Paramount Petroleum - Paramount - Executive Summary |
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PARAMOUNT REFINERY RISK MANAGEMENT PROGRAM Description of Paramount Refinery Paramount Petroleum Refinery (Paramount) operates a petroleum refinery located at 14700 Downey Avenue, Paramount, California. The present rated capacity of the refinery is 46,500 barrels per day (BPD) of crude. The current operating rate is about 39,000 BPD. In its current operating mode, known as "topping mode", Paramount does not operate its hydroprocessing units, but sells the intermediate feedstocks that would have been processed in these units to a neighboring refinery. Paramount's main product is asphalt. The Refinery occupies approximately 63 acres of land located in Paramount, Southern California. The address is 14700 Downey Avenue, Paramount, CA 90723. The site is bordered on the north by Contreras Street, on the south by Somerset Boulevard and Southern Pacific Railroad track, on the east by Lakewood Boulevard and on the west by Downey Avenue. On the north side of the refinery, a trailer par k, a shopping center, Wirtz Elementary School and single family houses are located. On the west side, Paramount High School and a new housing development are located. On the east side, there are single family homes and mobile home development. Across the railroad tracks on the south side is an apartment complex. The primary business of Paramount is the processing of local crude oils to finished hydrocarbon products, primarily asphalts for road construction and roofing materials. The present rated capacity of the refinery is 46,500 barrels per day (BPD) of crude. The current operating rate is about 39,000 BPD. In its current operating mode, known as "topping mode", Paramount does not operate its hydroprocessing units, but sells the intermediate feedstocks that would have been processed in these units to a neighboring refinery. Regulated Substances Handled Paramount processes crude oil and hence handles all the hydrocarbons that comprise crude oil. The quantities of regulated hydro carbons stored at the facility are as follows (expressed as quantities of normal parafins): Ethane: 750 lbs Propane: 26,000 lbs Butane: 590,000 lbs Pentane: 57,000 lbs Accidental Release Prevention and Emergency Response Policies Paramount Petroleum is committed to providing a safe and healthy work facility for its employees, the surrounding community and the environment. The prevention of accidents, injuries, fires, emergency releases and other emergency situations is of utmost importance and shall be the first priority for all persons working at the refinery. Organization Responsibility and Authority - All employees are equally responsible for insuring the health and safety of themselves and others in the facility. Management, however, by law and practice, is responsible for insuring that employees are trained to safely perform their jobs. Management is also responsible for enforcing safety rules and programs and assuring that employee are following safety requirements. Mana gers or supervisors may delegate a piece of work. However, they must ensure that the work is performed safely. Director of Fire, Safety, and Security - The Director of Fire, Safety, and Security has overall authority for the design and implementation of the Injury Prevention and process safety management and other related safety programs. This position is assigned the following duties and responsibilities: 1. Research, interpret and comply with applicable regulations and recommended industry and safety guidelines. Keep management informed of changing regulations and what actions the Company must take to comply. Keep management apprised of safety practices, problems and compliance attitudes within the company. 2. Recommend, design and implement training to further safety programs and comply with applicable regulations. Establish and implement communications progress to enhance safety performance. Recommend and establish certification, testing and other methods of measurement to insure employees have received adequate training concerning the hazards of their jobs. 3. Provide emergency responder training to Emergency Response Team Members. Provide emergency response procedures and training for all Company Employees. 4. Advise and consult with employees in all levels of the organization regarding safety matters and employee responsibilities to comply with Company safety programs and applicable regulations. Advise and assist line management in analyzing safety hazards and implementing safety programs within their individual areas of responsibility. 5. Establish enforcement procedures to insure that safety programs are followed including corrective action and discipline procedures. 6. Act as liaison between the Company and regulatory agencies such as the California and United States Departments of Occupational Safety and Health and their representatives. 7. Establish compliance, audit and inspection procedures to insure that safety programs are being followe d and safe working practices are in place. 8. Make regular and frequent analysis of OSHA 200 log, worker's compensation loss reports and other accident and loss information. Report findings and recommendations to management and the Safety Committee. Managers and Supervisors - Managers and supervisors are responsible for the safety and well being of themselves and their subordinates. Their responsibilities include the following functions and duties: 1. Providing leadership and example for employees by placing emphasis on safety and enforcing all safety and health programs. 2. Assure, when a task is assigned, that a review of potential hazards has been completed and that employees are instructed on how to accomplish the job safely. Assure that employees doing the work have adequate safety information. 3. Assure subordinates have received training and are familiar with hazardous materials with which they come in contact. Assure that subordinates and themselves have read, understo od and implement the precautions contained on the material Safety Data Sheets. 4. Remain current with regard Company safety programs and applicable regulations, by reading programs and communications, and by attending meetings and presentations hosted by the F,S&S Department. Hold safety meetings to insure safety information is passed to their subordinates. Assure that subordinates attend safety meetings and safety training programs. 5. Assure that units and equipment are maintained in safe operating condition. Correct any unsafe condition immediately. Report any unsafe condition, which cannot be corrected immediately to upper management and the F,&S Department. Notify subordinates, in writing, of any known unsafe condition or faulty equipment and the measures necessary to mitigate the risk. All Employees - All employees receive annual Health and Safety training and are encouraged to make safety suggestions at any time. In addition, "toolbox" or "tailgate" safety meetings are routinely conducted with all operating and maintenance teams. Worst Case Release Scenario and Alternative Release Scenarios Worst Case Scenarios Flammable Regulated Substances - The worst case scenario for the release of flammable regulated substances involves the instantaneous release of the contents of the largest Liquefied Petroleum Gas (LPG) Storage Tank (bullet). Procedures are in place to limit the maximum inventory of the bullet (D-1201) to 80% of the level (by volume). This is equivalent to a release of 960 barrels (BBL) or 200,000 lb. The contents are primarily butane. The worst case scenario is an unlikely scenario for the following reasons: 1. Comprehensive mechanical integrity program 2. Design pressure of the vessel is 250 psig in comparison with the normal operating pressure of 45 psig 3. The service is non-corrosive 4. There are excess flow valves on the vessel nozzles 5. Hazard and Operability Study did not identify any scenario that could lead to overpressur e of the bullet. Toxic Regulated Substances - No toxic regulated substances exist at the refinery in quantities equal to or greater than the threshold quantities specified in 40 CFR 68. Alternative Release Scenarios Flammable Regulated Substances - The alternative release scenario for flammable regulated materials at Paramount assumes a BLEVE at the LPG storage bullet. It is assumed that the tank is 50% full (of butane) at the time of the accident (max. operating volume is 80%). No credit is taken for any of the mitigation measures available. Several alternative scenarios were considered, per the guidelines provided by the EPA, and the BLEVE radiation hazard distance to the endpoint was the largest. Toxic Regulated Substances - No toxic regulated substances exist at the refinery in quantities equal to or greater than the threshold quantities specified in 40 CFR 68. General Accidental Release Prevention Program and Chemical-Specific Prevention Steps Paramount has a comprehensi ve process safety management program in place. This program is audited periodically to evaluate performance and identify opportunities for improvement. All equipment is subject to inspection and maintenance under a refinery wide mechanical integrity program. Most rotating equipment is duplicated. Operations manuals provide process safety information and operating procedures. There is a strong ongoing training and certification program. Spot audits are conducted daily of contractor operations. All safety significant changes are evaluated in accordance with an established management of change procedure and are subject to process hazard review. All startups after significant changes receive pre-startup safety reviews to assure safety of plant personnel and the public. Five-Year Accident History In the past five years Paramount has had no accidental releases of regulated substances (flammables) from processes that are still in operation that caused any injuries, deaths, seve re property damage or required any evacuations. Paramount policy requires reporting and investigating all accidents and near misses. There have been two releases in the last five years at processes that are no longer in operation. Those two releases also did not result in injuries, deaths or evacuation. Emergency Response Program Paramount Petroleum is committed to providing a safe and healthy work facility for its employees, the surrounding community and the environment. The prevention of accidents, injuries, fires, emergency releases and other emergency situations is of utmost importance and shall be the first priority for all persons working at the refinery. It is anticipated that accidents, injuries and emergency situations may still occur. The Emergency Response Plan (ERP) will provide guidelines for a coordinated emergency management system in the refinery to respond to such situations. The Plan utilizes proven techniques of the Incident Command System. When situations dictate, the system will utilize the combined effort from all departments, mutual aid groups and municipal agencies in order to mitigate emergency incidents in a safe, effective and timely manner. The ERP is implemented through an Incident Command System (ICS). The ICS has two levels of application. Small emergencies are responded to by an Emergency Response Team (ERT) consisting of a Shift Incident Commander, an operations chief, and a team of members responsible for coordinating issues related to off-site releases, rescue, and hazardous materials spills. The Shift Incident Commander also coordinates with the Los Angeles County Fire Department (LACoFD) via telephone. For larger emergencies an Emergency Management Team (EMT) is activated. The EMT is lead by the Vice President of Refining, the Emergency Management Officer and the Director of Fire, Safety, and Security serves as the Incident Commander. Other members of the EMT are members of the refinery senior management. The ER T, which may have initially responded to the emergency, relinquishes incident management to the EMT when the latter assumes command and then provides support to the EMT. The EMT Incident Commander communicates with the LACoFD and other outside agencies by telephone. Refinery personnel assigned to ERT or EMT responsibilities receive quarterly training. The plant emergency alarm system is tested weekly. Planned Changes to Improve Safety Paramount has a tracking system for implementing recommendations that result from Process Hazard Analyses. There is a continuing training and certification program in place. A comprehensive seismic assessment of equipment in covered processes has been performed in accordance with revised seismic design guidance criteria issued in 1999 The recommendations from that study are being evaluated. As noted earlier an audit of the process safety management program was completed in 1999. Findings and recommendations from that audit are being evaluate d for implementation of program improvements. |