Wynnewood Refining Company - Executive Summary |
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A. Accidential Release Prevention and Emergency Response: Wynnewood Refining Company (WRC) is required to follow the Process Safety Management Program under OSHA, and as such, has conducted audits in all affected units. WRC has also developed an emergency response plan following the National Response Plan Guidance Document to handle both on-site and off-site emergencies. B. Stationary Source and Regulated Substances Handled: WRC is a fully intregrated petroleum refinery. The main products are gasoline, diesel fuel, jet fuel, hydrocarbon solvents, liquified petroleum gases and asphalts. The covered processes considered for the RMP are as follows: 1. HFAlky/Olefin Treater - The HF Alky/Olefin Treater converts olefin and isobutane into gasoline using HF acid as a catalyst. These units contain about 44,000 lbs of butane, 1-butene, 2-butene, 2-butene-cis, 2-butene-trans, isobutane, propane, and propylene. 2. LPG Rack - This facility is an LPG storage, loading, and unloading facilit y. The LPG Rack contains 24 tanks and normally ~3,000,000 lbs of butane, 1-butene, 2-butene,2-butene-cis, 2-butene-trans, isobutane, propane, and propylene. 3. Fluid Catalytic Cracker/Gas Con Unit - The FCC/GC Unit processes gas oils into LPG's, gasoline, distillate, and slurry oil. The FCCU/GC Unit contains about 87,000 lbs of butane, 1-butene, 2-butene, 2-butene-cis, 2-butene-trans, isobutane, propane, and propylene. 4. Crude Unit - The Crude Unit distillation processes crude oil into LPG's, gasoline, diesel, naphtha, gas olils and vacuum unit charge. The Crude Unit contains ~18,000 lbs of propane, isobutane, butane, and pentane. 5. ROSE Unit - Extracts gasoils from the vacuum unit asphalts using butane as the solvent. The ROSE Unit normally contains ~73,000 lbs of butane. 6. Isomerization - The Isomerization Unit converts pentane into isopentane. This unit contains about 13,500 lbs of pentane and isopentane. 7. Hydrocracker - The Hydrocracker converts LCCO and Diesel type charge stocks into gasoline and lighter products. This unit contains ~3,000 lbs of hydrogen, 500 lbs of hydrogen sulfide, and ~65,000 lbs of propane, butane, isobutane, isopentane and heavier hydrocarbons. 8. Platformer - The Platformer converts low octane and straight chain naphtha into high octane gasoline. This unit conains ~1,500 lbs of hydrogen, and ~15,000 lbs of propane, butane, and heavier hydrocarbons. 9. Naphtha Unifiner - The Naphtha Unifiner removes sulfur from the naphtha charge to the platformer. This unit contains ~1,500 lbs of hydrogen, ~100 lbs of hydrogen sulfide, and 25,000 lbs of pentane and heavier hydrocarbons. C. The Worst Case Scenarios: Toxic - Release of 90,000 lbs of hydrofluoric acid from the settler vessel. Distance to endpoint using the OSC Anaylsis was determined to be 12 miles. No other toxics were found in the WRC facility which exceeded the threshold quantity. Flammable Worst Case - Release of 448,253 lbs of isobutane resulting from the fa ilure of a bullet tank. Distance to a 1 psi overpressure using the OSC Analysis was determined to be 0.47 miles Alternate Scenario - Toxic: A 4-inch valve on the settler vessel fails with a deluge system knocking down the HF acid vapors. Distance to endpoint was determined to be 0.43 miles. Flammables - A release of 206,196 lbs of isobutane. The distance to a 1 psi overpressure was determined to be 0.31 miles. D. General Accidential Release Prevention Program and Chemical Prevention Steps: WRC operators visually check their equipment to look for deterioration and signs of leakage. If a problem is found, the unit undergoes a thorough repair and inspection. Also, all process units undergo scheduled shutdowns, cleaning, and inspection, with any problems found repaired. Employees, as well as emergency response personnel, including off-site doctors and hospital staffs, have been informed as to what chemicals WRC uses and procedures to minimize effects from exposure. E. Five Y ear Accident History: During the past five years, this facility has had no releases of any regulated substances which resulted in deaths, injuries, or signilficant property damage on-site, or known off-site deaths, injuries, evacuations, sheltering in place, property damage, or environmental damage. F. Emergency Response Program: WRC has prepared an emergency response plan using the National Response Center Intregrated Contingency Plan Guidance Document to comply with a multitude of federal regulations. This Plan describes the response actions to be taken during an on-site or off-site emergency. G. Planned Changes to Improve Safety: WRC investigates, thoroughly, all incidents under OSHA and PSM regulations. Any recommendations resulting from the investigations are implemented. |