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Lone Star Refinery Services LLC Chalmette

Parent Companies:
La Grange Acquisitions, LP
EPA Facility ID:
100000174697
Other ID:
Facility DUNS:
0
Parent Company DUNS:
0

Location:

Address:
1701 Paris Road
Chalmette, LA 70043
County:
ST. BERNARD
Lat / Long:
29.930, -89.968 (Get map)
Method:
Interpolation - Map
Description:
Center of Facility
Horizonal accuracy:
1 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
1

Owner/Operator:

Name:
ETC Texas PL, Ltd
Phone:
(210) 403-7300
Address:
800 E. Sonterra Blvd
Suite 400
San Antonio, TX 78258 -3941
Foreign Address:

Person responsible for RMP implementation:

Name:
Nolan Huguet
Title:
Plant Supervisor

Emergency contact:

Name:
Nolan Huguet
Title:
Plant Supervisor
Phone:
(504) 281-1722
24-hour phone:
(504) 281-1722
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
St. Bernard Parish LEPC
Full-Time Equivalent Employees:
10
Covered by OSHA PSM:
Yes
EPCRA section 302:
No
CAA Title Air Operating Permit:
No
CAA Permit ID#:
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Inspecting Agency:
Never had one
Using Predictive Filing:
No

Processes:

Unspecified process
RMP ID:
1000059270
CBI claimed:
No
Program Level:
3
NAICS:
Natural Gas Liquid Extraction (211112)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
52,850
No
Propane
74-98-6
10,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
C-K Associates, LLC
Address:
2001 East 70th Street
Suite 503
Shreveport, LA 71105
Foreign Address:

Phone:
(318) 797-8636

Latest RMP Submission:

Date:
Nov. 13, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000047496

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 Unspecified process)
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 Unspecified process)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

, Natural Gas Liquid Extraction (211112)
Prevention Program ID:
1000049356
Safety Review Date
Feb. 12, 2007, since latest RMP submission
PHA Update Date
Nov. 6, 2012, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Cooling loss
  • Floods
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Backup Pump
  • Grounding Equipment
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Perimeter Monitoring
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Oct. 1, 2013, since latest RMP submission
Training Review Date
Oct. 13, 2014, since latest RMP submission
Maintenance Review Date
May 21, 2014, since latest RMP submission
Maintenance Inspection Date
April 30, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 10, 2014
Management of Change Review Date
Oct. 13, 2014
Pre-startup Review Date
March 10, 2014
Compliance Audit Date
July 1, 2013
Compliance Audit Change Completion Date
May 1, 2014
Incident Investigation Date
June 25, 2014
Incident Invest. Change Completion Date
June 26, 2014
Participation Plan Review Date
July 1, 2013
Hot Work Review Date
Sept. 17, 2014
Contractor Safety Review Date
July 1, 2013, since latest RMP submission
Contractor Safety Eval. Date
July 1, 2013, since latest RMP submission

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
Yes
Facility Own Response Plan:
No
Specific Facility Response Plan:
Yes
Inform. Procedures in Response Plan:
No
Emergency Care in Response Plan:
Yes
Plan Review Date:
Response Training Date:
June 26, 2014
Local Response Agency:
Local Response Agency Phone:
(504) 281-1300
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

This RMP submittal serves as a Minor Administrative Change (C03).



Facility Description



Lone Star has contracted with ExxonMobil Chalmette Refining, LLC for the extraction, transportation, and fractionation of the refinery products from two liquid hydrocarbon streams and two refinery gas streams. Lone Star has installed a cryognic gas processing plant at the Chalmette Refinery, an eighty mile long 10" pipeline from Chalmette to Geismar, LA and a fractionation plant in Geismar.



Lone Star's Chalmette Gas Processing Plant receives Chalmette Refining's off gas in two streams. The first is saturated off-gas and the second is unsaturated off-gas. These gas streams are processed through compression and low temperature separation to extract natural gas liquids. The natural gas liquids are then pumped into a transmission pipeline to Lone Star's fractionation plant in Geismar, LA. The Cryogenic Gas Processing Plant returns a residual gas and hydrogen to the Chalmette Refinery. The product is stored in a 15,000 gallon product surge tank prior to injection into the transmission pipeline.



The Accidental Release Prevention and Emergency Response Policies at the Facility



Lone Star has developed an overall safety and health policy to prevent accidental releases of flammable materials to the environment. The policy is supported by many programs such as compliance with OSHAs 29 CFR 1910.119 Process Safety Management regulation which includes communication of risks and hazards to the employees and contractors, the development of an employee training, certification, and retraining program with written operating procedures. Since the facility is subject to 29 CFR 1910.119, it qualifies as a Program 3 facility under EPA's Risk Management Plan regulation 40 CFR 68.



The facility management also stresses the development and documentation of the process safety information, a management of change procedure, pre-startup safety reviews, employee participation in safet
y reviews and an equipment mechanical integrity inspection program for all major equipment items and piping systems as well as new equipment purchases. The facility operations personnel also issue hot work permits and safe work permits for maintenance activities within the operating units.



Safety Inspections at the Facility



The facility also conducts the following safety inspection on the basis as noted:



1. Work Areas - as needed

2. Portable Fire Extinquishers - monthly

3. Pressure vessels - as specified in API

4. Extension cords, motorized hand tools - every three months

5. Yards, parking lots, roofs, etc. - annually



Compliance audits are conducted every three years as required by OSHA 29 CFR 1910.119 regulation. In addition, incident investigations will be conducted immediately after any accidental release or incident occurs. The cause of the incident will be determined and appropriate steps are taken to prevent recurrence of the event.



The facility also has an emergency action plan in the event of a release of a flammable material. The following provide support for the plant in the event of a fire:



1. Chalmette Fire Department

2. Chalmette Refinery fire brigade



The facility engineering staff also follows and adheres to guidelines set forth in American Petroleum Institute (API) standards and recommended practices. National Fire Protection Association (NFPA) codes for fire protection systems, National Boiler Inspection Codes (NBIC), the American Society of Mechanical Engineers (ASME) pressure vessel and piping codes, and the National Electric Codes for flammable environments.



The General Accidental Release Prevention Program and Chemical Specific Prevention Steps



Lone Star has implemented numerous procedures to ensure the safety and well being of its employees and the general environment surrounding the facility. The process units and storage tanks have been inspected as necessary prior to the introduction of hydrocarbon
s into the facility.



Since the facility is an OSHA covered facility, the various skids have undergone Process Hazards Analysis (PHA). The PHAs and subsequent safety analyses included employee participation at the unit operator level.



The facility has a written policy of periodic mechanical integrity inspections, depending on the type of equipment. The safety relief valves that protect vessels, tanks and piping systems, are integral parts of this program.



The Five-Year Accident History.



The Lone Star Chalmette Gas Processing Plant has never had an accident involving the covered mixture that caused deaths, injuries, property or environmental damage, evacuations, or sheltering in place. On June 25, 2014 a lightning strike ignited the facility's vent stack. Gas in the vent stack was the result of a leaking pressure safety valve (PSV). The leaking PSV was identified and repaired. There was not any injuries, property or asset damage, or environmental damage associated with this event.



The Emergency Action Plan.



The Chalmette Gas Processing Plant maintains a written emergency action plan, which is in place to help protect workers and public safety as well as the environment. The emergency action plan is designed to address the facility's main hazard - hazard of fires and/or explosions. The responsibilities for various functions during the emergency are clearly defined in the response plan. Gathering places (primary and secondary staging areas, as well as, one off-site staging area) for employees evacuated from the control room and plant area by the emergency conditions are also listed.



The action plan contains reporting procedures for employees when the fire is too large to be extinguished by a portable handheld fire extinguisher. The plan identifies steps to be taken in case of an accidental releases including first aid and medical treatment for exposures, evacuation plans and accounting for personnel after an evacuation, and notification
of local emergency response agencies. Employees receive training in these procedures as necessary based on their specific emergency duties. The emergency action plan is updated when necessary based on modifications made to the process or plant facilities.



The overall emergency action plan for the facility has been coordinated with the Chalmette Fire Department. This coordination includes meeting with the Fire Department personnel. The facility is manned 24 hours a day and has around-the-clock communications capability with the Fire Department. This interface provides the means of notifying the public of an incident, if necessary, as well as facilitating quick response to an incident. The Chalmette Refinery fire brigade is also available for assistance and this assistance plan has been communicated to the Chalmette Refinery fire brigade.



Planned changes for improved safety.



There are no planned changes for improved safety at this time.