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
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 15, 2015
Training Review Date
Dec. 9, 2014
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
June 8, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 7, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Dec. 7, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Jan. 15, 2013
Incident Invest. Change Completion Date
May 21, 2013
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Propylene Splitter Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055242
Safety Review Date
Oct. 9, 2015
PHA Update Date
Jan. 7, 2015
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 17, 2015
Training Review Date
Dec. 16, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
May 29, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Nov. 30, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Nov. 30, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
March 7, 2012
Incident Invest. Change Completion Date
March 14, 2012
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Saturated Gas Plant, Petroleum Refineries (32411)
Prevention Program ID:
1000055243
Safety Review Date
July 27, 2015
PHA Update Date
Nov. 3, 2014
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Nov. 18, 2015
Training Review Date
July 2, 2014
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
Oct. 15, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 23, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Dec. 23, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
May 13, 2015
Incident Invest. Change Completion Date
June 10, 2015
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
SRU Amine Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055244
Safety Review Date
Sept. 21, 2015
PHA Update Date
Nov. 13, 2015
PHA Techniques
  • HAZOP
  • FTA
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Equipment failure
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 3, 2015
Training Review Date
Oct. 1, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
March 11, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Nov. 18, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Nov. 18, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Aug. 28, 2015
Incident Invest. Change Completion Date
Sept. 28, 2015
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Tetra Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055245
Safety Review Date
Jan. 9, 2015
PHA Update Date
Jan. 5, 2016
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Overfilling
  • Equipment failure
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Dikes
  • Deluge System
  • Water Curtain
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 21, 2015
Training Review Date
Aug. 26, 2013
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
Nov. 17, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 4, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Dec. 4, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
March 5, 2015
Incident Invest. Change Completion Date
June 10, 2015
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Ultraformer Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055246
Safety Review Date
Oct. 30, 2015
PHA Update Date
April 8, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • 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
  • Purge System
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 17, 2015
Training Review Date
Nov. 12, 2014
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
Oct. 15, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 22, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Dec. 22, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Dec. 11, 2014
Incident Invest. Change Completion Date
March 23, 2015
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Butane-Butylene Treater, Petroleum Refineries (32411)
Prevention Program ID:
1000055247
Safety Review Date
Aug. 5, 2015
PHA Update Date
March 7, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Equipment failure
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
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Oct. 5, 2015
Training Review Date
May 1, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
April 8, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Nov. 4, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Nov. 4, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
May 21, 2015
Incident Invest. Change Completion Date
Oct. 13, 2015
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 25, 2015
Contractor Safety Eval. Date
July 2, 2015
Gasoline De-Sulfurization, Petroleum Refineries (32411)
Prevention Program ID:
1000055248
Safety Review Date
Feb. 6, 2015
PHA Update Date
May 4, 2012
PHA Techniques
  • What if
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • 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
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Jan. 6, 2016
Training Review Date
Nov. 1, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
June 27, 2013
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 31, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Dec. 31, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
Nov. 2, 2014
Incident Invest. Change Completion Date
Oct. 29, 2015
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015
Diesel Hydrotreater Unit, Petroleum Refineries (32411)
Prevention Program ID:
1000055249
Safety Review Date
Sept. 24, 2015
PHA Update Date
April 23, 2014
PHA Techniques
  • What if
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • 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
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 21, 2015
Training Review Date
Oct. 7, 2015
Maintenance Review Date
Dec. 14, 2015
Maintenance Inspection Date
March 24, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
Nov. 5, 2015
Management of Change Review Date
March 1, 2015
Pre-startup Review Date
Nov. 5, 2015
Compliance Audit Date
May 25, 2015
Compliance Audit Change Completion Date
Nov. 1, 2015
Incident Investigation Date
March 8, 2012
Incident Invest. Change Completion Date
May 11, 2012
Participation Plan Review Date
March 1, 2015
Hot Work Review Date
Jan. 14, 2015
Contractor Safety Review Date
May 12, 2015
Contractor Safety Eval. Date
July 2, 2015

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. 30, 2015
Local Response Agency:
Local Response Agency Phone:
(419) 227-3535
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
Yes
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES



The Lima Refinery has a long-standing commitment to worker and public safety. This commitment is demonstrated by the resources invested in accident prevention, such as training personnel and considering safety in the design, installation, operation, and maintenance of our processes. It is outlined in our Husky Operational Integrity Management System (HOIMS) through Husky Corporate. Our policy is to implement reasonable controls to prevent foreseeable releases of regulated substances. However, if a release does occur, our trained personnel will respond to control and contain the release.



DESCRIPTION OF THE STATIONARY SOURCE AND REGULATED SUBSTANCES



The Lima Refinery, located in Lima, Ohio, operates a variety of processes to produce petroleum products (e.g., gasoline, heating oil, diesel fuels, propane, and butane) from raw crude oil. The refinery handles the following regulated flammable substances: 1-butene, 2-butene-cis, 2-butene-trans, 2-methylpropene, butane, butene, ethane, ethylene, hydrogen, iso-butane, iso-pentane, methane, pentane, propane, and propylene. The refinery processes hydrogen sulfide, which is also a regulated substance but is below the EPA threshold quantity.



GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM STEPS



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



Employee Participation



The Lima Refinery encourages employees to participate in all facets of process safety management and accident prevention. Examples of employee participation range from updating and compiling technical documents and chemical information to participating as a member of a process ha
zard analysis (PHA) team. Employees have access to all information created as part of the refinery accident prevention program. Employees are involved in the accident prevention program which is documented in an employee participation plan that is maintained at the refinery and addresses each accident prevention program element. The OSHA PSM elements are also key components of our HOIMS expectations. In addition, the refinery has a number of initiatives under way that address process safety and employee safety issues. These initiatives include forming teams to promote both process and personnel safety. The teams typically have members from various areas of the plant, including operations, maintenance, engineering, and plant management.



Process Safety Information



The Lima Refinery keeps a variety of technical documents that are used to help maintain safe operation of the processes. The documents address chemical properties and associated hazards, limits for key process parameters and specific chemical inventories, and equipment design basis/configuration information. Specific departments within the refinery are assigned responsibility for maintaining up-to-date process safety information. These reference documents are available on the refinery intranet and/or central computer drive systems for easy access.



Chemical-specific information, including exposure hazards and emergency response/exposure treatment considerations, is provided in safety data sheets (SDS). This information is supplemented by documents that specifically address known corrosion concerns and any known hazards associated with the inadvertent mixing of chemicals. For specific process areas, the refinery has documented safety-related limits for specific process parameters (i.e., temperature, level, composition) in unit Safe Operating Limits documents. The refinery ensures that the process is maintained within these limits using process controls and monitoring instruments, highly trained person
nel, and protective instrument systems (e.g., automated shutdown systems).



The refinery also maintains numerous technical documents that provide information about the design and construction of process equipment. This information includes materials of construction, design pressure and temperature ratings, electrical testing 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 (PHA)



The Lima Refinery has a comprehensive program to help ensure that hazards associated with the various processes are identified and controlled. Within this program, each process is systematically examined to identify hazards and ensure that adequate controls are in place to manage these hazards.



The Lima Refinery primarily uses the hazard and operability (HAZOP) analysis technique to perform these evaluations. The analyses are conducted using a team of people who have operating and maintenance experience as well as engineering expertise. This team identifies and evaluates hazards of the process as well as accident prevention and mitigation measures, and makes recommendations for additional prevention and/or mitigation measures when the team believes such measures are necessary.



The PHA team findings and resolutions are reviewed with management. Implementation of mitigation recommendations is based on a relative risk ranking assigned by the PHA team. This ranking helps ensure that potential accident scenarios assigned the highest risk receive priority attention. All approved recommendations in response to PHA are tracked until they are completed. The final resolution of each recommendation is documented.



To help ensure that the process controls and/or process hazards do not deviate from the original desi
gn safety features, the Lima Refinery periodically updates and revalidates the hazard analysis results. These periodic reviews are conducted at least every five years for the life of the process. The results and the recommendations from these updates are documented. The team findings are forwarded to management for review. The final resolution of the recommendations is documented.



Operating Procedures



The Lima Refinery maintains written procedures that address various modes of process operations, such as (1) unit startup, (2) normal operations, (3) temporary operations, (4) emergency shutdown, (5) normal shutdown, and (6) initial startup of a new process.



In addition, Lima Refinery maintains a Safe Operating Limits and Alarm response documents that are linked in the central computer system and the Distributed Control System (DCS). These tools provide guidance on how to respond to upper or lower limit variances for specific process or equipment parameters. This information, along with written operating procedures, is readily available to operators in the process unit and for other personnel to use as necessary to safely perform their job tasks.



Training



To complement the written procedures for process operations, the Lima Refinery has implemented a comprehensive training program for all employees involved in operating a process. New employees receive basic training in refinery operations and pass a written and hands-on competency test. After successfully completing this training, a new operator is paired with a senior operator to learn process-specific duties and tasks. After operators demonstrate having adequate knowledge to perform the duties and tasks in a safe manner on their own, they can work independently. In addition, all operators periodically receive refresher training on the operating procedures to ensure that their skill and knowledge are maintained at an acceptable level. This refresher training is conducted at least every three years.




Contractors



The Lima Refinery uses contractors to supplement its work force during periods of increased maintenance or construction activities. Because some contractors work on or near process equipment, the refinery has procedures in place to ensure contractors (1) perform their work in a safe manner, (2) have the appropriate knowledge and skills, (3) are aware of the hazards in the workplace, (4) understand what they should do in the event of an emergency, (5) understand and follow site safety rules, and (6) inform refinery personnel of any hazards that they find during their work. This is accomplished by providing contractors with (1) a refinery overview, (2) information about safety and health hazards, (3) emergency response plan requirements, and (4) safe work practices before they begin work. In addition, the Lima Refinery evaluates contractor safety programs and performance during the selection of a contractor. Refinery personnel periodically monitor contractor performance to ensure that contractors are fulfilling their safety obligations.



Pre-Startup Safety Reviews (PSSRs)



The Lima Refinery conducts a PSSR for any new facility or facility modification that requires a change in the process safety information. The purpose of the PSSR is to ensure that safety features, procedures, personnel, and the equipment are appropriately prepared for startup prior to placing the equipment into service. This review provides an additional check to ensure construction is in accordance with the design specifications and all supporting systems are operationally ready. The PSSR review team uses checklists to verify all aspects of readiness. A PSSR involves field verification of the construction and serves as a quality assurance function.



Mechanical Integrity



The Lima Refinery has well-established practices and procedures to maintain pressure vessel, 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, (4) correcting identified deficiencies, and (5) applying quality assurance measures. In combination, these activities form a system that maintains the mechanical integrity of the process equipment.



Maintenance personnel receive training on (1) an overview of the process, (2) safety and health hazards, (3) applicable maintenance procedures, (4) emergency response plans, and (5) applicable safe work practices to help ensure that they can perform their job in a safe manner. Written procedures help ensure that work is performed in a consistent manner and provide a basis for training. Inspections and tests are performed to help ensure that equipment functions as intended, and to verify that equipment is within acceptable limits (e.g., adequate wall thickness for pressure vessels). If a deficiency is identified, employees will correct the deficiency before placing the equipment back into service, or an MOC team will review the use of the equipment and determine what actions are necessary to ensure the safe operation of the equipment.



Another integral part of the mechanical integrity program is quality assurance. The Lima Refinery incorporates quality assurance measures into the equipment purchases and repairs. This helps ensure that new equipment is suitable for its intended use and that proper materials and spare parts are used when repairs are made. New purchases and repairs follow the Lima Refinery Engineering Practices (LREP's) and generally accepted engineering practices.



Safe Work Practices



The Lima Refinery has safe work practices in place to help ensure worker and process safety. Examples 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 haza
rdous materials before process piping or equipment is opened, (4) a permit and procedure to control spark-producing activities (i.e., hot work), and (5) a permit and procedure to ensure that adequate precautions are in place before entry into a confined space. These procedures (and others), along with the training of affected personnel, form a system to help ensure that operations and maintenance activities are performed safely.



Management of Change



The Lima Refinery has a comprehensive system to manage changes to processes. This system requires that changes to items such as process equipment, chemicals, technology (including process operating conditions), procedures, and other facility changes be properly reviewed and authorized before being implemented. 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. All Management of Changes at Lima Refinery require a Pre-Start-up Safety Review.



Incident Investigation



The Lima Refinery promptly investigates all incidents that resulted in or reasonably could have resulted in a fire/explosion, toxic gas release, major property damage, environmental loss, or personal injury. The goal of each investigation is to determine the facts, determine the root cause, and develop corrective actions to prevent 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 resolutions. Corrective actions taken in response to the investigation team's findings and recommendations are tracked until they are completed. The f
inal resolution of each finding or recommendation is documented, and the investigation results are reviewed with all employees (including contractors) who could be affected by the findings. Incident investigation reports are retained for at least five years per regulation and to allow the reports to be reviewed at future PHAs.



Compliance Audits



The Lima Refinery periodically conducts an audit to determine whether the procedures and practices required by the accident prevention are being implemented and utilized. Compliance audits are conducted at least every three years. The audit team develops findings that are reviewed with applicable personnel. Corrective actions taken in response to the audit team's findings are tracked to completion. The final resolution of each finding is documented, and the two most recent audit reports are retained.



CHEMICAL-SPECIFIC PREVENTION STEPS



The processes at the Lima Refinery have hazards that must be managed to ensure continued safe operation. The accident prevention program summarized previously is applied to all Program 3 EPA RMP covered processes at the Lima 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 Lima Refinery has safety features on many units to help contain/control a release and reduce the consequences of a release. The following types of safety features are used in various processes:

Release Containment/Control:

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

- Valves to permit isolation of the process (manual or automatic)

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

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

- Curbing or diking to contain liquid releases

- Redun
dant equipment and instrumentation (i.e., uninterruptible power supply for process control system, backup process and firewater pumps)

- Atmospheric relief devices



Relief Mitigation



- Fire suppression and extinguishing systems

- Deluge systems for specific equipment

- Trained emergency response personnel

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



FIVE-YEAR ACCIDENT HISTORY



The Lima Refinery had one accident to report over the last 5 years as previously updated in June 2015. We investigate every incident and near-miss very carefully to prevent incidents from occurring and to use them as lessons learned when conducting refinery process hazard analysis.



EMERGENCY RESPONSE PROGRAM INFORMATION



The Lima Refinery maintains a written emergency response program, which is in place to protect worker and public safety as well as the environment. In addition, the emergency response plan includes and is further enhanced by the Spill Contingency and Counter Measure (SPCC) and Oil Prevention Act (OPA) plans. These are all contained in one document titled 'Integrated Contingency Plan (ICP)'. The program consists of procedures for responding to a release of a regulated substance, including the possibility of a fire or explosion if a flammable substance is accidentally released. The procedures address all aspects of emergency response, including proper first-aid and medical treatment for exposures, evacuation plans and accounting for 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, Lima Refinery has procedures that address maintenance, inspection, and testing 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 modi
fications made to refinery processes or other facilities. The emergency response program changes are administered through the Management of Change (MOC) process, which includes informing and/or training affected personnel regarding the changes.



The overall emergency response program for the Lima Refinery is coordinated with the Lima, Ohio Local Emergency Planning Committee (LEPC). This coordination includes periodic meetings of the committee, which includes local emergency response officials, local government officials, private citizens, and industry representatives. The Lima Refinery has around the clock communications capability with appropriate LEPC officials and emergency response organizations (e.g., fire departments). 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 periodic LEPC meetings, the Lima Refinery conducts periodic emergency drills that involve the LEPC and emergency response organizations, and the refinery provides annual refresher training to local emergency responders as applicable.



Lima Refinery is particularly proud of being an active and contributing member of the local LASER (Lima Allen County Security and Emergency Response) Task Force which won top award from the International Association of Emergency Managers. LASER addresses homeland security issues, in addition to typical emergency preparedness.



PLANNED CHANGES TO IMPROVE SAFETY



The Lima Refinery makes planned changes to improve safety through the findings of its proactive programs, such as Process Hazard Analysis, Management of Change, and Incident Investigations. The following illustrate the types of changes that result:



- Safety instrumented system packages installation at the Crude, Isocracker, and other units.

- Replacement of old towers with new in various refinery processes.

- Emergency isolation valves (EIVs) installation.

- Upgrades to the Fire Water system infrastru
cture.

- Improved Electrical Reliability

- Installation of new furnace tubes in the Isocracker Splitter Furnace and new furnaces being constructed at the Crude and Reformer units.

- County-wide LASER (Lima Allen County Security and Emergency Response) Task Force drill which includes homeland security issues.

- New blast resistant buildings.