Chevron Phillips Chemical Co. LP - Cedar Bayou - Executive Summary |
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Chevron Chemical Company LLC is a subsidiary of Chevron Corporation, headquartered in San Francisco, CA. The Cedar Bayou Plant, located on the North side of Interstate 10 between Cedar Bayou and Sjolander, is the largest Chevron Chemical Company plant. The plant site is situated on approximately 1000 acres. The plant was initially built by Gulf Oil and began operating in 1963. In 1984, it became part of Chevron through the Chevron-Gulf merger. The basic business of Cedar Bayou is to produce simple olefins, mostly ethylene and propylene, and derivatives which include polyethylene resins, normal alpha olefins, and polyalphaolefins. These products are primarily "intermediates" which are processed further by our customers to produce finished consumer products. End uses for our products include: plastics and packaging, biodegradable detergents, synthetic lubes and hydraulic fluids, and waxes. We also convert by-product acetylene into acetylene black which is used in battery and magne tic tape production. ELABORATION ON ACCIDENT PREVENTION The Cedar Bayou plant complies with our Chevron Corporate Policy 530 for "Protecting People and the Environment" and the Chemical Manufacturers' Association (CMA) Responsible Care initiative. The processes at Cedar Bayou comply with the OSHA Process Safety Management (PSM) standard. This standard is intended only for the management of highly hazardous chemicals. However, Cedar Bayou has applied its programs and policies to the entire plant, regardless of the degree of hazard. Specific programs include: (1) A detailed hazard assessment conducted on all processes to ensure they have been designed safely, (2) An intensive equipment inspection program to ensure equipment remains in good condition to prevent releases, (3) A work permit system to ensure that all work on process equipment is conducted in a safe manner, (4) A Management of Change system to ensure that any change is thoroughly reviewed prior to being im plemented, (5) A training program to ensure that all personnel are well trained in the duties of their jobs, (6) An operating procedure system to ensure that approved procedures cover all aspects of the process unit operaton. The Cedar Bayou plant became an OSHA STAR Worksite in the Voluntary Protection Program (VPP) in 1997. This voluntary program is a partnership between OSHA and industry to recognize and encourage excellence and continuous improvement in safety programs. STAR certification represents the highest form of recognition OSHA can give a company for outstanding safety performance. ELABORATION ON EMERGENCY RESPONSE ALARM SYSTEMS: Cedar Bayou has an internal plant wide alarm system for fires and emergencies. In addition, the Baytown alarm system can be activated in the event of incidents with potential offsite consequences. TRAINED EMERGENCY RESPONDERS: To protect our people and property, Cedar Bayou has fully trained responders consisting of volunteer employees covering all four rotating shifts to ensure 24-hr coverage. Each shift has a Fire & Safety Specialist, 10 Fire Brigade members, and 3 Emergency Medical Service / Rescue members. ERT members receive training in all recognized categories of response (Fire, Haz-Mat, Emergency Medical Treatment, Rescue, and Environmental Protection). One recent accomplishment of our ERT was their first place finish in the heavy rescue segment of the 1998 International Rescue & Emergency Care Association (IRECA) competition. COMMUNICATIONS LINK TO OFFSITE RESPONDERS: The Cedar Bayou Emergency Command Center (ECC) is our link for internal and external responders. The ECC is staffed by Environmental, Health & Safety personnel, as well as individuals who are on-call. City of Baytown emergency assistance would be through 911. Industry assistance would be through mutual aid groups listed below. Our Safety Supervisor participates with the Local Emergency Planning Committee (LEPC). In 1988, we shared release scenario information with the LEPC. This Risk Management Program information will update our scenarios. MOBILE FIRE PROTECTION EQUIPMENT: Cedar Bayou has six emergency vehicles, which are: (1) Mobile Emergency Command Post, (2) E-ONE 75-ft Aerial Ladder - 2000 gpm Foam Pumper, (3) International 1000 gpm Foam Pumper, (4) One-Ton Fire Truck with 250 gallons foam solution. A foam trailer with 1000 gallons of foam is also available, (5) 1/2-Ton Ford Fire Truck with equipment trailer (includes: 4 additional Scott Air Packs with extra breathing air bottles, 1 Resuscitator with refill, 2 mutual aid radios, 400 ft of 1-1/2" fire hose, and 200 ft of 2-1/2" fire hose), (6) A fully equipped ambulance In addition to our plant fire water system with ground-level and elevated fire monitors, mobile fire hose carts are located throughout the plant. MEMBER OF MUTUAL AID GROUPS WITH OTHER PLANTS: Cedar Bayou is a member of both tHe Channel Industries Mutual Aid (CIMA) and Mutual Aid of Mont Belvieu (MAMB). Both of these organizations offer additional emergency response assistance if on-site responders and equipment can not handle an emergency. Assistance would be requested through our Emergency Command Center. As mutual aid members, we also offer our assistance to others, as needed. DESCRIPTION OF THE FLAMMABLE WORST CASE SCENARIO CHEMICAL: 1,3-Butadiene ASSUMPTIONS: (1) Instantaneous failure of C4 storage sphere, (2) Failure of all active safety systems, (3) Worst-case weather conditions (stable, low wind speed), (4) Total release - entire contents of vessel (5,100,000 lbs. in 10 minutes) at administrative capacity limit of 80%. Predicted impact will reach off-site ACCIDENT PREVENTION EXAMPLES BESIDES THOSE PREVIOUSLY ELABORATED ON: (1) Area hydrocarbon detectors with alarms to notify personel of a leak, (2) Remote valves to isolate other process equipment and limit release. EMERGENCY RESPONSE SAMPLES: (1) Alarm systems, (2) Trained Emergency R esponders, (3) Communication link to off-site responders, (4) Mobole fire protection equipment, and (5) Member of mutual aid groups with other plants. HEALTH HAZARDS FROM EXPOSURE: CHEMICALS: Flammables (Butadiene, Butane, Isobutane, Butene, Ethane, Ethylene, Isoprene, Pentane, Propane, Propylene. ( While there is the possibility of exposure to the flammable material in the vapor form, the release scenario assumes the combustion of the flammable substance. The resulting health hazards from this fire and explosion are injuries due to flying debris or glass). Low concentration exposure to the vapors (typically at a distance from the release site) is not an irritant. High concentration & prolonged exposure (typically very close to the release site) may have the following effects: (1) Simple asphyxiant; not normally considered an acute hazard. Symptoms might include Headache, nausea, dizziness, or unconsciousness due to oxygen deficiency. First aid measures are: Remove to fresh ai r; get medical attention immediately, include oxygen administration. Initiate CPR if breathing stops. (2) Irritates eyes. Symptoms are burning sensation, and first aid includes rinsing eyes with fresh water at least 15 minutes; and seeking medical attention after all but minor exposure. (3) Irritates skin. Symptoms are burning sensation; and first aid includes washing skin with soapy water, and seeking medical attention after all but minor exposure. DESCRIPTION OF FLAMMABLE ALTERNATIVE RELEASE SCENARIO CHEMICAL: Ethylene ASSUMPTIONS: (1) 2" hole in reflux drum. Level at 60% of vessel, (2) Active and passive safety systems work to isolate the rest of the process, (3) Most comon weather conditions, (4) Total release 17,700 lbs. Predicted impact will reach off-site ACCIDENT PREVENTION: Same as worst case above. EMERGENCY RESPONSE: Same as worst case above. HEALTH HAZARDS FROM EXPOSURE: Same as in worst case above. DESCRIPTION OF TOXIC WORST CASE RELEASE SCENARIO CHEMIC AL: Boron Triflouride ASSUMPTIONS: (1) Instantaneous failure of a single tube on tube truck, (2) Failure of all active safety systems, (3) Worst-case weather conditions (stable, low wind speed), and (4) Total release - entire contents of tube (3,300 lbs. in 10 minutes). Predicted impact will reach off-site ACCIDENT PREVENTION EXAMPLES BESIDES THOSE PREVIOUSLY ELABORATED ON: (1) Only one tube on the tube trailer is connected at any given time, (2) Video camera surveillance of the tube trailer area, (3) Remote valves to isolate trailer tube and limit release, (4) Manual Boron Triflouride alarms in the unit to notify personnel in immediate area of release, (5) Largest capacity truck used to minimize the number of tubing connections made. This also decreases truck traffic on roadways. EMERGENCY RESPONSE SAMPLES: (1) Boron Triflouride safety seminar for emergency response personnel held on-site with vendor, (2) Water deluge system with remote activation to minimize release mpact, (3) Alarm systems, (3) Trained emergency responders, (4) Communication link to off-site responders, (5) Mobile fire protection equipment, and (6) Member of mutual aid groups with other plants. HEALTH HAZARDS FROM EXPOSURE: Low concentrations may irritate the nose, throat and lungs. symptoms include: burning sensation, discomfort/difficulty in breathing/coughing. First aid measures are: remove to fresh air, and get medical attention if symptoms persist. High concentration & prolonged exposure may have the following effects: (1) Severely irritates the nose, throat and lungs. Severe exposure can be fatal. Symptoms might include burning sensation, coughing and gagging. First aid measures are: remove to fresh air; get medical attention immediately, including oxygen administration. Initiate CPR if breathing stops. (2) Irritates eyes. Symptoms are a burning sensation. First aid measures to take are: Rinse eyes with water for at least 15 minutes, and seek medical attention aft er all but minor exposure. (3) Irritates skin. Symptoms include a burning sensation. First aid measures are: Wash skin with soapy water, and seek medical attention for all but minor exposure. DESCRIPTION OF TOXIC ALTERNATIVE RELEASE SCENARIO CHEMICAL: Boron Triflouride ASSUMPTIONS: (1) Failure of 3/8" tubing used for unloading, (2) Active and passive safety systems do not work (To get a scenario off-site for emergency response planning), (3) Most common weather conditions, and (4)Total release - entire contents of trailer tube (3,300 lbs.). Predisted impact will reach off-site. ACCIDENT PREVENTION EXAMPLES: Same as for the worst casetoxic release. EMERGENCY RESPONSE SAMPLES: Same as for the worst case toxic release. HEALTH HAZARDS FROM EXPOSURE: Same as for the worst caset oxic release. DESCRIPTION OF ADDITIONAL TOXIC ALTERNATIVE RELEASE SCENARIO: CHEMICAL: Titanium Tetrachloride ASSUMPTIONS: (1) Failure of 1" unloading hose, (2) active and passive safety systems do no t work (To get a scenario off-site for emergency response planning), (3) Most common weather conditions, and (4) Release is based on evaporation rate from pool of liquid spilled. Rate of release - 10.9 lbs/min. Predicted impact will reach off-site. ACCIDENT PREVENTION EXAMPLES BESIDES THOSE PREVIOUSLY ELABORATED ON: (1)An operator is present during the entire unloading process and would be able to take corrective action to block in the Titanium Tetrachloride and the nitrogen used as the motive force. In addition, the catalyst supervisor audits chemical unloadings to confirm proper operation, and (2) As extra levels of protection, the unloading hoses are designed for a higher pressure service. These stainless steeel braided hoses are also supported to prevent unnecessary bending and crimping. They are left hooked up under nitrogen pressure to prevent moisture from degrading hose integrity. EMERGENCY RESPONSE SAMPLES: (1) Water monitor (fire protection equipment) in area could be u sed to mimimize release/disperse vapor cloud, (2) Alarm systems, (3) Trained emergency responders, (4) Communications link to off-site responders, (5) Mobile fire protection equipment, (6) Member of mutual aid groups with other plants. HEALTH HAZARDS FROM EXPOSURE: Low concentrations may irritate the nose, throat and lungs. Symptoms include a burning sensation. First aid measures are: Remove to fresh air, and get medical attention if symptoms persist. High concentrations and prolonged exposure may have the following effects: (1) Severely irritates the nose, throat and lungs. Severe exposure can be fatal. Symptoms include coughing, gagging, shortness of breath, and possible nausea. First aid measures are: Remove to fresh air; get medical attention immediately, including oxygen administration. Initiate CPR if breathing stops. (2) Irritates eyes. Symptoms include a burning sensation. First aid measures are: Rinse eyes with fresh water for at least 15 minutes, and seek medical attention after all but minor exposure. (3) Irritates skin. Symptoms include a burning sensation. First aid measures are: wash skin with soapy water, and seek medical attention for all but minor exposure. DESCRIPTION OF ADDITIONAL TOXIC ALTERNATIVE (worst case) RELEASE SCENARIO: CHEMICAL: Ammonia, Aqueous>20% ASSUMPTIONS: (1) Worst case scenario used to prove no off-site consequences, (2) Instantaneous failure of vessel, (3) Failure of al active safety systems, (4) Worst-case weather conditions (stable, low wind speed), (5) Total release - entire contents of vessel (150,000 lbs.) released into a containment basin. Vapor cloud based on evaporation rate from liquid pool. Utilized EPA Guidance for wastewater treatment plants. Predicted impact will not reach off-site. ACCIDENT PREVENTION EXAMPLE BESIDES THOSE PREVIOUSLY ELABORATED ON: (1) Containment basin is designed for full volume release, (2) A water scrubber is located on the tank vent and is used during the unloading proce ss to minimize air emissions, (3) An operator is present during the unloading process and would be able to block in the tank truck. With the ammonia tank being filled by an overhead line with a diptube into the vessel, any unloading hose problem will not result in tank leakage. Only the tank truck would need to be isolated, (4) Manual alarms in unit to notify personnel in the immediate area of the release, and (5) Aqueous Ammonia is replacing Anhydrous Ammonia in 1999. This will eliminate ammonia release scenarios with off-site consequences. EMERGENCY RESPONSE SAMPLES: (1) Water deluge system with remote activation to minimize release impact, (2) Alarm systems, (3) Trained emergency responders, (4) Communication link to off-site responders, (5) Mobile fire protection equipment, (6) Member of mutual aid groups wit other plants. HEALTH HAZARDS FROM EXPOSURE: Low concentrations may irritate the nose, throat and lungs. Symptoms include a burning sensation, discomfort/difficulty in brea thing/coughing. First aid measures are: Remove to fresh air, and get medical attention if symptoms persist. High concentrations & prolonged exposure may have the following effects: (1) Severely irritates the nose, throat and lungs. Severe exposure can be fatal. Symptoms include a burning sensation, coughing, gaging, shortness of breath, and possible nausea. First aid measures are: Remove to fresh air; get medical attention immediately, including oxygen administration. Initiate CPR if breathing stops. (2) Irritates eyes. Symptoms include a burning sensation. First aid measures are: Rinse eyes with fresh water for at least 15 inutes,and seek medical attention after all but minor exposure. (3) Irritates skin. Symptoms include a burning sensation. First aid measures are: Wash skin with soapy water, and seek medical attention for all but minor exposure. FIVE YEAR ACCIDENT HISTORY: ETHYLENE: There has been one flammable release of ethylene in the Cedar Bayou plant in the past fiv e years that meets the EPA Risk Management Program (RMP) reporting requirements for off-site damage. There have been no incidents at the facility that meet the EPA RMP reporting requirements with respect to on-site damage or injury. 1/23/98 - A polyethylene reactor experienced a runaway reaction. A safety system activated as designed to prevent the escalation of the release scenario, releasing the small volume of ethylene (2,000 lbs.) at high pressure (25,000 psig) to the atmosphere. This small vapor cloud ignited and carbon fallout landed off-site. This resulted in vehicle clean-up costs of $40 for a neighbor. BORON TRIFLOURIDE, TITANIUM TETRACHLORIDE, AQUEOUS AMMONIA: There have been no releases of Boron Triflouride, Titanium Tetrachloride, or Aqueous Ammonia at the Cedar Bayou plant in the past five years that have had an adverse impact on the community or that meets the EPA Risk Management Program (RMP) reporting requirements with respect to on-site injuries or damage. |