Hillsboro Bulk Petroleum Plant - Executive Summary
Executive Summary for Propane Storage and Distribution Facilities. |
1. ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES:
The primary function of the "Hillsboro Farmers Co-op Bulk Petroleum Plant", is to act as a propane distribution facility. By virtue of the flammable effects associated with propane, it is necessary to observe certain safety precautions in handling propane to prevent unnecessary human exposure, to reduce the threat to our own personal health as well as the health of our co-workers, and to reduce the threat to nearby members of the community. We are strongly committedto employee, public and environmental safety. Safety at our facility depends upon the manner in which we handle propane as well as on the various safety devices incorporated into the design of our equipment. Furthermore, comprehensive training received by our employees adds to the inherent safety of our facility.
Our emergency response program is based upon the NFPA's LP-Gas Safety Hand
book, "Guidelines for Developing Plant Emergency Procedures", and "40 CFR part 68". In addition to the presence of appropriate controls to prevent possible releases of propane, if a release does occur, we are completely coordinated with the "Vernon County Sheriff Department" which provides highly trained emergency response personnel to control and mitigate the effects of a release.
2. THE STATIONARY SOURCE AND THE REGULATED SUBSTANCES HANDLED
The primary purpose of this facility is to repackage and distribute propane to both retail and wholesale customers for use as a fuel. Propane arrives at our facility via truck and is stored in three storage tanks. This facility has equipment for unloading transports and equipment to load transports and containers. Access to this site is restricted to authorized facility, authorized management personnel and authorized contractors.
The regulated substance handled at this facility is propane. The maximum amount of propane that can be stored
at this plant is 264,180 lb.
3. THE WORST CASE RELEASE SCENARIO AND THE ALTERNATE RELEASE SCENARIO, INCLUDING
ADMINISTRATIVE CONTROLS AND MITIGATION MEASURES TO LIMIT THE DISTANCE FOR EACH
We have calculated worst case release scenarios based on the NPGA-EPA approved TNO-Multi energy method. For alternative release scenario analysis, we have employed the equations provided by the EPA in the "RMP Offsite Consequence Analysis Guidance". The following paragraphs provide details of the chosen scenarios.
The worst case release scenario submitted for propane involves a catastrophic release from "Hillsboro Farmers Co-op Bulk Petroleum Plant". The scenario involves a release of 264,180 lb. of propane. The release quantity has been limited by 15 percent resulting from written procedural mechanisms. It is assumed that the entire quantity is released as a vapor that finds an ignition source, with 10 percent of the released quantity participating in a vapor cl
oud explosion. Under worst case weather, the maximum distance of 0.42 miles was obtained corresponding to a flammable endpoint of 1 psi overpressure.
The alternative release scenario submitted for program 2 Flammable substances involves a release from "Hillsboro Farmers Co-op Bulk Petroleum Plant" resulting in a Pool Fire. In this scenario 408 lb. of propane is released in 1 minute. The release is also controlled by active mitigation measures that include automatic shutoff valves. Under neutral weather conditions, the maximum distance to the flammable endpoint of
5 kw/m2 for 40 seconds is 0.02 miles.
4. THE GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM AND THE CHEMICAL-SPECIFIC
Our facility has taken all necessary steps to comply with the accidental release prevention requirements set out under 40 CFR part 68 of the EPA. This facility was designed and constructed in accordance with NFPA Standards.
The following sections briefly describe the release p
revention program that is in place at our stationary source.
"Hillsboro Farmers Co-op Bulk Petroleum Plant" maintains a detailed record of written safety information, which describes the chemical hazards, operating perameters and equipment designs associated with all aspects of our distribution facility.
A checklist is used to carry out hazard reviews at our facility. The reviews focus on operating procedures, equipment functions and handling practices to identify possible hazards. The studies are undertaken by a team of qualified personnel with extensiveknowledge of facility operations and are revalidated annually. Any findings related to the hazard reviews are addressed in a safe and timely manner.
For the purpose of safely conducting activities within our covered processes, "Hillsboro Farmers Co-op Bulk Petroleum Plant" maintains written operating procedures. These procedures address various modes of operation such as i
nitial startup, normal operations, temporary operations, emergency shutdown, emergency operations,normal shutdown and startup after a turnaround. The information is regularly reviewed and is readily accessible to operators involved with the process.
"Hillsboro Farmers Co-op Bulk Petroleum Plant" has a comprehensive training program in place to ensure that employees that are operating processses are completely competent in the operating procedures associated with these processes. New employees receive basic training in process operations followed by on-the-job supervision until they are deemed competent to work independently. Refresher training is provided at least every two years and more frequently as needed.
"Hillsboro Farmers Co-op Bulk Petroleum Plant" carries out highly documented maintenance checks on process equipment to ensure proper functioning. Maintenance activities are carried out by qualified personnel with previous training in these practices.
Furthermore, personnel are offered specialized training as needed. Any equipment deficiencies identified by the maintenance checks are corrected in a safe and timely manner.
"Hillsboro Farmers Co-op Bulk Petroleum Plant" conducts audits on a regular basis to determine whether the provision set out under the RMP rule are being implemented. These audits are carried out at least every 3 years and any corrective actions required as a result of the audits are undertaken in a safe and prompt manner.
"Hillsboro Farmers Co-op Bulk Petroleum Plant" promptly investigates any incident that has resulted in, or could reasonably result in, a catstrophic release of propane. These investigations are undertaken to identify the situation leading to the incident as well as any corrective actions to prevent the release from recurring. All reports are retained for a minimum of 5 years.
5. FIVE-YEAR ACCIDENT HISTORY
"Hillsboro Farmers Co-op Bulk Petroleu
m Plant" has had an execellent record in preventing accidental releases over the last 5 years. Due to our stringent release prevention policies, there has been no accidental release during this period.
6. EMERGENCY RESPONSE PLAN
"Hillsboro Farmers Co-op Bulk Petroleum Plant'" carries a written emergency response plan to deal with accidental releases of propane. The plan includes all aspects of emergency response including adequate first aid and medical treatment, evacuations, notifications of local emergency response agencies and the public, as well as post-incident decontamination of affected areas.
Our facility's emergency response plan is based upon the NPGA's LP-Gas Handbook and local emergency response procedures. To ensure proper functioning, our emergency response equipment is regularly inspected and serviced. In addition, the plan is promptly updated to reflect any pertinent changes taking place within our processes that would require a modified emergency response.
PLANNED CHANGES TO IMPROVE SAFETY:
Several developments and findings have resulted from the implementation of the various elements of our accidental release prevention program. A maintenance and training program shall be implemented for each employee involved with the mechanical integrity of the process equipment. An on-going program training employees how to avoid or correct unsafe conditions are some of the major steps we want to take to improve safety at our facility. These changes shall be implemented by June 1, 1999.
8. CERTIFICATION STATEMENT:
The undersigned certifies that to the best of my knowledge, information, and belief, formed after reasonable inquiry, the information submitted is true, accurate and complete.
Name: Robert Stekel
Title: Safety Coordinator
Date signed: 05/25/99