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HomeMy WebLinkAboutMINUTES - 11202006 - D.3 14s3y �s Contra Costa TO: BOARD OF SUPERVISORS :•._<• s _ County FROM: William Walker, M.D., Health Services Director DATE: November 20, 2005 SUBJECT: Annual Industrial Safetv Ordinance Report SPECIFIC REQUEST(S)OR RECOMMENDATION(S) & BACKGROUND AND JUSTIFICATION RECOMMENDATIONS: Accept the Industrial Safety Ordinance Annual Report submitted by Health Services. FISCAL IMPACT: No fiscal impact BACKGROUND/REASONS FOR RECOMMENDATIONS: Chapter 450-8 of the County Ordinance Code known as the Industrial Safety Ordinance Risk Management Chapter requires Health Services to submit annual reports to the Board of Supervisors. The ordinance outlines what is to be included in this report. Attached is a copy of this report. CONTINUED ON ATTACHMENT: ®YES ❑ NO SIGNATURE fECOMMENDATION OF COUNTY ADMINISTRATOR _RECOMMENDATION OF BOARD COMMITTEE _ APPROVE _OTHER SIGNATURE(S): ACTION OFB(A ON ✓ APPROVED A/S/�ARECOMMENDED_�HBE�R,_ C� VOTE OF SUPERVISORS Qom' � Alm g— "' G`W& 6 "v I HEREBY CERTIFY THAT THIS ISA TRUE A D \ UNANIMOUS(ABSENT CORRECT COPY OF AN ACTION TAKEN AND AYES: NOES: ENTERED ON THE MINUTES OF THE BOARD ABSENT: ABST OF SUPERVISORS ON THE DATE SHOWN. Contact: Randy Sawyer( 25)646-2879) ATTESTED cc: Randy Sawyer, Health Services Department JOHN CULLEN,CLERK OF Ty E BOARD OF SUPERVISORS AND COUNTY ADMINISTRATOR BY DEPUTY RLS KAndustrial Safety Ordinance/Annual Report/2006/Board Order 112806 ADDENDUM December 5, 2006: Agenda Item D.3 On this day the Board of Supervisors accepted the annual report from the Health Services Department addressing the effectiveness of the Industrial Safety Ordinance, including accidents that have occurred, the public participation process, the status of audits and Safety Plans, and the effectiveness of the Hazardous Materials Ombudsman. Randy Sawyer, Health Services Department,provided the Board with a brief description of the impact of the Industrial Safety Ordinance. He advised the Board that the number and severity of Major Chemical Accidents and Releases has decreased since implementing the Industrial Safety Ordinance. Mr. Sawyer reported that the Health Services Department developed the Contra Costa CalARP and Safety Program Guidance Documents which may be downloaded through Health Services Department's web page. Cho Nai Cheung, Engineer,Health Services Department, advised the Board that the Industrial Safety Ordinance requires the Health Services Department to hold public meetings to review safety plans and to provide an opportunity for the public to review any audit findings. She noted the Public meetings were held with little participation, with four to ten people attending. She said the Hazardous Materials Programs has a strong public outreach process and is constantly looking at ways to improve this process. Ms. Cheung said the Annual Performance Review and Evaluation report of the Hazardous Materials Program is available for view on the web through Health Services Department. Supervisor Piepho expressed concern regarding the differentiation in"Major" or"Minor" accidents pointed out in the Industrial Safety Ordinance report. She requested that the Health Services Department review the names of the different categories of Major Chemical Accident and Releases and come up with something that is not so confusing. Supervisor Uilkema requested Health Services Department attend one of the Bay area Quality Management District's Title 5 hearings to assess opportunities to extend outreach efforts. Chair Gioia commented that the number and severity of the Major Chemical Accidents and Releases has decreased since completing the Industrial Safety Ordinance. He requested Health Services Department provide copies of the informational ISO comic book to the Board for further review, stating that this might not be the best approach to public education. He also suggested discussing the distribution. Referring to the Laotian Community, he said it would be useful to develop some suitable materials and language for the West County. He noted it is important to be proactive in public participation. By unanimous approval with District IV seat vacant the Board took the following action: ACCEPTED the annual report from the Health Services Department addressing the effectiveness of the Industrial Safety Ordinance; and REQUESTED Health Services Department staff give consideration to the concerns raised by the Supervisors in the discussion. Parform8mccA oal Evaluldom Reporta � a o m Hod* ° P a ° o � Goma o �� Qa x d e —ra __ � r•�-r. tea. s'^b Am: :§iB">�.9#"" �. '&iec wP�' s assan.� x r 1 � e skg k �g" bog CONTRA COSTA ��dsx• V � H xa . m Table of Contents ExecutiveSummary..................................................................................................... 1 PublicParticipation....................................................................................................................................1 Audits.........................................................................................................................................................1 General Chemical Bay Point Works..........................................................................................................1 Major Chemical Accidents and Releases....................................................................................................2 Industrial Safety Ordinance Amendments.................................................................................................2 Conclusion.................................................................................................................................................2 Introduction................................................................................................................ 3 Annual Performance Review and Evaluation Report................................................................................4 Effectiveness of Contra Costa Health Services'Implementation of theIndustrial Safety Ordinance .................................................................................. 5 Effectiveness of the Procedures for Records Management.........................................................................6 Number and Type of Audits and Inspections Conducted.........................................................................6 Number of Root Cause Analyses and/or Incident Investigations Conducted by Health Services............8 Health Services Process for Public Participation.......................................................................................8 Effectiveness of the Public Information Bank............................................................................................8 Effectiveness of the Hazardous Materials Ombudsman.............................................................................9 Other Required Program Elements Necessary to Implement and Manage the Industrial Safety Ordinance ...............................................................................................................10 RegulatedStationary Sources Listing........................................................................ 11 The Status of the Regulated Stationary Sources' Safety Plans and Programs ..........................................11 Locations of the Regulated Stationary Sources Safety Plans....................................................................11 Annual Accident History Report and Inherently Safer Systems Implemented as Submitted by the Regulated Stationary Sources..........................................................................................................12 & 13 Status of the Incident Investigations Including the Root Cause Analyses Conducted by the Regulated StationarySources....................................................................................................................................14 Major Chemical Accidents and Releases..................................................................................................18 Legal Enforcement Actions Initiated by Health Services ........................................................................19 PenaltiesAssessed as a Result of Enforcement........................................................... 20 Total Fees, Service Charges, and Other Assessments Collected Specifically for the IndustrialSafety Ordinance ...................................................................................... 20 Total Personnel and Personnel Years Used by Health Services to Implement theIndustrial Safety Ordinance ................................................................................ 20 Comments From Interested Parties Regarding the Effectiveness of the Industrial SafetyOrdinance....................................................................................................... 21 The Impact of the Industrial Safety Ordinance on Improving Industrial Safety ...... 21 City of Richmond Industrial Safety Ordinance...............oo..........—...........—...........o. 22 AttachmentsA........................................................................................................... 23 AttachmentB ............................................................................................................ 31 AttachmentsC.,...o—...........o...........oo—o.........o—o.........—...........o..........o..........—oo..... 37 The main goal of the Industrial Safety Ordinance is • ConocoPhillips Rodeo Refinery—September to prevent chemical accidents from occurring that 2006 could have a detrimental impact to the community • Shell Martinez Refinery —November 2006 surrounding chemical facilities and petroleum refineries. This is accomplished by requiring the GENERAL CHEMICAL BAY POINT regulated facilities to implement a safety program WORKS that is designed to be the most stringent in the The Accidental Release Prevention Program United States, if not the world. The Industrial Engineers inspected General Chemical Bay Point Safety Ordinance is designed to include participation Plant and met with the representatives of that site from all of the stakeholders, including industry, monthly. This was done because of the poor results agencies, elected officials, and the public. of implementing the required programs under the Industrial Safety Ordinance. The meetings and PUBLIC PARTICIPATION inspections help to ensure that General Chemical The Hazardous Materials Programs has a very does implement the required programs. strong public outreach process and is constantly looking at ways to improve this process. The following items were implemented this year based on recommendations from interested stakeholders: • Public meeting to be held with existing venues • General Chemical Audit Findings Presentation to the Bay Point Latino Community with other like organizations- over 100 people attended • General Chemical Audit Findings Presentation in cooperation with the Bay Point Municipal Advisory Committee -40people attended • Shell Oil, Tesoro Golden Eagle Refinery, and Air Products facilities at the Shell Refinery and the Golden Eagle Refinery Presentations at the Martinez Farmer's Market and Italian Festival ; • Audit findings given in easily read format int, r both English and Spanish • Information on regulated businesses in an easily read format in English and Spanish ° • Industrial Safety Ordinance Information Sheet in English and Spanish ai AUDITS Audits of the regulated businesses are required at least once every three years to ensure that the facilities have the required programs in place and are implementing the programs. The audits that were completed this year are: FINI • Tesoro Golden Eagle Refinery —November 2005 • General Chemical Richmond Works —July 2006 1 MAJOR CHEMICAL ACCIDENTS AND RELEASES Another measure of the effectiveness of the Industrial Safety Ordinance is by the number and severity of the Major Chemical Accidents and Releases that have occurred. Since the last report to the Board there has been four Major Chemical Accidents and Releases. Three of the releases are considered minor while the fourth release is considered medium. The medium release occurred at the General Chemical Richmond Works plantm when there was a release of sulfur dioxide and ^' sulfur trioxide that required contract workers at the Chevron Richmond Refinery to seek medical attention. £y° INDUSTRIAL SAFETY ORDINANCE AMENDMENTS The Board approved amendments to the Industrial Safety Ordinance in June that will strengthen the required Safety Programs at the`regulated businesses. The amendments include: • Expanding the Human Factors Programs to include maintenance operations • Conduction a management of Organization d change for temporary changes exceeding 90 � days • Increasing the regulated businesses' security by requiring a Security and Vulnerability Analysis to be done and re-evaluated at least every 5 years �r • Improve the overall safety at these sites by requiring a Safety Culture Assessment. CONCLUSION N The number and severity of the Major Chemical Accidents and Releases have been decreasing since " j the implementation of Industrial Safety Ordinance. ` ° The implementation of the Industrial Safety Ordinance has improved and, in most cases, being Fp . done as required by the ordinance. It is believed that by continuing the implementation of the ' Industrial Safety Ordinance and strengthening the requirements of the Ordinance that the possibility of accidents that could impact the community is decreased. D A44 7S UCT :, Sr �. 2 The Board of Supervisors passed the Industrial • Contra Costa Health Services will give an Safety Ordinance because of accidents that have annual performance review and evaluation occurred at the oil refineries and chemical plants report to the Board of Supervisors in Contra Costa County. The effective date of the Industrial Safety Ordinance was January 15, 1999. Six stationary sources that are now covered by the The ordinance applies to oil refineries and chemical Industrial Safety Ordinance are: plants with specified North American Industry Classification System (NAICS) codes, that were • Air Products at the Shell Martinez Refining required to submit a Risk Management Plan to Company the U.S. EPA and are a program level 3 stationary • Air Products at the Tesoro Golden Eagle sources as defined by the California Accidental Refinery Release Prevention (Ca1ARP) Program. The • Shell Martinez Refining Company ordinance specifies the following: • General Chemical West in Bay Point • ConocoPhillips Rodeo Refinery • Stationary sources had one year to submit a • Tesoro Golden Eagle Refinery Safety Plan to Contra Costa Health Services stating how the stationary source is complying with the ordinance, except the Human Factors Contra Costa Health Services completed and issued portion (completed January 15, 2000) the Contra Costa County Safety Program Guidance • Contra Costa Health Services develop Document on January 15, 2000. The stationary a Human Factors Guidance Document sources were,required to comply with the Human (completed January 15, 2000) Factors section of this guidance document by • Stationary sources had one year to comply January 15, 2001. with the requirements of the Human Factor Guidance Document that was developed by Contra Costa Health Services (completed January 15, 2001) • For major chemical accidents or releases, the 0 stationary sources are required to perform a s root cause analysis as part of their incident O investigations (ongoing) . • Contra Costa Health Services may perform it's own incident investigation, including a root cause analysis (ongoing) � • All of the processes at the stationary source are covered as program level 3 processes as defined by the California Accidental Release Prevention Program • The stationary sources are required to consider Inherently Safer Systems for new processes or facilities or for mitigations resulting from a process hazard analysis ®s • Contra Costa Health Services will review all of � the submitted Safety Plans and audit/inspect all of the stationary source's Safety Programs within one year of the receipt of the Safety Plans (completed January 15, 200 1) and every three years after the initial audit/inspection (ongoing) 3 Contra Costa Health Services has reviewed all of the by the ordinance, including the status of Safety Plans submitted to the department and are implementation of recommendations now in the process of completing the third round e) A summary, including the status, of any of audits for all of the stationary sources as required audits, inspections, root cause analyses and/or by the ordinance. In addition, Contra Costa Health incident investigations conducted by Health Services has performed a specialized audit for all the Services, including the status for implementing stationary sources for their human factors programs the recommendations and for Inherently Safer Systems completed in 2002. f) Description of inherently safety systems The status of the reviews and audits are discussed implemented by the regulated stationary within the report. source g) Legal enforcement actions initiated by Health ANNUAL PERFORMANCE REVIEW Services, including administrative, civil, and AND EVALUATION REPORT criminal actions The Industrial Safety Ordinance specified that the 3) Total penalties assessed as a result of contents of the annual performance review and enforcement of the ordinance evaluation report contain the following: 4) Total fees, service charges, and other assessments collected specifically for the support of the 1) A brief description of how Health Services is ordinance meeting the requirements of the ordinance as 5) Total personnel and personnel years used by the follows: jurisdiction to directly implement or administer a) Effectiveness of the Department's program to the ordinance ensure stationary source's compliance with the 6) Comments from interested parties regarding ordinance the effectiveness of the local program that raise b) Effectiveness of the procedures for records public safety issues management 7) The impact of the ordinance in improving c) Number and type of audits and inspections industrial safety conducted by Health Services as required by the ordinance d) Number of root cause analyses and/or incident investigations conducted by Health Services e) Health Services process for public participation f) Effectiveness of the Public Information Bank g) Effectiveness of the Hazardous Materials Ombudsperson h) Other required program elements necessary to implement and manage the ordinance 2) A listing of stationary sources covered by the y. ordinance, including for each: a) The status of the stationary source's Safety - Plan and Program b) A summary of all stationary sources' Safety Plan updates and a listing of where the Safety Plans are publicly available c) The annual accident history report submitted by the regulated stationary sources and required by the ordinance d) A summary, including the status, of any root cause analyses and incident investigations conducted or being conducted by the stationary sources and required 4 EFFECTIVENESS OF CONTRA EFFECTIVENESS OF THE COSTA HEALTH SERVICES' PROCEDURES FOR RECORDS IMPLEMENTATION OF THE MANAGEMENT INDUSTRIAL SAFETY ORDINANCE Health Services has setup hard copy and computer Health Services has developed policies, procedures, files for each of the stationary sources. The files protocols, and questionnaires to implement both include the following folders: the California Accidental Release Prevention Program and the Industrial Safety Ordinance. These • Annual status reports policies, procedures,protocols, and questionnaires • Audits & Inspections for these programs are listed below: • Communications • Completeness Review • Audits/Inspections Policy • Emergency Response • Conducting the RMP/Safety Plan • Incident Investigation ��II Completeness Review Protocol • Trade Secret Information • RMP Completeness Review Questionnaires • Safety Plan Completeness Review Questionnaires • Conducting Audits/Inspections Protocol • Safe Work Practices Questionnaires + U • CalARP Program Audit Questionnaires •. Safety Program Audit Questionnaires • Conducting Employee Interviews Protocol Employee Interview Questionnaires ■ 1 • Public Participation Policy , • Dispute Resolution Policy O tea_ • Reclassification Policy • Covered Process Modification Policy • CaIARP Internal Performance Audit Policy • Conducting the Internal Performance Audit The paper files for the stationary sources • CaIARP Internal Audit Performance Audit are kept in a central location. The Submission Accidental Release Prevention Program • Fee Policy has a file setup on the Health Services • Notification Policy Network where the files for each of • Unannounced Inspection Policy the different stationary sources are • Risk Management Plan Public Review Policy found and are accessible to each of the Accidental Release Prevention Program Health Services has developed the Contra Costa Engineers and the Program Director. County CaIARP Program Guidance Document and The Accidental Release Prevention the Contra Costa County Safety Program Guidance Program files also contain regulations, Document. These documents give guidance to the policies, information from the U.S. EPA, stationary sources for complying with the Industrial the Governor's Office of Emergency Safety Ordinance. The policies, procedures, Services, the Chemical Safety and protocols, and questionnaires, are available through Hazards Investigation Board, and other Health Services. The guidance documents can be information pertinent to the engineers. downloaded through Health Services Website: The risk management and safety plans AMLIk http://www.cchealth.org/groups/hazmat/ received are kept at two different Health industrial_safety ordinanceguidance.php Services locations: the Hazardous Materials Program Offices and the Accidental Release Prevention Program 5 Offices. NUMBERAND TYPE OF AUDITS to the Notice of Deficiencies. When the stationary AND INSPECTIONS CONDUCTED source has responded to this Notice of Deficiencies, Health Services was required to audit and inspect Health Services will review the response. Health all seven (currently six) regulated stationary sources Services will either determine that the Safety Plan is that were required to comply with the Industrial complete or will work with the stationary source, Safety Ordinance within one year after the initial until the Safety Plan is determined to be complete. submittal of their Safety Plans. Health Services When the Safety Plan is deemed complete, Health reviewed all of the Safety Plans and audited/ Services will open a public comment period on inspected all of the stationary sources' Safety the Safety Plan and will present the plan in a Programs within that year (2000). Health Services public meeting or venue. Health Services will performed focused audits of the stationary sources respond to all written comments in writing and for their Human Factors Programs (this was not when appropriate use the comments in the audit/ included in the original audit/inspection, since the inspection of the regulated stationary sources. stationary sources were not required to have their Human Factor Program in place until January Health Services will issue Preliminary Audit 2001) and Inherently Safer Systems in 2001 and Findings after an audit/inspection is complete. The 2002. Additional focused audits were performed to stationary source will have ninety days to respond look at how two stationary sources would manage to these findings. Health Services will review the organizational change in case there was a strike the response from the stationary source on the and non-striking personnel were used instead of Preliminary Audit Findings. When the stationary the striking personnel (2002). Health Services has source has developed an action plan to come into completed the second round of audits for all of the compliance with the regulations, Health Services Industrial Safety Ordinance stationary sources in will issue the Preliminary Audit Findings for public 2003 and 2004 and began a third round of audits in comment and will present the findings in a public Fall 2005, which will be completed in the Spring of meeting or venue. Health Services will consider 2007. any public comments that were received during the public comment period and if appropriate will revise the Preliminary Audit Findings. When this is m complete, Health Services will issue the Final Audit Findings and will respond in writing to any written public comments received. Table I lists the status of Health Services review of the different stationary sources Safety Plans and audit and inspections of their Safety Programs. When Health Services reviews a Safety Plan, a Notice of Deficiencies is produced that documents what changes to their Safety Plan a stationary source are required to make before Health Services determines that the Safety Plan is complete. The stationary source has sixty to ninety days to respond 6 .�s awe a +cam 't s � e NM 11 00 (71 00 O O Co O r * n x 0 O V A A A N \ v la's" . °l. M ingHl HF SP Dest�erminedgi� � CK a, 00 P as&*Z. _° _ a `F AA A V A A r Of O O M O DA DD NIZZLIV MTV Ln Ln ZRFAR t"­111-1 C' -1 406 O O O O O O { 'e6narreik" fr &"�� " V A A A A A 'O �D V1 N �D N HumabOTactors(H ) 1. O M O O O N O M O M O F•-��/" O V O V O A V O V O O V O \ 00 clq CN C. Ln � n �a, r �r Lr) C. a, L .-� O 7 O �I- O M u1 O �D O '1 "D O in ��- - V� ,� V *s�. O O M O O O M - \ \ \ \ \ \ \ \ O \ \ \ O \ \ N 00 .p 00 W O O •--� -- i p C M C) M .--� M O N M Cl) €+ 0 0 O O O O A O O O O O Cl O M �--� Lr) V' 00 �D N •--� '-� N lD N .\-+ V\i \-� A A d' Ln A 1\f) Ov 01 s W U _ OO 00 V O N M ti M rm^zr; O O V O O C) � O O Co a a x x n O O O n O \ r _ _ ay ae *s=� �dwc��5€ta�Fes'�*isT N Ql Qv N "Irk s v'-a�,. A A A V A 00 00 00 ON A V A V A L t m T� ®, O O O O �D O M �D O O a � O O O O O O O O O No"tice 6PDeficiencies iiia, p O M CO O M �O O O tn O N �O O N Al €U, N x � RIEN ".. a'. �"�'Ziis' : vii s P O �O O p40 04 v Sy LU f ,mom ws»�w n =«AA «s a. V 0 .4z. Fy 7 Ordinance, Industrial Safety Ordinance webpage NUMBER OF ROOT CAUSE information, a Spanish and English video on ANALYSES AND/OR INCIDENT performing Hazardous Materials Programs INVESTIGATIONS CONDUCTED inspection, including the Industrial Safety BY HEALTH SERVICES Ordinance, and a Spanish and English translation of a comic strip introducing the "ISO Four." Examples Health Services has not performed any incident of this information are included in Attachment A. investigations, including a root cause analysis The community representatives suggested within the last year. Health Services has reviewed that Health Services look at venues that the the reports submitted to the department and has Health Services' Preliminary Audit Findings commented and requested additional information and the stationary source's Safety Plans can be on the stationary sources' own incident presented and input from the community can be investigations and root cause analyses for Major received. Stand-alone meetings have not been Chemical Accidents or Releases. A listing of the successful. Health Services created a venue where Major Chemical Accidents or Releases can be found presentations were done on the Industrial Safety on the Health Services website at the following Ordinance, Community Warning System, Contra address: http://www.cchealth.org/groups/hazmat/ Costa County CAER Group, Integrated Pest a ccident_history.php. This list of accidents includes Management, Household Hazardous Waste, and accidents that occurred prior to the adoption of the Citizens Emergency Response Team (CERT) in Industrial Safety Ordinance. Spanish to the Bay Point Latino Community on November 16, 2005. Over one hundred people HEALTH SERVICES PROCESS FOR attended this event. A second Spanish presentation PUBLIC PARTICIPATION was given on November 8, 2006 to the Bay Point Health Services, in 2005, worked with the Latino Community and over 25 People attended. community in developing material that would describe the Industrial Safety Ordinance using a The Shell Martinez Oil Refinery, Tesoro Golden number of different approaches. The approaches Eagle Refinery, and Air Products at the Shell and include a display board describing the Industrial Tesoro Refineries' Preliminary Audit Findings Safety Ordinance, fact sheets and one-page were presented to the community at the Martinez summaries of audit findings on the stationary Farmer's Market and Italian Festival held on sources that are regulated by the Industrial Safety September 24, 2006 in downtown Martinez. Many people stopped by and asked questions on the Hazardous Materials Programs and the Industrial • - • Safety Ordinance and looked through the audit findings of the four facilities listed above. This as �6'"t9A°• e a�safeeyM venue worked well in providing the information to costaHomadt What'3ftce'Pro6#v»? h1YiY�rMb'�Y 1 ien6a4MSs�MwtN �Lw(rYr�6`yt♦tw� N e a......t�� ^ rrwv«..r+r...e..ca ttn..r«w.m at w�w�.-,rte.*p�-.,'� to- ;iso- .'�`� u"Sy".�y'�' the community. t EFFECTIVENESS OF THE PUBLIC r Aad �ms 6y,61, INFORMATION BANK The Hazardous Materials Programs section of Health Services Website http://www.cchealth.org/ groups/hazmat/ include the following information: • Industrial Safety Ordinance o Description of covered facilities a J"r, e o Risk Management Chapter Discussion Copy of the ordinance o Land Use Permit Chapter Discussion • 8 Copy of the ordinance o Safety Program Guidance Document • Facility Search o Frequently Asked Questions o On-line search of the facilities that handle o Public Outreach Strategies hazardous materials by name of the facility, • California Accidental Release Prevention street name, and city or any combination of (CaIARP) Program the three o Contra Costa County's • Unannounced Inspection Program California Accidental Release Prevention o Lists the facilities that are subject Program Guidance Document to unannounced inspections under the o Program Level description Unannounced Inspection Program o Discussion on Public Participation for both • Hazardous Materials Interagency Task Force CalARP Program and the Industrial Safety o Includes a Matrix of who has and what Ordinance hazardous materials regulatory o A map locating the facilities that are responsibilities subject to the CalARP Program and are o Minutes from past meetings required to submit a Risk Management o Presentations from past meetings Plan to Health Services. The map links to • Incident Response a description of each of the facilities and the o Accident History that list summaries of regulated substances handled. major accidents from industrial facilities in • Hazardous Materials Inventories and Contra Costa County from most recent to Emergency Response Program 1992 o Descriptions • Additional resource links for more o Forms information • Hazardous Waste Generators o Description of the program EFFECTIVENESS OF THE o Forms HAZARDOUS MATERIALS o Copies of the HazMat Recorder OMBUDSMAN • Underground Storage Tanks The Board of Supervisors created the Hazardous o Description of the program Materials Ombudsperson position in 1997. This o Copies of the Underground Storage Tanks position was filled in April 1998. The Board Health & Safety Code sections believed that the ombudsperson would be a conduit o Underground Storage Tanks Forms for the public to express their concerns about • Green Business Program Description of the Green Business Program how Hazardous Materials Programs personnel are o with link to the G' website ss the Performing their duties. Attachment B is a report from the Hazardous Materials Ombudsman on the Green Business Program • effectiveness of the position. Hazardous Materials Incident Response Team o Including information of the Major Chemical Accidents and Releases that have occurred �€�';�;� " �, o The County's Hazardous Materials Incident Notification Policy � x o A link to the ConocoPhillips Fenceline e� h Monitors �- • Hazardous Materials Program Incident Search a fl o On-line search of the hazardous materials incident database for incidents3 that have occurred from 1993 to current . year by entering a date range, address, city, and/or facility name. 9 --------------- '11x3 ry �tf d L9 Ste' Y - a, tax. MW/M�+�.'.cChCd[horCkrcuxlh:LlRn./ -e,— ±J1 CONTRA COSTA 1' HCAITH SERVICES f 1,WXd0u;Fowl,r I.ro:r:M €�<: -71 Hazardous HitdfdQ08 M7it+NiilS PPOgt71A1S Praorarns r €. ;- Cud!:,trdn CLU hr's iumJJJ�Atalsrtllo 4u�':+m xrrts artc 1.-ids Uy-raaT 1 _;, brxmirvii near rr>ine € e`' [O em?'GerIC ES afM 1a9rL:799�9aZffiQOtq m0:?'IBD. q�; tldem»4�d ndikkxre � 4 Main WfICe h n Ixfiid:.y h AMnnevn •' £T y'• �? ,g ' a sc le,: PB rEco EQIE*'dids JMpprPNq,2 14a lama kl.'lfflnt9 "YI.1Tdl:1GT5� r, _ '� # ,�s �'�, s r P a ,; e. c 1'3-=W.9'Zr"416sC7c fa7( 1a nr c=1m f 04-Deur hatline hufABer Ibr eMernencles ontv.,923-i112 f :`a'"1} r 9.n1• € S'1 '� rtit en?2»poree �b 1` m rt swch Aarl�Mttdt I �� n«ogerc.,la-er to '� Latest Ird li iiit ivn ri'i-N'-c-.trrrl.rrrmrm rnrnrtil s:-frrr rn -t r�rn nrnrr�i F.1-1i ix.xJiu�U:Irliek M ;:irnxon ,', kESDOn9C47«l EDtbnD AD=Etl t_:EnCr4q(:rErcaca Uab HJricom-travi ORm-ti:.bU(A i-LY Ifl(1(J; 7A:n�lT-n rxl Wi:u nlg rr.r 8u1 �� safety of G a t3 21^hetro:_I Fal Say,�d 1: t.Iea'IS-i FLLi: a[ri 811.iligi Dim h1j.l ai Silifil Ordhl r:r.'.r.: l.i trr lnml iMnI�nfl ornii L'Rf:!7r tinAn?i'11TI rr.!tr!!1'S rr rr ri.ror.l rri-r Sr!^.'fA5iNi1'.9-w?T.ni rkyra df31^_'11"I oantlxctgr a r_crverdentill form, � G'--l-!lt w:S-J:1!-Lill Lu"IINrI tr J'L-ALLI e'rtiLI liibrliJ W1d Hd:A'dUuS-MJl ii i F`t=Id6-+Ved QUuN-AI 5&6uul Lxr11Aril li!atr ErC i1a2ardOUi iS w. Hazardous Materials Incident Saarch-Seal cu7a:aaa*efcrrcidents:la-iioccJredfil1993totldsyesr. Sit.-tIVtrSara7nlnwersjbuW81e1'IJJ.h_el,EaftltOrtldhart:dl35G1_._...___ A",77-77 -77,737777 OTH E R RE QU I RED P RO G RAM Health Services performs Unannounced Inspections ELEMENTS NECESSARY TO of the stationary sources that are part of the IMPLEMENT AND MANAGE THE CalARP Program and are also required to submit INDUSTRIAL SAFETY ORDINANCE a Risk Management Plan to the U.S. EPA. These The California Accidental Release Prevention inspections look at a focused portion of the CalARP Program or Industrial Safety Ordinance (CalARP) Program is administered by Contra Costa Health Services. The Industrial Safety Ordinance Hazadousrequirements, t well as elements from the other expands on this program. Stationary Sources are Hazardous Materials Programs. required to submit a Risk Management Plan to Health Services that is similar to the Safety Plans that are submitted. Health Services reviews these Risk Management Plans and performs the CalARP Program audit simultaneously with the Industrial Safety Ordinance audit. 10 THE STATUS OF THE REGULATED complete and prior to going out for a forty- STATIONARY SOURCES' SAFETY five day public comment period, Health P LAN S AN D P ROG RAMS Services will place the plan in the library(ies) All of the stationary sources that are regulated by closest to the regulated stationary source. 773 Below in Table II is a listing of the regulated the Industrial Safety Ordinance were required to Q stationary sources with the location of each submit their Safety Plans to Health Services by of their Safety Plans. January 15, 2000 and to have their Safety Programs completed and implemented. The stationary sources were also required to have a Human Factors Program in place that follows the County's Safety Program Guidance Document by January 15, 2001. The status of each of the regulated stationary sources is given in Table I and includes the 1r'I following: • When the latest updated Safety Plan was submitted O • When the Notice of Deficiencies were issued Q • When the plan was determined to be complete by Health Services • When the public meeting was held on the Safety Plan • When the audits were complete • When the public meetings were held on the U preliminary audit findings Q • When the Human Factors to the Safety Plan were revised • When the Notice of Deficiencies were issued O for the Human Factors revised Safety Plan • When the Human Factors Safety Plan was 0 determined to be complete �;� • When the Audit/Inspection was completed x � _ • When the Human Factors Audit Findings a , Audit preliminary findings Public Meeting was . held LOCATIONS OF THE REGULATED STATIONARY SOURCES SAFETY � . o PLANS Each of the regulated stationary sources was required to submit their Safety Plan to Health Services on January 15, 2000 and an updated r " Safety Plan that includes the implementation of the stationary source's Human Factors Program by January 15, 2001. These plans are available for ' -A public review at the Hazardous Materials Programs Offices at 4333 Pacheco Blvd., Martinez. When Health Services determines that the Safety Plan is 11 TABLE II LOCATION OF SAFETY PLANS - LIBRARIES Ur IPA Regulated Locatlon 1 ,Loatlon2� Lflcatlon 3 aa' �� �� a SEN tatlonRE � Fa i G P 3'd�"�"s"N�r �RJ6Y!dY �'dry ' �'d�'`$$°ypp�W �"� JiMn i d .qa RI ttl Source Air Products at Hazardous Materials Martinez Public Shell Programs Office Library Air Products at Hazardous Materials Martinez Public Tesoro Programs Office Library Shell Refining Hazardous Materials Martinez Public - Martinez Programs Office Library General Hazardous Materials Bay Point Public Chemical West Programs Office Library Bay Point Works ConocoPhillips Hazardous Materials Rodeo Public Crockett Rodeo Refinery Programs Office Library Public Library Tesoro Golden Hazardous Materials Martinez Public Eagle Refinery Programs Office Library 12 TABLE III INHERENTLY SAFER SYSTEMS ,5"� -"" ;J osr i aZx esl n ' d Regulated SGilon�ary Source �Inherently�Safer Sysiem Implemented Category �� Strate t gYF Air Products at the Shell o new inherently safer systems implemented Martinez Refinery Air Products-Tesoro No new inherently safer systems implemented ConocoPhillips Rodeo Refinery Reduction of inventory (three times) Inherent Minimization Simplifying the process (once) Inherent Simplify Revised equipment design features (once) Passive Minimization General Chemical West Bay No new inherently safer systems implemented Point Works Shell Martinez Refinery Reduction of inventory by elimination of dead Inherent Minimization leg (once) Dead leg removal (four times) Inherent Simplify Tesoro Golden Eagle Refinery Remove out of service or unnecessary Inherent Simplify equipment or piping (four separate times) Improved capacity,temperature, and/ Passive Simplify overpressure design rating of equipment (three separate times) Reduced potential of a hazard or the frequency Passive Simplify by changing design features, and/or installation of blinds (eight separate times) Reduced the potential of a hazard by Passive Moderate eliminating the hazard or moving to an alternate location (two separate times) 13 STATUS OF THE INCIDENT 1. Results in one or more fatalities INVESTIGATIONS, INCLUDING 2• Results in greater than 24 hours of hospital THE ROOT CAUSE ANALYSES treatment of three or more persons CONDUCTED BY THE REGULATED 3. Causes on and/or off-site property damage STATIONARY SOURCES (including clean-up and restoration activities) initially estimated at $500,000 or more. On- The Industrial Safety Ordinance requires the site estimates shall be performed by the regulated stationary sources to do an incident regulated stationary source. Off-site estimates investigation with a root cause analysis for each of shall be performed by appropriate agencies and the major chemical accidents or releases as defined compiled by Health Service by the following: "Major Chemical Accident or 4. Results in a vapor cloud of flammables and/or Release means an incident that meets the definition combustibles that is more than 5,000 pounds of a Level 3 or Level 2 incident in the Community Warning System incident level classification system The regulated stationary source is required to defined in the Hazardous Materials Incident submit a report to Health Services thirty days after Notification Policy, as determined by Contra Costa the root cause analysis is complete. The record of Health Services; or results in the of a regulated the major chemical accidents or releases that have substance and meets one or more of the following occurred within the last year and the status of each criteria: of these incidents investigations are included in Table IV. ® b- a.' r 0 d� e 4 � w PDA . e 14 U [L G N O N r o mRa o R od RQEm ro r- 1, k rrt y G �O O 2 O N N sj N y i y L 7 L N C d N C R O A EUA O b v N G N✓ y N O r r G p C i N L N GnN R p } N J E 9 r d�~ NGE a O✓ A AGN O¢A�L N ✓ ELO U �E Ji r �R .TJ ab } yp Y �OJ GANUNR RG A R T A J b G N N 4 0, @ 9 A N p �. LGL n b 4 } a .p o a ✓ A p N C `py O O N T i1 N L R E ✓ tJ N r✓j...% E a A ✓ G 9 y r Cn � O !p`�y • A C'LEI" ✓' Gdyp. N NEG NA0 9 N d ON y AA A A7 Aa NO G?N w0'n.'NU NAE2 r OG Sc l A N 40 O %OPINA J `n p Jco�a N N A�i N A 'nG RCL J L T N O 7i r�j N N N bl ,A4. 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N NO.N� O@C „° o N R N t:.0 1u N N R O m p r L-N r O W 7 ° C m 0 U C O G C✓ Y'P Nr- O G Ouf r@ N'r- O E tN0 T N O L N m NC @ m N0 C@ m m @CN@ ° � 7 p ° N @mr dE O N4=C9 @ O'D1r N GS 0 NU�' ✓ @ 01 , ON V?9O .�°G VN R N m,Y OEM O - O. ¢ C4 cE ° E m6 N LL N N U G L II tab m y,C°W c m L V O U Z@ � N N a N U m O � d d O C5 �" N � U t UJ 3 OIJ N � n v r� m 17 MAJOR CHEMICAL ACC1DENTS Below are charts showing the number of MCAR's AND RELEASES from January 1999 through September 2006 for Health Services has analyzed the Major Chemical all stationary sources in Contra Costa County Accidents and Releases (MCAR) that have occurred MCAR's, the MCAR's that have occurred at the since the implementation of the Industrial Safety County Industrial Safety Ordinance stationary Ordinance. The analysis includes the number of sources, and a chart showing the MCAR's that have MCAR's and the severity of the MCAR's. Three occurred at the County and the City of Richmond different levels of severity were assigned: Industrial Safety Ordinance stationary sources. The • Serious—A fatality, serious injuries, or major charts also show the number of serious, medium, onsite and/or offsite damage occurred and minor MCAR's for this period. NOTE: The • Medium —An impact to the community charts do not include any transportation MCAR's occurred, or if the situation was slightly that have occurred. different the accident may have been considered major, or there is a recurring type of incident at that facility • Minor—A release where there was no or minor injuries, the release had no or slight impact to the community, or there was no or minor onsite damage �a� � � �Nla�orCherii� l�Acc�dents and Releaes ., r% x� Q �q , ME 01 I'LL "WWIWWF� I- U � rTota IMCARS p V � � u s� .�� ,, ate � P' &� c a —.Serious r � b ?�� M£ Xy$`FyG eb°gM `W �/ d Medium Minor a- I w �- X1999 X000001`2002 2003 2004 2005 2 06 �� P; 4i' a @' 18 III�31r ' . ..: ". "WF irs RIM IV a —Teod"k tal MCAR � �� = Serious �a E T45 � fxXv, _ e� _._ Medium 4 r� Nx-V' E 3 � r — Minor 1, �� ~ .e Is rIs- ''ro' � sa 0-a 7". "®skAkA / -%�... .tea �„�1999 200Q"��001 ,�2002 200 2004 2005r�2�006 »E LI � Z, Axa I,,ViF V1 i€- v ° i �Countya r�i Rrchmor�d ISOMG _R�'s a �, , z r -*' r;r'o - 9` T s'gFa .`a a Is b .m— s^ S °' .rs$'a r'�^,5 s swx.., +'r !�.Po _ ''' o- a'x',t�•+�-c �, za 'C e ems^ A Apar ar " ItthL"� d` i4 R'�"a53 k . $V-b"' IU �K /� �� . q &":"' '� '� �: a� � "+^x^�x rs`c+��. 'd#I `#��.n��avakUyv ide"�'- �a ,3 s: Total MC/`1 FZ � � — _Serious yi �a a ,¢S is ^e A e = qr r ,6 ' Medium 4a �s n a a mak, s ir° !sir➢.k s�" a>4 ab w { 9`" ,,` Minor -ter+" r ti €w^p� ° sR t' a "�. r a« re.d�aa� a &kdCa.�* ��..,e„ a`4 ,c�..'eF'+''y ^� t' i*,,VIt nct a . was - � "6 '"� 1999` 200 2001 2002 0{��3 200420000 20'06 = } LEGAL ENFORCEMENT ACTIONS taken by Health Services. Health Services has not I N I T IAT E D BY HEALTH SERVICES taken any action through the District Attorney's As part of the enforcement of the Industrial Safety Office for noncompliance with the requirements of Ordinance and the CalARP Program, Health the Industrial Safety Ordinance. Services issues Notice of Deficiencies on the Safety and Risk Management Plans and issues Audit Findings on what a stationary source is required to change to come into compliance with the regulations. Table I shows the action that,has been 19 PENALTIES ASSESSED AS A RESULT Chemical Accident or Release. The following is OF ENFORCEMENT a breakdown of the time that was spent on the No penalties have been assessed this year for Industrial Safety Ordinance: noncompliance with the Industrial Safety Ordinance. ® Accidental Release Prevention Programs Engineers Time: 838 personnel hours or .42 TOTAL FEES, SERVICE CHARGES, personnel years AND OTHER ASSESSMENTS o Three ISO/CaIARP Program audits were COLLECTED SPECIFICALLY done in 2006. It takes four or five engineers four weeks to perform an ISO/CaIARP FOR TH E INDUSTRIAL SAFETY Program audit for a total of 640 or 800 ORDINANCE hours per audit. Approximately 1/3 of the The fees charged for the Industrial Safety time is dedicated to the Industrial Safety Ordinance are to cover the time that the Accidental Ordinance for a total of 213 or 267 hours Release Prevention Engineers use to enforce the per audit for a total of 693 hours. ordinance, the position of the Hazardous Materials o Follow-up work to audits -30 hours Ombudsman, outreach material, and to cover a o It took approximately forty hours to portion of the overhead for the Hazardous Materials prepare and hold public presentation at Programs. The fees charged for administering this the Martinez Farmer's Market and Italian ordinance for the fiscal year 2006- 2007 is $320,959. Festival and another forty hours for the e ; All =aim•.-P ° s x � � ;: �'�'� ,T' a-°'it•,•:: ter_.. e , TOTAL PERSONNEL AND presentation to the Bay Point Latino PERSONNEL YEARS USED Community and the Bay Point MAC,. o Review and meeting with stationary sources BY HEALTH SERVICES TO on Root Cause Analysis Reports took IMPLEMENT THE INDUSTRIAL approximately 20 hours. SAFETY ORDINANCE o Reviewing information for the website 15 The Accidental Release Prevention Programs hours. Engineers have reviewed resubmitted Safety Plans, ° Health Services Communications Office in prepared and presented information for public preparing material for presentations and public meetings, performed audits of the stationary sources meetings total approximately 500 personnel for compliance with both the California Accidental hours or 0.25 personnel years Release Prevention Program and Industrial Safety ° Unannounced Inspections approximately Ordinance and did follow-up work after a Major 20 40 personnel hours on the Industrial Safety • The number of chemicals regulated Ordinance or 0.02 personnel years • The threshold quantity of these chemicals • Total of 1378 hours is the approximate • An external events analysis, including seismic personnel time spent on the Industrial Safety and security and vulnerability analysis, is Ordinance or 0.69 personnel years. required • Additional information in the Risk This is not including the ombudsman time spent Management Plan helping prepare for the public meetings,working • Health Services is required to audit and inspect with the engineers on questions arising from stationary sources at least once every three the Industrial Safety Ordinance, and answering years questions from the public on the Industrial Safety • The interaction required between the Ordinance. stationary source and Health Services. The differences between the CalARP and the COMMENTS FROM INTERESTED Industrial Safety Ordinance Safety Programs PARTIES REGARDING THE are as follows: EFFECTIVENESS OF THE Stationary sources are required to include INDUSTRIAL SAFETY ORDINANCE a root cause analysis with the incident investigations for Major Chemical Accidents Comments and questions were raised from the or Releases public comment period. Some of the comments and questions were for stationary sources that are covered by the Richmond Industrial Safety " Ordinance. Attachment C is a copy of the questions and comments that were received and `" t Health Services response to these questions and comments. THE IMPACT OF THE INDUSTRIAL SAFETY ORDINANCE ON IMPROVING INDUSTRIAL SAFETY Four programs are in place to reduce the potential of an accidental release from a regulated stationary source that could impact the surrounding community. The four programs are the Process Safety Management Program administered by Cal/OSHA, the federal Accidental Release Prevention Program administered by the U.S. EPA, the California Accidental Release Prevention Program administered by Health Services, and the Industrial Safety Ordinance administered by Health • The stationary sources are required to consider Services. Each of the programs is very similar with inherently safer practices the Industrial Safety Ordinance being the most • All of the process at the regulated stationary stringent. The prevention elements of the program source are covered level 3 regulated stationary sources under the federal • Managing changes in the organization for Accidental Release Prevention Program is identical operations and emergency response to the Process Safety Management Program. The • The implementation of a Human Factors main differences between the federal Accidental Programs Release Prevention and the CalARP Programs are as follows: 21 The Board of Supervisors amended the County's Chevron and General Chemical West Richmond Industrial Safety Ordinance to expand the Works submitted their Safety Plans to Health requirement of the ordinance in 2006. These Services, which have been reviewed by Health amendments are as follows: Services. The public comment period for these plans ended in January 2004. Public meetings held in • Expand the Human Factors section of the 2004 in North Richmond and Richmond discussed Industrial Safety Ordinance to include the Chevron and General Chemical West Richmond following: Works audit findings. The second Industrial Safety o Maintenance procedures Ordinance/CalARP Program audits for these o Management of Organizational Changes facilities occurred in 2006. • Maintenance personnel • A job task analysis for each of the positions that work in operations, maintenance, emergency response and Health and Safety • Include temporary changes in the Management of Organizational Change • A requirement that the stationary sources perform a Security and Vulnerability Analysis and test the effectiveness of the changes made as a result of the Security and Vulnerability Analysis • The stationary sources perform a Safety Culture Assessment All of these requirements will and have made a changes in the probability of an accident occurring. CITY OF RICHMOND INDUSTRIAL SAFETY ORDINANCE The City of Richmond passed their version of the Industrial Safety Ordinance on December 18, 2001 that became effective on January 17, 2002. Richmond's Industrial Safety Ordinance mirrors the County's Industrial Safety Ordinance. Richmond's Industrial Safety Ordinance covers two stationary sources: Chevron and General Chemical West Richmond Works. 22 3 s ru p rarr^r^r^ ?� 1111 11 NrAftgffil- t i '- c- a�.,�- s, x NO m a ti < 4k F I��. xr ss *""rte"' t* �,. • a F y y � k as r � ,AnugEamenteconocida'c uki�qu'zlon lar�snec Rehriin;C orzipan�^'( fRG},l ' ['11:1LtSCai1C3 S 3 II TOSa macer.das=O ,� - a refiners Slzell C�s11'resclucts,i .S.lianu3ezTt?C1tC iCdS �ri35,li#S�adC1OT7E3S 'QSt1S - Rehiiery Elie l laiartiYzex Refirzer�}se ; f,,e,otos.inineda t©s s bare 1 aluc: enctientraien aproxe madamentc 880'acrc E r ; en'el eondado,tontra t'osta,°parcialrzzerzte taspiuHanzbles ue:z ser l�vemerit dentro,de los limiter do 13 Ciudad de, rrnt06,12 gargasfta,lanazui }�los,' . Iti4sticzex,CA.,Esta planta que trabaja It F ,f„3 pttlrritatre 1'uetlen ttrszr rnolias ixulases. Z4 horas del ds'a;dice tener 7-16 mpleados 3• Sulfu'ro de ludro eno sg s rncoloro,carrosivo a tienzpo co nigleto sr,un'adtcional de; ;,�.q xa icts,con c fear a Nuevo rYdcs 1'uarle' 200 Contrati$M en la.{-instal'aciones para rrntar l gargania;la izartx v pulmones.: realiar erhajcrs contratados. Hausa drzlor de°caUeza; snareus .dsfieulcdes a La refrneria Shell VlartsnL-z'�Keftnery se; restr2tartaS enctsexztra sobre propiedad industrial; a moniaco anludro PSI La enrressivo La Berra tlrededar,de.la retuzeria 51ze1I a rmt n€e gene can(verse olor sofocante. Martinez Re�nery es.una c-ombinacicrn { La razl alacihir puede causar rrrxtarican eat Ia de espaciostiszdustrialc al+iertt>S, rat t;,,lanMr Z los pulmones 1}uede conse �ci,an medioambiental}r find; ;@ r, ,: causar resprrzcon ertirecortada,doloar de rtir residenuzles.. �� cabeaai;nauseas v °onuzos La,refitzerra Shell Marxinim Re# err � rn uiar cs 3igia do.Irqu do rrrcpl xro cQn olor procet r apro�inadanzeizte lfi5,£C47 barriles i° fu+erte= T�uede s ausar nauseas,cLScultacies (t laarrrl ��#►lanes}.de petrrrleo.erixdp resprratonis�conruLss snes Se fabrics gzse se c orzvrerca en;asolrna,conzbusuble �� +' AM I.”h dt luex'n`�de amonfacc+•asihidm N- & aiaeson,,ctanibtcstrbledresel r produrtosasfal rw� a`pl�nca iMuce suficiente gasnlina para lienar 252COCE auto�lovrl ,SUfiCrenTe_ fln7bUs(re drese l f mb x s a a R para 1lert tr l i,l s arizie�nes de 18 ruedasx„ .' - efi suficrcnte c oiitlustibl de zs'iacion para ab;�te"cera �1`ai+ican�(7�7},pnr,`cis3, ov i�"w"tY � f y�. UT 9sJ ''���FFFFF y�1 p � r% � w `�� �� SLY {i ` ^�fi u5v= 's41."' X^Jly+UUt " 2 RE 4,3; iS ` F � $} §}sl 3iIRip"' � .•Y_§ " ffi# &$P[ y§ x� a �, C ¢ � �-* � �. .�.: �A�,sz..:` `a.,.. a..a `'.�a�a✓;r:^-.� �"mat .�.^;;�:�',�. .ce*,�?.u��.,xE�,.� � .4yrY'a�` =eY ,� § +pxa ti 9NM' , IS, valij VR� Pill AheN { d� 4Z 55k NO 2,12 �� v��'�'"a` ia?a6r�pkce3a �m3. ^=a�a`au'"� ���•���:: � .w-=--_ `=�r�, 'S.s,�. - �.r�& 24 QUESTIONS ASKED BY THE PUBLIC DURING THE MARTINEZ OUTREACH (9/24/2006 FARM.ER'S MARKET) • What do you do? We work for Contra Costa County Health Services, Hazardous Materials Programs. We have engineers that oversees the California Accident Release Prevention Program and the Industrial Safety Ordinance and we also have HazMat Specialists that inspects business plan facilities and respond to hazardous materials incidents. • Why are you here? A community members panel recommended that Health Services utilize existing venue where public are already congregated to make available information about our programs. This approach may help to improve the public's understanding of our programs and make us more available to address questions and issues that the general public may have without the extra burden of setting aside another time to just come ask us questions. • Where can I drop off my left over paints and solvents? We have brochures that cover household hazardous waste locations and hours of operations. • Several individuals visiting the CCHS table asked for and reviewed the audit reports for the facilities audited by CCHS. • A few of the individuals visiting the CCHS table asked for the duration of a typical audit conducted by the CalARP team and the frequency of these audits. CCHS staff responded that for major facilities, the compliance audits conducted by CCHS staff takes about four weeks and the audits are conducted about once every three years. CCHS added that the unannounced Inspection Program allows the CalARP/HAZMAT Program staff to conduct additional inspections that usually takes about two to five days to perform in which CCHS staff would conduct specific audit of selected areas of the safety program requirements. • There were general interest in the pamphlets, and written material available in addition to our staff education background and training requirements. • The HazMat response truck was available for tour during this event. 25 SeSAons* n r,rte•. Contra xCosta Ha az rdous Materials Jan Sept 2006 inclusive e .w. 1 /groups/hazmat/ 4,859 2 /groups/hazmat/accident history.php 2,475 3 /topics/environmental/eh hazmat fag.php 2,061 4 /groups/hazmat/industrial safety ordinance.php 1,462 5 /groups/hazmat/fag.php 1,412 6 /groups/hazmat/california accidental release prevention.php 1,351 7 /groups/hazmat/business plan.php 1,343 8 /groups/hazmat com/ 1,309 9 /groups/hazmat/risk management.php 1,238 10 /groups/hazmat/underground storage tanks.php 1,204 11 /groups/hazmat/accident shell martinez.php 1,161 12 /groups/hazmat/incident response.php 1,147 13 /groups/hazmat/green business.php 1,146 14 /groups/hazmat/iso comic.php 1,061 15 /groups/hazmat/facilities/tesoro.php 1,057 16 /groups/hazmat/hazardous waste generator.php 1,031 17 /groups/hazmat/pdf/ 982 18 /espanol/hazmat esl.html 955 19 /groups/hazmat/unannounced inspections.php 942 20 /groups/hazmat/iso outreach.php 903 21 /groups/hazmat/iso fag introduction.php 890 22 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/groups/hazmat/pdf/calarp 452 28 HAZARDOUS MATERIALS County can know about and utilize the OMBUDSMAN EVALUATION FOR program. THE PERIOD 2) Investigating and responding to questions and FROM NOVEMBER' 2005 complaints, and assisting people in gathering THROUGH OCTOBER, 2006 information about programs,procedures, or issues. I. Introduction 3) Participating in a network of environmental On July 15, 1997 the Contra Costa County programs for the purpose of providing Board of Supervisors authorized creation of an technical assistance. Ombudsman position for the County's Hazardous Materials Programs. The first Hazardous Materials This evaluation covers the period from November, Ombudsman began work on May 1, 1998. The 2005 through October, 2006 for the Hazardous Contra Costa County Board of Supervisors adopted Materials Ombudsman program. The effectiveness an Industrial Safety Ordinance on December 15, of the program shall be demonstrated by describing 1998. Section 450-8.022 of the Industrial Safety that the activities of the Hazardous Materials Ordinance requires the Health Services Department Ombudsman meet the goals established in the to continue to employ an Ombudsman for the Industrial Safety Ordinance. Hazardous Materials Programs. Section 450- 8.030(B)(vii) of the Industrial Safety Ordinance II. Program Elements requires an annual evaluation of the effectiveness of the Hazardous Materials Ombudsman, with the first 1. Continuing an Outreach Strategy evaluation to be completed on or before October 31, 2000. This period, efforts were focused on maintaining the outreach tools currently The goals of section 450-8.022 of the Industrial available. Copies of the Ombudsman Safety Ordinance for the Hazardous Materials Brochure were translated into Spanish and Ombudsman are: were distributed to the public at meetings, presentations, public events, and through the 1) To serve as a single point of contact for people who live or work in Contra Costa County mail. A contact person was also established in Public Health that could receive calls regarding environmental health concerns, and from the public in Spanish and serve as questions and complaints about the Hazardous an interpreter to respond to these calls. In Materials Programs. addition to explaining the services provided 2) To investigate concerns and complaints, by the position, the brochure also provides rLn the phone numbers of several other related facilitate their resolution, and assist people County and State programs. The web page in gathering information about programs, was maintained for the program as part 73 procedures, or issues. of Contra Costa Health Services web site. This page contains information about the 3) To provide technical assistance to the public. program, links to other related web sites, and information about upcoming meetings The Hazardous Materials Ombudsman currently and events. A toll-free phone number is still accomplishes these goals through the following Published in all three Contra Costa County phone books in the Government section. program elements: The Ombudsman also made 18 presentations 1) Continuing an outreach strategy so that the to community groups, civic organizations people who live and work in Contra Costa and other groups on various topics that promoted the services of the Ombudsman. 29 2. Investigating and Responding to Questions B.Assisting in Information Gathering and Complaints, and Assisting in Information Gathering Many of the environmental pollution issues that Contra Costa residents are concerned about are on- A.Responding to Questions and Complaints going regulatory programs or industrial activities. Helping people to participate in these regulatory During this period, the Hazardous Materials activities or to effectively advocate their interests Ombudsman received 321 requests for assistance about an industrial activity usually means providing from the general public. This was a 24% increase them with more information or advice than can be over last year. Over 95 percent of these requests done with a single phone call. Often these issues are occurred via the telephone, and have been requests complex and can take months to resolve. Some of for information about environmental issues. this is done through technical assistance, which will Requests via e-mail are slowly increasing, mainly be covered in the next section. through referrals from Health Services main web page. Most of these requests concern problems Another way of helping the public to gather around the home such as asbestos removal, information is to ensure the public has the household hazardous waste disposal, pesticide opportunity to be informed about, and participate misuse, and lead contamination. in, important decisions related to environmental protection. The Hazardous Materials Ombudsman Information requests about environmental issues has done this by organizing, promoting and received via the telephone were generally responded facilitating public involvement in important to within one business day of being received. Many hazardous materials issues. These are as follows: of the information requests were answered during the initial call. Some requests required the collection • Industrial Safety Ordinance Public of information or written materials that often took Participation—The ordinance requires that several days to compile. Telephone requests were public meetings be held at various stages responded to by telephone unless written materials of the process. The Hazardous Materials needed to be sent as part of the response. Ombudsman has worked closely with the Hazardous Materials Programs staff and the Complaints about the Hazardous Materials Board of Supervisors to develop an intensive Programs have been received via telephone and public outreach strategy for the Industrial in writing. Persons that have made complaints Safety Ordinance. During this period, via telephone have been also asked to provide the Ombudsman helped the Hazardous those complaints in writing. During this period, Materials Program conduct a Spanish- the Hazardous Materials Ombudsman received language public meeting in Bay Point in two inquiries about activities or actions of the November, 2005, a meeting in Bay Point Hazardous Materials Programs. Both complaints in January, 2006 about General Chemical were about the proposed hazardous materials fees and an outreach effort in Martinez for four being assessed against their businesses. In regards Central County facilities in October, 2006. to the first complaint, the Ombudsman supported the position that the fees being assessed by the • Post- Chemical Incident Surveys —As a Hazardous Materials Programs were justified. The result of discussions held at a Protecting the key consideration was whether the material being Public conference in 1999, the Hazardous stored by the business qualified as a hazardous Materials Ombudsman took the lead in material. The Ombudsman independently developing a telephone survey that would determined that the material did meet the definition be administered to people in the area of a hazardous material. The second complaint is affected by a chemical accident. During still under investigation. 2001, funding was secured to develop the survey, a consultant was hired to create the survey, and the first survey was initiated 30 after an incident at a refinery in October, study was accepted by the Internal Operations 2001. In 2002, four additional surveys were Committee of the Board of Supervisors. In 2005 conducted after level 2 and 3 incidents at the Hazardous Materials Ombudsman worked with facilities. In 2003 two additional surveys the Community Warning System Program in the were completed after level 3 incidents, Sheriff's Office to begin installing 300 of these alert one at a refinery and one resulting from boxes. The installation of these boxes is on-going. a railroad incident. Another survey was conducted after a release from a refinery 3. Participating in a Network of Environmental in October, 2004. A ninth survey was Programs for the Purpose of Providing conducted in March of 2006 after a release Technical Assistance. from the Shell Refinery in Martinez. The results of these surveys were shared with Technical assistance means helping the public various committees of the Contra Costa understand the regulatory, scientific, political, and CAER group to help them with planning legal aspects of issues. It also means helping them their activities. understand how to effectively communicate their concerns within these different arenas. This year, • Laotian Telephone Emergency Notification the Ombudsman continued to staff a number of Project —As a result of a major fire at a County programs, as well as participate in other refinery in Richmond in 1999, the Laotian programs to be able to provide technical assistance community in the Richmond area was to the participants and the public. concerned about the lack of understanding of many Laotians about the Community • CAER (Community Awareness and Warning System and what to do in the Emergency Response) -This non-profit event of a release. They requested the organization addresses industrial accident County to develop a way to send the prevention, response and communication. Telephone Emergency Notification System The Ombudsman participated in the message, which is part of the Community Emergency Notification subcommittee of Warning System, to Laotian households CAER. in four Laotian languages. The Hazardous Materials Ombudsman worked with • Hazardous Materials Commission —In 2001, the Director of the Hazardous Materials the Ombudsman took over as staff for the Programs and the Laotian Organizing commission. As staff to the commission, the Project to develop a pilot methodology. Ombudsman conducted research, prepared In 2001, $140,000 of funding was secure reports, and facilitated Commission to implement the pilot project and a meetings. project coordinator was hired. In 2002 the Hazardous Materials Ombudsman hired • Public and Environmental Health Advisory 4 outreach staff and supervised all 5 staff Board—As staff to the Environmental people to implement this pilot program. Health subcommittee of PEHAB, the The pilot project was completed in the Ombudsman completed a report on pest spring of 2003. management issues in the County in March, 2001. In response to this report, the Board At that time, the Board of Supervisors directed the of Supervisors asked Health Services and Ombudsman to participate in an evaluation of a the County Agricultural Commissioner new technology to provide automated telephone to convene a Task Force to develop an alerts in various languages. The Ombudsman hired Integrated Pest Management Policy for 2 Laotian staff to test this technology in 100 Laotian the County. The Ombudsman represented homes. This test was completed in early 2004 and Health Services as co-chair of this Task the recommendation to pursue this new technology Force. The policy was adopted by the instead of the methodology used in the first pilot Board of Supervisors in November of 31 2002. During this period the Ombudsman The Hazardous Materials Ombudsman also attended continued to represent Health Services on workshops, presentations, meetings and trainings the Task Force as they implemented the on a variety of environmental issues to be better policy. able to provide technical assistance to the public. These were sponsored the Federal Environmental • Asthma Program— The Ombudsman Protection Agency,the State Department of Health participated in the Public Health Services, the Bay Area Air Quality Management Department's asthma management team District, the Regional Water Quality Control Board as a resource on environmental health and CalEPA. issues. The Ombudsman also participated in county-wide asthma coalition meetings, III.Program management and represented the Asthma program at regional meetings pertaining to asthma The Hazardous Material Ombudsman continued issues,particularly diesel pollution. to report to the Public Health Director on a The Ombudsman provided extensive day-to-day basis during this period, while still technical support on the development of handling complaints and recommendations about an Asthma Coalition Report summarizing the Hazardous Materials Programs through the environmental factors influencing the Health Services Director. The duties of the asthma rates in Contra Costa County. Hazardous Materials Ombudsman also included The Ombudsman also co-wrote a grant direct supervision of two contract employees for the to CalTrans that secured funding to allow Laotian Telephone Emergency Notification System Asthma Advocates and other County project and managing the contract for the Industrial residents get involved in land-use issues Safety Ordinance Post-Incident surveys, which related to diesel pollution and goods began in 2001. movement. IV.Goats for 2007 • Environmental justice —In September of 2003,the Board of Supervisors adopted an In 2007, the Ombudsman will provide essentially Environmental justice policy. At that time the same services to Contra Costa residents as was they directed each County Department provided in 2006. The Ombudsman will continue to designate an existing staff member respond to complaints about the actions of the as a representative to a County-wide Hazardous Materials Programs; answer questions Environmental justice committee. The that come from the public and assist them in Ombudsman was designated by the Health understanding regulatory programs; staff the Services Director to be the representative Hazardous Materials Commission and the Public for the Health Services Department. The and Environmental Health Advisory Board; provide Ombudsman is also actively working with technical support to the Asthma program and the the Public Health Division to develop their Public Health Collaboration unit; and participate in Environmental justice Program. the Integrated Pest Management Taskforce, CAER • LEAP —During this period the committees, the Environmental justice Committee Ombudsman provided extensive technical and the Laotian Telephone Emergency Notification assistance to LEAP (Latino Environmental System multi-lingual project. In particular, the Action Project), a Public Health program Ombudsman will oversee the implementation of in Bay Point. The role of the Ombudsman the Caltrans goods movement grant and continue to e tech in this project was to help community providnical support to the LEAP project. residents understand the risk presented to The Ombudsman will continue to manage the them by various environmental sources contract for the post chemical-incident surveys, but of pollution so that they could better the Industrial Safety Ordinance public participation determine which of these, if any, were of program will be managed by the Hazardous concern to them. Materials Programs as part of their normal activities. 32 In 2007,the Ombudsman will continue efforts to re-distribute his brochures throughout the County, and will give presentations to community groups and governmental agencies to promote the services of the position. 33 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE ­,000 �_'�— REVIEW AND EVALUATION CONTRA COSTA Document No.: Date Effective: Page: 1 of 5 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 Annual Performance Review and Evaluation Submittal June 27, 2006 *Attach additional pages as necessary 1. Name and address of Stationary Source: ConocoPhillips Rodeo Refinery, 1380 San Pablo Avenue,Rodeo,CA 94572 2. Contact name and telephone number(should CCHS have questions): John Driscoll 510-245-4466 3. Summarize the status of the Stationary Source's Safety Plan and Program(450-8.030(B)(2)(i)): The 2005 Safety Plan resubmittal is in the process of being modified after review by CCHS. 4. Summarize Safety Plan updates(i.e., brief explanation of update and corresponding date)(450-8.030(13)(2)(ii)): The original Safety Plan for this facility was filed with Contra Costa Health Services on January 14,2000. A revised plan was filed on April 7, 2000 with the updated recommendations requested by CCHS. A Human Factors Amendment was submitted on January 15, 2001. In coniunction with CCHSs required 2"d public meeting on our plan and audit findings, we submitted a complete revision of the plan to reflect the change in ownership of our facility and to update where needed. We took this opportunity to include Human Factors within the plan instead of having it as an amendment. On August 9, 2002 the plan was resubmitted. Public meetings for our plans were held on June 22,2004 in Rodeo and July 8,2004 in Crockett.As required the Plan was fully updated in August 2005 on the 3 year cycle. The Plan has been reviewed by CCHS and is currenting being revised with recommended changes. The RMP was submitted for public notice from 1/27/06 through 3/13/06 without comment. . 5. List of locations where Safety Plans are/will be available for review,including contact telephone numbers if the source will provide individuals with copies of the document(450-8.030(13)(2)(ii)): CCHS office,4333 Pacheco Blvd. Martinez and the Crockett and Rodeo libraries. 6. Provide any additions to the annual accident history reports (i.e. updates) submitted pursuant to Section 450 Tq - 8.016(E)(2) of County Ordinance 98-48 (450-8.030(13)(2)(iii)) (i.e., provide information identified in Section 450-8.016(E)(1) for all major chemical accidents or releases occurring between the last accident history report submittal(January 15)and the annual performance review and evaluation submittal (June 30)): There has been one addition to the accident history :5-1-06 Flaring Event At 0947,on Monday,May 1 st 2006,the Pacific Gas&Electric(PG&E)electrical supply breaker to the"C"electrical distribution bus transformer was disconnected to perform maintenance on the transformer.The electricity for the"C"distribution bus was then supplied solely(islanded)by the"C"Gas Turbine Generator(GTG). The"C"GTG tripped off line,deenergizing the"C"bus and simultaneously reducing the steam production rate. The loss of electrical power caused some process unit and equipment shutdowns which resulted in flaring. 35 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION CONTRA COSTA Document No.: Date Effective: Page: 2 of 5 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 At 1005,the refinery steam supply decreased below the quantity required to maintain smokeless burning of the flare gas at the main refinery flare.The duration of the flare smoking was approximately 10 minutes. A CWS(Community Warning System)Level 3 was immediately initiated for the community to "Shelter in Place"due to visible smoke.Emergency operating procedures for the affected units and a steam usage curtailment were implemented.Emergency response personnel performed air monitoring both on and off site, with only trace indications of sulfur dioxide&odor off-site in the Cummings Skyway/Crockett area. Refinery operators restarted critical equipment,increased alternative steam production,and restored sufficient steam supply to the flare to prevent smoking at 1015.The event was reduced to a CWS Level 1 ("Shelter in Place"was lifted)at 1115 and called an"All Clear"at 1445. In addition to visible smoke from the flare,NO2&SO2 Reportable Quantities were exceeded. The calculated released amounts are:NO2-80 lbs; SO2-8300 lbs. The following agencies were immediately notified:Contra Costa Health Services(CCHS)via the CW,the Bay Area Air Quality Management District(BAAQMD,Rodeo/Hercules Fire Dept.,Crockett/Carquinez Fire Dept., NRC,and the County and State Office of Emergency Services(OES).Those responding were CCHS, BAAQMD and the Rodeo/Hercules Fire Department. Average wind speed was approximately 3 mph,out of the South and variable. The weather was clear and sunny with temperatures approximately 65 degrees F. No injuries were reported on or offsite. 7. Summary of each Root Cause Analysis(Section 450-8.016(C))including the status of the analysis and the status of implementation of recommendations formulated during the analysis(450-8.030(B)(2)(iv)): For the 5-1-06 Flaring Event a Root Cause Analysis was performed utilizing the Reason method,the Human Factors checklists,and other tools.The following root causes were determined. 1.The generator trip was caused by the turbine control system.The controls will not support the stable operation of the GTG in an islanded condition 2.The electrical switching procedure did not adequately specify GTG operating conditions. The switching procedure directed Operations to shed loads or manually reduce the power output of the generator to be"null',but did not specify a maximum power level or for the GTG to be operated below the EGT limit(as mentioned earlier is now recommended by the turbine controls system vendor).Additionally,the procedure did not specify requirements for refinery steam demand conditions prior to islanding. 3.The`B"and"C"COEN fire eye cooling air blowers are both powered from the"C"Bus. In the event of a single electrical fault at this source,both duct burners will shutdown. The COEN burners were tripped by the low fire eye cooling air pressure switch when the blowers shut down. 36 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION CONTRA COSTA Document No.: Date Effective: Page: 3 of 5 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 4.The"C"GTG controls contractor did not provide sufficient operator training for using the new TRICONEXTM control system in island mode or sufficient operating and maintenance manuals for the islanded condition. 5.The MOC conducted for the control system change to the"C"GTG did not fully address the non-standard operating conditions. The unidentified need for operating in islanded situations should have emphasized the requirement for additional testing or new operating limitations for the"C"GTG.Additionally,the HAZOP did not identify changes due to electrical load creep from other projects(ULSD,etc). Recommendations/Preventive actions resulting from the Root Cause: 1.Perform an engineering study of turbine and generator controls to address the following: a.Revise and test the TRICONEXTM controls to operate reliably in an island condition. b.Evaluate raising or eliminating the EGT limit during an island condition. c. Review alarm and shutdown trip points for EGT,under-frequency,and overfrequency protection. d. Implement changes made to"C"GTG on`B"GTG. e.Do not island prior to the completion of the above recommendations. Target completion date:July 31, 2007 2.Modify procedures for islanding to include operations and electrical tasks and review and address the following: a.Designate the Shift Superintendent as the owner of the electrical distribution system with final authority for approval of switching procedures. b.Evaluate specifying a 15-20%reserve electrical load limit prior to islanding. c.Evaluate implementing an electrical load shedding procedure/scheme to address a PG&E power outage and minimize its impact on the refinery. d.Evaluate specifying required initial conditions,such as minimal steam demand, prior to islanding operations to minimize the effect of the loss of a single GTG. Target completion date:June 30, 2007 3.Evaluate the COEN system for more reliable operations: a.Change the"B"COEN Blower power supply to`B"Bus. b.Evaluate moving the low air pressure switch tap so it will detect back up air to the blowers. Target Completion date:March 31, 2007 4.Obtain islanding-related manuals,procedures, and training on the controls from the contractor. Target Completion date:September 30, 2006 5.Ensure non-standard control modes are adequately addressed in future HAZOP evaluations of control projects.Also include significant changes to infrastructure in project PHAs. Target Completion date:December 31, 2006 37 Title: _ INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION C O N T R A COSTA Document No.: Date Effective: Page: 4of5 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: I 8. Summary of the status of implementation of recommendations formulated during audits, inspections, Root Cause Analyses,or Incident Investigations conducted by the Department(450-8.030(B)(2)(v)): CCHS conducted a review of our Safety Plan and noted recommendation are currently being addressed. 9. Summary of inherently safer systems implemented by the source including but not limited to inventory reduction(i.e.,intensification)and substitution(450-8.030(B)(2)(vi)): See attached 10. Summarize the enforcement actions (including Notice of Deficiencies, Audit Reports, and any actions turned over to the Contra Costa County District Attorney's Office) taken with the Stationary Source pursuant to Section 450-8.028 of County Ordinance 98-48(450-8.030(13)(2)(vii)): None 11. Summarize total penalties assessed as a result of enforcement of this Chapter (450-8.030(3)): No penalities have been assessed against any facility. 12. Summarize the total fees, service charges, and other assessments collected specifically for the support of the ISO (450-8.030(B)(4)): CaIARP Program fees for these eight facilities are - $325,581, the Risk Management Chapter of the Industrial Safety Ordinance fees are-$296,179. 13. Summarize total personnel and personnel years utilized by the jurisdiction to directly implement or administer this Chapter (450-8.030(B)(5)): 4000 hours were used to audit/inspect and issue reports on the Risk Management Chapter of the Industrial Safety Ordinance. 14. Copies of any comments received by the source(that may not have been received by the Department)regarding the effectiveness of the local program that raise public safety issues(450-8.030(B)(6)): No comments have been received regarding the effectiveness of the local program.. 15. Summarize how this Chapter improves industrial safety at your stationary source(450-8.030(B)(7)):_ Industrial SafM has been improved by expanding safety programs to cover all operating units. PHAs are performed on all units and recommendations that are generated have a faster implementation timeframe. Root Cause Analysis is conducted for all major chemical accidents and releases, 16. List examples of changes made at your stationary source due to implementation of the Industrial Safety Ordinance (e.g., recommendations from PHA's, Compliance Audits, and Incident Investigations in units not subject to CaIARP regulations; recommendations from RCA's) that significantly decrease the severity or likelihood of accidental releases The Refinery's project to revamp/reformat operating procedures has been completed. Human factor checklist have been applied in the updating of the procedures as well as in the application of performing Process Hazards Analysis (PHA) on all units and in conducting incident investigation on major chemical and accident 38 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION CONTRA COSTA Document No.: Date Effective: Page: 5 of 5 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner. Approved By: Revision No.: 1 releases. Inherently Safer System review have been implemented.. 17. Summarize the emergency response activities conducted at the source (e.g., CWS or CAN activation) in response to major chemical accidents or releases: Please refer to item#6 for the emergency response to the 5-1-06 flaring event. 39 ConocoPhillips Company—Rodeo Refinery Inherently Safer Systems Report June 2006 Reference Primary Source Description Strategy 021-06 Inherent Facility The inherent level of risk reduction was implemented by minimize the inventory of hazardous materials on site 06-178 Inherent Facility The inherent level of risk reductions was implemented by simplifying the process reducing the potential for release. 200-19-R4 Passive PHA The passive level of risk reduction was implemented by minimizing the hazard through equipment design. 05-090 Inherent Facility The inherent level of risk reduction was implemented by minimizing the amount of hazardous material. 106-119-155 Inherent Facility The inherent level of risk reduction was implemented by minimizing inventory on site through elimination of tankage. 40 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION Document No.: Date Effective: Page: CONTRA COSTA 1of2 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 Annual Performance Review and Evaluation Submittal June 15,2006 *Attach additional pages as necessary 1. Name and address of Stationary Source: General Chemical Bay Point Works, 501 Nichols Road, Bay Point, California 94565 2. Contact name and telephone number(should CCHS have questions): Reza Lorestany, (925)458-7365 3. Summarize the status of the Stationary Source's Safety Plan and Program(450-8.030(13)(2)(i)): GCC-13PW Stationary Source's Safety Plan and Program are currently in place. They are undergoing enhancement as part of normal improvement as well as findings from CCHS audit in August 2005. 4. Summarize Safety Plan updates(i.e.,brief explanation of update and corresponding date)(450-8.030(13)(2)(ii)): No update to the Safety Plan has occurred in the previous review period. The next planned update is scheduled to occur in the 2nd half of 2006. 5. List of locations where Safety Plans are/will be available for review, including contact telephone numbers if the source will provide individuals with copies of the document(450-8.030(13)(2)(ii)): CCHS Office,4333 Pacheco Boulevard,Martinez,Bay Point Library(library closest to the stationary source). 6. Provide any additions to the annual accident history reports (i.e. updates) submitted pursuant to Section 450- 8.016(E)(2) of County Ordinance 98-48 (450-8.030(13)(2)(iii)) (i.e., provide information identified in Section 450-8.016(E)(1) for all major chemical accidents or releases occurring between the last accident history report submittal(January 15)and the annual performance review and evaluation submittal(June 30)): There has been no major chemical accident or release during the current reporting period, 7. Summary of each Root Cause Analysis (Section 450-8.016(C)) including the status of the analysis and the status of implementation of recommendations formulated during the analysis(450-8.030(B)(2)(iv)): There were no RCAs conducted during this time period. 8. Summary of the status of implementation of recommendations formulated during audits, inspections, Root Cause Analyses,or incident Investigations conducted by the Department(450-8.030(13)(2)(v)): An audit was conducted by the Dept. in Aug. 2005 and resulted in 132 findings. To date, more than half of the findings have been completed and the remainder are expected to be closed by the December 31,2006. 41 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION CONTRA COSTA Document No.: Date Effective: Page: 2 of 2 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 9. Summary of inherently safer systems implemented by the source including but not limited to inventory reduction(i.e.,intensification)and substitution(450-8.030(B)(2)(vi)): One Inherently Safer System (ISS) was implemented during the previous review period. Multiple scrubbers were replaced w/ one new scrubber. The ISS served to minimize inventory as well as simplify the process. 10. Summarize the enforcement actions (including Notice of Deficiencies, Audit Reports, and any actions turned over to the Contra Costa County District Attorney's Q yiice) taken with the Stationary Source pursuant to Section 450-8.028 of County Ordinance 9848 (450-8.030(13)(2)(vii)): No enforcement actions were taken during this time period. 11. Summarize total penalties assessed as a result of enforcement of this Chapter (450-8.030(3)): No penalities have been assessed against any facility. 12. Summarize the total fees, service charges, and other assessments collected specifically for the support of the ISO (450-8.030(B)(4)): CaIARP Program fees for these eight facilities are - $325,581 the Risk Management Chapter of the Industrial Safety Ordinance fees are-$296,179. 13. Summarize total personnel and personnel years utilized by the jurisdiction to directly implement or administer this Chapter (450-8.030(B)(5)): 4000 hours were used to audit/inspect and issue reports on the Risk Management Chapter of the Industrial Safety Ordinance. 14. Copies of any comments received by the source(that may not have been received by the Department)regarding the effectiveness of the local program that raise public safety issues(450-8.030(B)(6)): The facility has not received any comment(that may not have been received by the department). 15. Summarize how this Chapter improves industrial safety at your stationary source(450-8.030(B)(7)): The chapter helps to minimize the potential risk and exposure to the employees, the community, and the environment. 16. List examples of changes made at your stationary source due to implementation of the Industrial Safety Ordinance (e.g., recommendations from PHA's, Compliance Audits, and Incident Investigations in units not subject to CalARP regulations; recommendations from RCA's) that significantly decrease the severity or likelihood of accidental releases. Several PHAs were conducted for processes and some are subject to CalARP regulations. Many recommendations from the PHAs have been completed. 17. Summarize the emergency response activities conducted at the source (e.g., CWS or CAN activation) in response to major chemical accidents or releases: There has been no emergency response activities associated w/this facility during the period. 42 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION C O N T R A COSTA Document No.: Date Effective: Page: 1 of 5 HEALTH SERVICES , HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 Annual Performance Review and Evaluation Submittal June 29, 2006 *Attach additional pages as necessary 1. Name and address of Stationary Source: Shell Martinez Refinery 3485 Pacheco Blvd. Martinez,CA 94553 2. Contact name and telephone number(should CCHS have questions): Ken Axe,(925)313-5371 3. Summarize the status of the Stationary Source's Safety Plan and Program (450-8.030(13)(2)(i)): SMR's Safety Program is being implemented. Inherently Safer Systems analyses for existing processes are being conducted, and are expected to be complete for all processes at SMR by August 15, 2008. SMR's Safety Plan was last updated in January 2006. 4. Summarize Safety Plan updates(i.e., brief explanation of update and corresponding date)(450-8.030(13)(2)(ii)): The January 2006 update of the SMR Safety Plan included the following changes: removed reference to (closed) Stretford Unit and Lubes plant; added reference to(new) Flexsorb Unit; updated accident history with 11/8/2005 slurry release; reflected reduced headcount from 1060 to 920 (employees and contractors); updated department names; updated Safety Plan sections on Procedures, Training, and PHA Action items: inco orp rated language in the Incident Investigation section to the effect that CCHS may elect to conduct RCA's. 5. List of locations where Safety Plans are/will be available for review,including contact telephone numbers if the source will provide individuals with copies of the document(450-8.030(B)(2)(ii)): CCHS Office,4333 Pacheco Boulevard,Martinez;Martinez Public Library(library closest to the stationary source). 6. Provide any additions to the annual accident history reports (i.e. updates) submitted pursuant to Section 450- 8.016(E)(2) of County Ordinance 98-48 (450-8.030(B)(2)(iii)) (i.e., provide information identified in Section 450-8.016(E)(1) for all major chemical accidents or releases occurring between the last annual performance review report and the current annual performance review and evaluation submittal(12-month history): 11/8/2005 Catalytic Cracking Unit Gas Plant Slurry_Release(see Attachment 1) 3/26/2006 Sulfur Recovery Unit#3 Sulfur Dioxide Release(see Attachment 1) 7. Summary of each Root Cause Analysis (Section 450-8.016(C)) including the status of the analysis and the status of implementation of recommendations formulated during the analysis(450-8.030(B)(2)(iv# 11/8/2005 Catalytic Cracking Unit Gas Plant Slurry Release RCA: final RCA report complete; see Attachment I for summary of RCA and status of implementation of recommendations. 3/26/2006 Sulfur Recovery Unit#3 Sulfur Dioxide Release: final RCA report not vet complete. 8. Summary of the status of implementation of recommendations formulated during audits, inspections, Root Cause Analyses,or Incident Investigations conducted by the Department(450-8.030(B)(2)(v)): All recommendations are complete following the CCHS on-site audit of SMR during the fall of 2000. All recommendations are complete following CCHS's unannounced inspection that occurred in January 2002. All recommendations are complete following CCHS's audit of SMR's Human Factors and Inherently Safer Systems in April 2002 36 of 37 recommendations from CCHS's November 2003 RMP/PSMASO Audit have 43 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE _ REVIEW AND EVALUATION CONTRA COSTA Document No.: Date Effective: Page: 2of5 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 been closed: a single action item remains open. The county has conducted no RCAs or Incident Investigations at SMR. 9. Summary of inherently safer systems implemented by the source including but not limited to inventory reduction(i.e.,intensification)and substitution(450-8.030(13)(2)(vi)): (see Attachment 2) 10. Summarize the enforcement actions (including Notice of Deficiencies, Audit Reports, and any actions turned over to the Contra Costa County District Attorney's Office) taken with the Stationary Source pursuant to Section 450-8.028 of County Ordinance 98-48(450-8.030(B)(2)(vii)):None 11. Summarize total penalties assessed as a result of enforcement of this Chapter (450-8.030(3)): No penalities have been assessed against any facility. 12. Summarize the total fees, service charges, and other assessments collected specifically for the support of the ISO(450-8.030(B)(4)): CaIARP Program fees for these eight facilities are - $325,581, the Risk Management Chapter of the Industrial Safety Ordinance fees are-$296,179. 13. Summarize total personnel and personnel years utilized by the jurisdiction to directly implement or administer this Chapter (450-8.030(B)(5)): 4000 hours were used to audit/inspect and issue reports on the Risk Management Chapter of the Industrial Safety Ordinance. 14. Copies of any comments received by the source(that may not have been received by the Department)regarding the effectiveness of the local program that raise public safety issues(450-8.030(B)(6)):None received. 15. Summarize how this Chapter improves industrial safety at your stationary source (450-8.030(B)(7)): SMR has integrated requirements of the Industrial Safety Ordinance into our Health, Safety, and Environment Management System;in the context of our HSE MS,the ISO requirements help drive continual improvement in our HSE performance. 16. List examples of changes made at your stationary source due to implementation of the Industrial Safety Ordinance (e.g., recommendations from PHA's, Compliance Audits, and Incident Investigations in units not subject to CaIARP regulations; recommendations from RCA's) that significantly decrease the severity or likelihood of accidental releases:(see Attachment 1 for changes made as a result of 11/8/2005 RCA) 17. Summarize the emergency response activities conducted at the source (e.g., CWS or CAN activation) in response to major chemical accidents or releases: 11/8/2005 Catalytic Cracking Unit Gas Plant Slum Release was responded to by CCHS personnel; CWS Level 2 3/26/2006 Sulfur Recovery Unit #3 Sulfur Dioxide Release was responded to by CCHS personnel; CWS Level 3.CAN activation 44 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION C C• T R A COSTA Document No.: Date Effective: Page: 3 of 5 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 Attachment 1 11/8/2005 Catalytic Cracking Unit Gas Plant Slurry Release Date, time, and approximate duration of the release: November 8, 2005; 20:20-20:42; approximately 22 minutes (pressurized slurry release duration)—time to final isolation approximately 4'/s hours Chemicals released: slurry(heavy gas oil with CCU catalyst),flushing oil Estimated quantity released in pounds: 58,000 lbs(150 bbls) Type of release event and its source: pressurized liquid release through partially opened 8" valve upstream of Debutanizer Slurry Strainer;release initially formed some aerosol/small droplets Weather conditions at the time of the release: initial wind speed 3.5 mph,wind direction out of NE,no rain On-site impacts: contractor injury (thermal burn); substantial deposit of slurry on surrounding equipment and on ground in vicinity of release requiring cleanup Known off-site impacts: offsite deposition of slurry droplets south and cast of Refinery resulting in more than 3000 claims related to cleaning of cars and property Initiating event and contributing factors: Debutanizer Slurry Strainer was taken out of service for maintenance to address plugging in slurry system that provides heat to Debutanizer Reboiler Root cause(s): inlet block valve to Debutanizer Slurry Strainer was not completely closed, most likely due to plugging in the valve seat; single block valve isolation was applied to taking the strainer out of service for maintenance Off-site responders notified: Contra Costa County Health Services; Contra Costa County Sheriff, Martinez Police Department; Contra Costa Consolidated Fire Department Operational or process changes that resulted from the investigation of the release (status of implementation of recommendations): 1.Install Double Block and Bleed(DBB)on the Debutanizer Slurry Strainers: installed January 19,2006 2.Documentation processes to communicate status of unusual strainer line-up: a.Operating Procedure Revisions: revisions issued February 7,2006 b.Provide additional guidance to operators on how to properly communicate changes to strainer valve line- up positions and conditions in shift reports: last of six training sessions delivered June 9,2006 3.Revise isolation procedure and provide training: the revised isolation procedure will be issued July 1,2006 after incorporating comments received during the training sessions; the last of six training sessions was completed on June 9,2006 45 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION Document No.: Date Effective: Page: CONTRA COSTA 4of5 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 3/26/2006 Sulfur Recovery Unit#3 Sulfur Dioxide Release(see Attachment 1) Date,time,and approximate duration of the release: March 26,2006; 16:03-16:22; 19 minutes Chemicals released: sulfur dioxide Estimated quantity released in pounds: approximately 255 pounds Type of release event and its source: gas emission from atmospheric stack at tailend of SRU#3 Weather conditions at the time of the release: wind speed ranged from 1 to 6.3 mph; conditions were partly cloudy and the temperature was 63 degrees;wind direction in the vicinity of the release was from NNE On-site impacts: on-site plume,no exposures/injuries Known off-site impacts: offsite plume(across Shell Avenue); SMR received approximately 35-45 community calls as a result of the CWS shelter-in-place sirens and CAN phone messages; Ground Level Monitors(GLM)located on the refinery fence line did not detect any H2S or SO2; Contra Costa County Health Services conducted monitoring in the community during the incident and did not detect any hazardous concentrations of SO2; SMR also deployed personnel to conduct monitoring in the community and found no detectable amount of SO2 or H2S Initiating event and contributing factors: an operational upset in the Flexsorb(FLS)unit reduced the available acid gas supply to SRU#3;due to the low flow rates the temperature increased approximately 180°F in the Catalytic Oxidizer;the increase in temperature heated the Cat Ox bed and caused the oxidation of sulfur previously deposited on the catalyst bed resulting in emissions of SO2, which at peak temperatures became visible Root cause(s): un-oxidized sulfur built up on the Cat Ox catalyst on occasions when the bed temperature was not maintained above a minimum required temperature (not specified by catalyst vendor); a sudden drop in flow rate through F-109 resulted in rapid temperature increase in the Cat Ox bed and oxidation of the sulfur to SO2 Off-site responders notified: Contra Costa County Health Services; Contra Costa County Sheriff;Martinez Police Department;Contra Costa Consolidated Fire Department Operational or process changes that resulted from the investigation of the release (status of implementation of recommendations): pending finalization of RCA 46 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION CONTRA COSTA Document No.: Date Effective: Page: 5 of 5 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: I Attachment 2 OU ce/StudDeSCII tiOn ISS,ItemNumbe ISS Types _5y p rs s, A M20051956-001 Minimization MOC Dead leg minimization M20051956-004 Minimization MOC Dead leg minimization M20051956-006 Minimization MOC Dead leg minimization 1x120052249-001 Minimization MOC Remove unused propane line(dead leg), inventory reduction M2006928-001 Minimization MOC Dead leg removal 47 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION CONTRA COSTA Document No.: Date Effective: Page: 1 of 2 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 Annual Performance Review and Evaluation Submittal June 23, 2006 *Attach additional pages as necessary 1) Name and address of Stationary Source: Air Products Shell Martinez Refinery, 110 Waterfront Road,Martinez,CA 94553 2) Contact name and telephone number(should CCHS have questions): Michael Cabral (925)372-9302 3) Summarize the status of the Stationary Source's Safety Plan and Program(450-8.030(11)(2)(i)): The Stationary Source's Safety Plan is complete per CCHS requirements and submitted to CCHS for review. The Program has been implemented, as required. 4) Summarize Safety Plan updates(i.e.,brief explanation of update and corresponding date)(450- 8.030(13)(2)(ii)): Date: 22 June 2006-update: Section 7(Annual Accident History)and Section 8(Annual Performance Review and Evaluation Submittal) 5) List of locations where Safety Plans are/will be available for review, including contact telephone numbers if the source will provide individuals with copies of the document (450-8.030(11)(2)(ii)): CCHS Office, 4333 Pacheco Boulevard, Martinez; Martinez Library (library closest to the stationary source); Air Products — See contact in 42,above. 6) Provide any additions to the annual accident history reports(i.e. updates)submitted pursuant to Section 450- 8.016(E)(2)of County Ordinance 98-48(450-8.030(13)(2)(iii))(i.e.,provide information identified in Section 450-8.016(1;)(1)for all major chemical accidents or releases occurring between the last accident history report submittal(January 15)and the annual performance review and evaluation submittal(June 30)): None 7) Summary of each Root Cause Analysis(Section 450-8.016(C))including the status of the analysis and the status of implementation of recommendations formulated during the analysis(450-8.030(B)(2)(iv)): No events triggered this requirement since the previous Annual Performance Review and Evaluation submittal. 8) Summary of the status of implementation of recommendations formulated during audits,inspections,Root Cause Analyses,or Incident Investigations conducted by the Department(450-8.030(13)(2)(v)): APCI submitted proposed remedies to the audit findings to Contra Costa County before M August 2004. All outstanding actions of this audit were completed by 16 August 2005. In addition, CCCHS completed an unannounced inspection on 18 January 2006. A response to proposed remedies from three Action Items was accepted by CCCHS on March 27'"2006 APCI has completed the remedies as proposed for each Action Item. 9) Summary of inherently safer systems implemented by the source including but not limited to inventory reduction(i.e.,intensification)and substitution(450-8.030(13)(2)(vi)): 1) Plant uses aqueous ammonia rather than anhvdrous ammonia in its emission control system. This helps reduce the off-site consequence ofan ammonia release. 2) Plant is designed without a liquid hydrogen backup system. This reduces the inventory of hazardous chemicals on-site. 48 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION C O N T R A COSTA Document No.: Dale Effective: Page: 2 of 2 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: I 3) Plant switched from 99% monoethanolamine to 85% monoethanolamine in order to eliminate the need for insulation around the water treatment tanks. This reduces the potential for afire. 10) Summarize the enforcement actions(including Notice of Deficiencies,Audit Reports,and any actions turned over to the Contra Costa County District Attorney's Office) taken with the Stationary Source pursuant to Section 450-8.028 of County Ordinance 98-48(450-8.030(13)(2)(vii)):No enforcement actions were taken since the previous Annual Performance Review and Evaluation Submittal. 11) Summarize total penalties assessed as a result of enforcement of this Chapter(450-8.030(3)): No penalities have been assessed against this facility since the previous Annual Performance Review and Evaluation submittal. 12) Summarize the total fees, service charges, and other assessments collected specifically for the support of the ISO (450-8.030(B)(4)): CalARP Program fees for these eight facilities are - $314,013, the Risk Management Chapter of the Industrial Safety Ordinance fees are-$319,669. 13) Summarize total personnel and personnel years utilized by the jurisdiction to directly implement or administer this Chapter (450-8.030(B)(5)): 4000 hours were used to audit/inspect and issue reports on the Risk Management Chapter of the Industrial Safety Ordinance. 14) Copies of any comments received by the source(that may not have been received by the Department) regarding the effectiveness of the local program that raise public safety issues(450-8.030(B)(6)): None 15) Summarize how this Chapter improves industrial safety at your stationary source(450-8.030(B)(7)): Air Products is committed to the safe operation o our facilities and has implemented applicable requirements outlined in the ISO, as well as the CaIARP regulation. The Human Factors program is implemented, and has helped the site maintain a safety record of no recordable or Lost Time Iniuries since the last plan submittal. Likewise, there have been no events that resulted in offsite impact. This Chapter has helped reinforce the need to maintain and follow a structured safety program to help ensure the safety o our employees and the communities in which we operate. 16) List examples of changes made at your stationary source due to implementation of the Industrial Safety Ordinance(e.g.,recommendations from PHA's,Compliance Audits,and Incident Investigations in units not subject to CaIARP regulations;recommendations from RCA's)that significantly decrease the severity or likelihood of accidental releases: Air Products has develloed and implemented a Human Factors Program as required b>> the Industrial Safety Ordinance. Per the request of CCCHS, the site clarified issues associated with the Management of Change by creating a site-specific Tier IV document. In addition, the Air Products Corporate Assurance Department formulated an internal audit template developed specificallyto o veri compliance to the elements of the CCC ISOprogram. 17) Summarize the emergency response activities conducted at the source (e.g., CWS or CAN activation) in response to major chemical accidents or releases: There were no emergency response activities to this site since the previous Annual Performance Review and Evaluation submittal. 49 ANNUAL PERFORMANCE REVIEW AND EVALUATION SUBMITTAL The Safety Plan for this facility will be updated JUNE 30, 2006 whenever changes at the facility warrant an update 'Attach additional pages as necessary or every three years from June 17, 2002. An updated Safety Plan will be submitted this year 1. Name and address of Stationary Source: along with an updated RMP. In addition, the accident history along with other information is Tesoro Golden Eagle Refinery updated every year on June 30. This submittal 150 Solano Way serves as the 2006 update. Martinez, CA 94553 5. List of locations where Safety Plans are/will 2. Contact name and telephone number (should be available for review, including contact CCHS have questions): telephone numbers if the source will provide individuals with copies of the document (450- James Jeter at (925) 372-3169 or Sabiha Gokcen at 8.030(B)(2)(ii)): CCHS Office,4333 Pacheco (925) 370-3620. Boulevard, Martinez library 3. Summarize the status of the Stationary 6. Provide any additions to the annual accident Source's Safety Plan and Program (450- history reports (i.e. updates) submitted 8.030(B)(2)(i)): pursuant to Section 450-8.016(E)(2) of County Ordinance 98-48 (450-8.030(B)(2)(iii)) (i.e., The original Safety Plan and two Safety Plan provide information identified in Section 450- updates have been submitted (see below). Contra 8.016(E)(1) for all major chemical accidents or Costa Health Services has completed four audits releases occurring between the last accident of the safety programs. The first audit was in history report submittal (January 15) and the September, 2000 on the safety programs. The annual performance review and evaluation second audit was in December, 2001 and focused on submittal (June 30)): Inherently Safer Systems and Human Factors. An The accident history was updated in the 2005 unannounced inspection occurred in March, 2003. update. Since that update, there have been three A CalARP/ISO audit was in August, 2003. The incidents that meet the Major Chemical Accident or most recent CalARP/ISO audit was in November December, 2005. All safety program elements Release criteria in the last year. required by the ISO have been developed and are August 24, 2005 —Fire on the FCCU (see attached being implemented. root cause report) 4. Summarize Safety Plan updates (i.e., brief October 26, 2005 —Power Outage (see attached root explanation of update and corresponding date) (450-8.030(B)(2)(ii)): cause report) March 24, 2006—Fire on#2 HDS Unit. The The original Safety Plan for this facility was filed with Contra Costa Health Services on January 14, investigation of this incident is complete, however 2000. An amended plan, updated to reflect CCHS the report is still being written. recommendations and ownership change, was 7. Summary of each Root Cause Analysis filed on November 30, 2000. A Human Factors Amendment was submitted on January 15, 2001. A (Section 450-8.016(C)) including the status of Power Disruption Plan was submitted,per Board of the analysis and the status of implementation Supervisor request, on June 1, 2001. An amended of recommendations formulated during the Safety Plan, updated to reflect ownership change analysis (450-8.030(B)(2)(iv)): was submitted on June 17, 2002. 50 Root Cause Analysis information is included in "CCHS Information": CalARP program fees attachments for#6. for these nine facilities were $325,581. The Risk Management Chapter of the Industrial Safety 8. Summary of the status of implementation of Ordinance fees were $296,179. recommendations formulated during audits, inspections,Root Cause Analyses, or Incident 13. Summarize total personnel and personnel Investigations conducted by the Department years utilized by the jurisdiction to directly (450-8.030(B)(2)(v)): implement or administer this Chapter (450= 8.030(B)(5)): "CCHS Information": CCHS completed an audit on September 15, 2000, December, 2001, August, "CCHS Information": 4000 hours were used 2003 and November/December, 2005. There are to audit/inspect and issue reports on the Risk no RCA or Incident Investigations that have been Management Chapter of the Industrial Safety conducted by the Department. Ordinance. 9. Summary of inherently safer systems 14. Copies of any comments received by the implemented by the source including but source (that may not have been received by not limited to inventory reduction (i.e., the Department) regarding the effectiveness intensification) and substitution (450 of the local program that raise public safety 8.030(B)(2)(vi)): issues(450-8.030(B)(6)): This facility has not received any comments to date Golden Eagle is submitting a list of the Inherently regarding the effectiveness of the local program. Safer Systems (ISS) that meet the criteria for Inherent or Passive levels only and that were 15. Summarize how this Chapter improves completed within the last year (see attached). industrial safety at your stationary source (450- 8.030(B)(7)): 10. Summarize the enforcement actions (including Notice of Deficiencies, Audit Reports, and Chapter 450-8 improves industrial safety by any actions turned over to the Contra Costa expanding the safety programs to all units in the County District Attorney's Office) taken with refinery. In addition, the timeframe is shorter to the Stationary Source pursuant to Section implement recommendations generated from the 450-8.028 of County Ordinance 98-48 (450- Process Hazard Analysis (PHA) safety program than 8.030(B)(2)(vii)): state or federal law. This has resulted in a faster implementation of these recommendations. "CCHS Information": CCHS issued a Administrative Preliminary Audit Findings on Chapter 450-8 also includes requirements for February 13, 2006 based on a CalARP/ISO audit/ inherently safer systems as part of implementing inspection. Tesoro responded to the Preliminary PHA recommendations and new construction. findings on June 6, 2006. This facility has developed an aggressive approach to implementing inherently safer systems in these II.Summarize total penalties assessed as a result of areas. enforcement of this Chapter (450-8.030(3)): Chapter 450-8 has requirements to perform root "CCHS Information": No penalties have been cause analyses on any major chemical accidents or assessed against any facility. releases (MCAR). This facility has applied that rigorous methodology to investigate any MCARs 12. Summarize the total fees, service charges, and that have occurred since January, 1999. other assessments collected specifically for the support of the ISO (450-8.030(B)(4)): 51 Chapter 450-8 requires a human factors program. ROOT CAUSE ANALYSIS REPORT This facility has developed a comprehensive TESORO GOLDEN EAGLE human factors program and is in the process of REFINERY implementing the program. AUGUST 24TH FCCU FIRE 16. List examples of changes made at your Summary of Event: stationary source due to implementation At approximately 16:15 hours on August 24, 2005, of the Industrial Safety Ordinance (e.g., afire started at the Mini Blower (which is near recommendations from PHA's, Compliance Audits, and Incident Investigations in the Main Blower) of the Fluid Catalytic Cracking units not subject to CaIARP regulations; Unit (FCCU) creating a smoke plume that had recommendations from RCAs) that no off site impact. This incident is a CWS level 2 significantly decrease the severity or likelihood event due to the visibility of the smoke plume from significantly releases. offsite. Golden Eagle Operations personnel began of immediate operational actions to shut down the unit This question was broadly answered under question in a controlled manner and take appropriate action 15 above. Some examples of changes that have been to quench the fire. Refinery emergency response made due to implementation of the ordinance are as crews quickly responded to the scene and the follows. There are some units that were not covered Emergency Operations Center (EOC) was activated. bNotifications were made to requisite outside y RMP, CaIARP or PSM. Those units are now subject to the same safety programs as the units agencies and to Golden Eagle personnel. One odor complaint was received from Bay Point, but it was covered by RMP, CaIARP and PSM. They have had unconfirmed by BAAQMD inspectors. During PHAs performed on them according to the timeline and a specified in the ISO and the PHA recommendations after the less than one hour fire, Golden Eagle have been resolved on the timeline specified in the dispatched Odor Science and Engineering personnel throughout the community from Clyde to Bay ISO. A list of inherently safer systems as required Point to assess possible community impact. Other by the ISO for PHA recommendations and new than the one odor complaint, no community impact construction is attached to this filing as mentioned was detected or reported. No reportable quantities in the response to question 9. With respect to of hazardous compounds were exceeded. At Compliance Audits, there was a compliance audit approximately 17:05 hours, the event was declared performed in June, 2003 in addition to the CCHS under control, and at 17:22 hours,the all clear was audits mentioned above. All audit findings are being submitted to the CCCHSD. actively resolved. Root Cause Analysis findings and recommendations for MCARs are listed in the The fire was determined to be the result of a response under question 6. complete failure of the FCCU Mini Blower. The failure, and likely severe vibration prior to the 17. Summarize the emergency response activities failure, damaged the associated lube oil piping. The conducted at the source (e.g., CWS or CAN resulting loss of lube oil containment provided the activation) in response to major chemical fuel consumed in the fire. Although the ignition accidents or releases: source cannot be confirmed, it is likely that hot Please refer to #6 which has the CWS classifications metal fragments (from bearing housings, etc.) were for the major chemical accidents and releases as well Present at the time of ignition. as any information regarding emergency responses During the investigation, it was determined that by agency personnel. the Mini Blower was deadheaded following the activation of an emergency shutdown (ESD) associated with a trip of the Main Blower, the initiating event of this incident. Deadhead operation means there was no flow through the 52compressor. Deadhead operation resulted in accelerated Mini Blower speed, which exceeded Emergency Response Actions: both the electronic and mechanical over-speed trip Operations personnel shut down the FCCU and settings. However, these existing safeguards failed activated fire monitors on the unit. Refinery to protect the Mini Blower from the over-speed emergency response crews immediately responded condition. As a result of the incident investigation, to the scene with additional fire fighting equipment. the investigation team recommended changes in CCCFPD was ready to assist as mutual aid if system design, procedures, and testing practices to needed. prevent the recurrence of a similar event. Material Released: Chronology of event: The material that burned was lube oil. The amount Vv'rfime l,.a v of lube oil estimated to be combusted in the fire is 16.14127 bra: Main Blower turbine trips off-line(tripphrottle valve closes). Process data and alarm 3,665 Ounds. history indicate smooth unit and blower operation prior to trip. P 16:14:36 his: FCCU emergency shutdown(ESD)activates on low-low Regenerator Riser flow.ESD logic includes diversion of Mini Blower flowfrom Regenerator rings to vent. 16:14:38 his: Regenerator air ring valve closes;Mini Blower vent valve remains closed. Meteorological Conditions: 16:1439Ins: Mini Blower discharge pressure increases and discharge flow decreases,Mini Blower The weather was clear on 8/24/05. The wind was speed increases.Mini Blower is deadheaded. 16,14:41 his: Mini Blower speed begins rapid acceleration,exceeding electronic(Trisen)and from the West at 4-9 MPH. The temperature was mechanical(bolt)over-speed trip settings(6600 RPM and 6900 RPM,respectively). 16:4143 hrs. First Mini Blower shutdown alarm:Trieen initiates shutdown signal,received by about 73 degrees F. Triconex(PLC). However,the Mini Blower turbine does not trip(speed is 7620 RPM). Various Continuous fluctuations in Mini Blower speed,discharge flow,and discharge pressure: classicsymptomsofoompressorsurge. Mini Blower discharge pressure is generally off- Injuries: stale(greater than 50 PSIG). 1 1614:49 hrs.IMini Blower vent valve position still fully closed.Mini Blower speed is 8010 RPM. No injuries were reported on or offsite. 16:14:51 hrs'. Manual FCCU emergency shutdoim button activated by board operator. 16:14:53 his: Mini Blower speed is 8370 RPM 16.14:58 hrs-. Mini Blower common vibration/temperature alarm is received from Bently Nevada. Community Impact: Mini Blower speed is 8730 RPM 16:15:00 his Mini Blower auxiliary lube oil pump starts.Possible start of lube it leak.No related A CWS level 2 incident was declared due to the low lube oil pressure alarm is received. 16:15:02 hrs'. Mini Blower speed is 8679 RPM visibility of the smoke plume from the fire. One 16:15:03 his Bently Nevada initiates Mini Blower shutdown signal;Mini Blower vibration exceeds odor complaint was received from Bay Point. It danger threshold. 16:15:06 hrs:IMmi Blower speed is 9492 RPM Mini Blower vent valve is still closedwas unconfirmed by the BAAQMD inspector. In 16'.15:08 his Mini Blower speed is 11281 RPM Qast recorded speed). 16:15.16hra: Mini Blower trip/throttle valve closes, addition, Odor Science and Engineer personnel Min`Blower ventvewmpletionis4 damage ,6%, indicated that there were no odors found in the 16:15:18 hrs'. Mini Blower vent valve position is 47.6%. 16:15 hrs.: Fire at FCCU near Main and Mini Blowers surrounding communities during the incident 1628 hrs.: CWSlevelB 2no[ifiration issued over CWS[eitninal (Clyde, Concord, Bay Point areas). 16.25 hrs.: Notified BAAQMD 1630 his: UN[secured,no injuries 16:43 hrs.: OS&E personnel dispatched to monitor wmmunity Incident Investigation of the event: 16:55 hrs.: CCHS personnel arrive on scene 17:00 his.: Fite is out A Root Cause Analysis investigation was performed 17:05 his.: Under control issued. 7:22 hra.: All clear issued to refinery utilizing Causal Mapping for developing a causal 17:29 itis.: ccHs iaanea all clear over CWS. factor tree. This report fulfills the requirements set forth in County Ordinance 98-48 the "Industrial Agency Notification and Response: Safety Ordinance" for conducting a Root Cause The following agencies were immediately notified: Analysis for a CWS Level 2 incident. Contra Costa Health Services (CCHS) via the Areas of focus during investigation: CWS, the Bay Area Air Quality Management District (BAAQMD) via the CWS, Contra Costa The FCCU has a regenerator/reactor circulation Fire Protection District, and the Contra Costa system for the catalyst used in the cracking reaction County Office of Emergency Services. Agencies of the heavy hydrocarbons. The catalyst is used responding with personnel to the site included for cracking in the reactor section and then it is CCHS, BAAQMD, Contra Costa Sheriff, Cal- circulated to the regenerator section to restore its OSHA and the Contra Costa Fire Protection catalytic properties. Two blowers, the Main Blower District (CCCFPD). CCCFPD responded with and the Mini Blower, provide air to the reactor, two Engines (5 and 9), two Quints (6 and 12) and a which is used for both catalyst movement and Battalion Chief; they were ready to assist as mutual catalyst regeneration. aid if needed. 53 The incident initiated with the trip of the Main A trip of the Main Blower turbine was the initiating Blower turbine. An FCCU emergency shutdown event of this incident. Data collected indicates (ESD) activated by low-low Regenerator Riser that the first Main Blower shutdown signal was flow was initiated at approximately 16:14:36 initiated by Trisen. Process data confirms that unit hours, which resulted in deadhead operation of the and blower operation were smooth and normal for Mini Blower a few seconds later. This deadhead several hours prior to the trip. No process alarms condition resulted in the acceleration of the blower were recorded in the alarm history in the four hours speed above the trip settings for the over-speed prior to the incident. It appears the Trisen control safeguards in place for equipment protection. These system of the Main Blower detected a"memory safeguards did not activate, which allowed sustained glitch" and rebooted to return to normal status. over-speed operation at ever increasing speeds. The reboot process shuts down the Main Blower. Related increases in blower vibration and bearing temperatures resulted in complete damage to the Mini Blower Deadhead Operation: The loss of flow Mini Blower at approximately 16:15:18 hours. from the Main Blower resulted in the activation of an automatic FCCU emergency shutdown (ESD) The investigation primarily focused on three areas: on low-low Regenerator Riser flow at 16:14:36 Why did the Main Blower trip? Why did the Mini hours. The logic of this ESD completes several Blower become deadheaded? Why did the Mini actions designed to quickly stabilize the unit Blower over-speed safeguard fail? operation following the loss of the Main Blower, and minimize the possibility of equipment damage The Blower Control System: The Main Blower has resulting from the related process upset. Included a Trisen electronic governor with surge control in the logic is the diversion of the Mini Blower . capabilities. The Trisen surge control output signal discharge flow from the Regenerator air rings to goes to the surge control valve and the speed output the vent (atmosphere) to prevent the backflow of signal goes to a Moore Fieldpac valve positioner. hot catalyst into the blower case. Diversion of the The Fieldpac receives a Trisen input as well as its Mini Blower discharge flow is accomplished by the own local input. The Fieldpac output signal is a high concurrent closing of the Regenerator air ring valve select of the two inputs and goes to a Blac hydraulic with the opening of the Mini Blower vent valve. actuator which operates the steam admission valve. Following activation of the ESD during the In addition to being a speed controller, the Trisen incident, the air ring valve closed within three is also programmed to initiate trip events and has seconds. However,the vent valve remained input/output channels connected to the Triconex completely closed until at least 16:15:08 hours, Digital Control System (DCS).For over-speed when the alarm history indicates that the valve there are two systems which dump the oil pressure, began to open. Therefore,the Mini Blower was tripping the trip/throttle valve: 1) A mechanical completely deadheaded for more than 28 seconds. over-speed bolt opens a valve which dumps the The vent valve was still less than 50 percent open oil pressure off the trip/throttle valve hydraulic at the time the blower suffered complete damage at actuator. 2) A solenoid controlled by the Triconex approximately 16:15:18 hours (42 seconds after it which dumps the oil pressure off the trip/throttle was given a signal to close). The slow response time valve hydraulic actuator. for the Mini Blower vent valve was subsequently determined to be caused by an undersized solenoid The Mini Blower is similar to the Main Blower, valve, which overly restricted the air flow from the with the following differences: 1) The Mini Blower actuator upon activation. does not have a surge control valve, so the Trisen does not have any surge control capabilities. 2) The Sustained Mini Blower Over-speed: As a result Mini Blower also does not have a Blac hydraulic of deadhead operation, the Mini Blower speed unit. The steam admission valve on the Mini Blower continued to increase, including a rapid acceleration is controlled by a Valtek pneumatic actuator. from 6720 RPM to 7020 RPM (within one second) at approximately 16:14:41 hours. This speed exceeds 54 both the electronic and mechanical over-speed trip mechanical over-speed components were inspected, settings (6600 RPM and 6900 RPM, respectively). and there was no indication that the dump valve A Trisen trip signal was recorded at 16:14:43 itself was stuck. hours,which was recognized by the Triconex PLC. However, neither the steam admission valve Based on the evidence, it is not possible to nor the trip/throttle valve closed as evidenced by conclusively determine why the trip/throttle valve the blower speed (7620 RPM) and no significant failed to close. Therefore, the incident investigation decrease in the steam flow to the turbine. team concluded that sustained Mini Blower over- speed was caused by either (1) both the mechanical The Mini Blower thrust vibration and radial over-speed valve and the trip solenoid valve failing outboard bearing temperature entered "alarm" to operate -a double failure, or (2) the hydraulic status and a common Bently Nevada vibration/ piston in the trip/throttle valve actuator failing to temperature alarm was recorded at 16:14:58 hours move. with the Mini Blower speed at 8730 RPM. Within the next five seconds, the Mini Blower thrust and Root Cause# 1: There was a spurious trip of Main outboard bearings entered "danger" status, and Blower operation by the Trisen control system. the Bently Nevada initiated a shutdown signal on high-high vibration at 16:15:03 hours. Again, based Root Cause#2: An undersized solenoid in the Mini on the recorded steam flow to the turbine, the Blower vent valve hindered timely opening of the trip/throttle valve did not respond. Also during this valve, which resulted in Mini Blower deadhead period,the alarm history indicates that the Mini operation. Blower auxiliary lube oil pump started at 16:15:00 hours. However, there was no associated low Root Cause#3: The trip system for the Mini lube oil pressure alarm recorded. Nonetheless,the Blower failed to trip the blower. automatic start of this pump was likely in response to reduced lube oil pressure, and may have indicated Additional Finding#1: Failure of some Main Blower the start of a Mini Blower lube oil leak. speed pickups since the last unit turnaround implies that the pick-ups may have been installed with The last recorded Mini Blower speed by the Bently insufficient clearance from the speed pick-up gear. Nevada System 1 was 11281 RPM at 16:15:08 hours. The trip/throttle valve was recorded closed by Additional Finding#2: Descriptors in the DCS the alarm history at 16:15:16. The steam flow to alarm history can be unclear or misleading. The the turbine (decrease) and the 600# steam supply significance and priority of blower common-trouble pressure (increase) at this time were consistent alarms may not be universally understood by all with the valve closing. The trip/throttle valve did operators. not close in time to protect the Mini Blower from complete failure. Additional Finding#3: The various data historians used during the analysis of this incident had clocks The mechanical over-speed valve (dump valve) with settings that deviated from "actual time" by as was found in the tripped (open) position after the little as 58 seconds and by as much as more than 13 incident. However,physical evidence observed minutes. There was only 41 seconds between the during disassembly indicated the dump valve trip of the Main Blower and the destruction of the was still closed at the time bearing damage was Mini Blower. Therefore, precise synchronization occurring. Bearing metal debris was found in a of the historians was crucial to the accurate recess in the dump valve which is only exposed determination of the sequence of events and incident when the valve is in the closed position. This causes. indicates that the bearing damage was occurring while the dump valve was closed. Vibration data Additional Finding#4: The Bently Nevada "System shows no indication of bearing problems until 1" data historian provided data that was vital to well into the over-speed event. Furthermore,the the timely evaluation and analysis of this incident. 55 Many critical pieces of machinery with Bently ROOT CAUSE ANALYSIS REPORT Nevada protection systems do not have the "System T E S O RO GOLDEN EAG L E 1" data historian installed. REFINERY Additional Finding#S: The existing procedure for OCTOBER 26TH POWER OUTAGE the trip testing of turbine-driven rotating equipment was found to be vague with respect to testing Summary of Event: requirements for unspared equipment. At approximately 11:50 PM on October 26, 2005, the refinery experienced a power outage which Additional Finding#6: The FCCU Main Blower affected a portion of the refinery 12 KV electrical and Mini Blower control systems and safeguards distribution system. The power from the Foster have similarities and commonalities with those of Wheeler Cogen plant bus to Switching Station #7 other major rotating equipment throughout the was lost. This resulted in no electrical power to #4 refinery. HDS unit, 50 Unit,the field charge pump for#1 HDS, portions of the#3 Water treating plant and wastewater treatment plant and various „=q Cornenve Ac4ons * ` "`f'd, ,""$ .�,.` `.-„��= �' Annupated Dau'of�F"" . -a�� buildings and shops through the I Review currentprocedmefor installation and gap setting ofspeed Complete refinery. The Plant Information (PI) pickups (addresses Additional Finding 91) 2 ConsidermodificationofFieldpaktoallowgovernorvalvetocloseforbothMain Main and Mini Blowers data collection system was housed in and Mini Blower(addresses Root Cause#3) Complete 3 Consider modifying Trisen trip initiators for both Main and Mini Blowe". Main Blower—12/31/06 one of the buildings that lost power. (addresses Root Cause 41) There was also a large dip in the voltage Mini Blower Complete 4 ReviewacNaturresponseofMini-Blowerventvalvetodermasertroketime(close Complete of the 12 KV system that caused several to-open).(addresses Root Cause#2) 5 Cordon close-mopentime for Mini Blower vent valve and opcn-to-close time of Complete pieces of equipment that are powered vent valve for air bow in rings are sufficiently matched to avoid deadhead L Other feeders to shutdown including operation of Mini Blower(addresses Root Cause#2) y n 1 d shutdown, 1 d g 6 Ensure procedures call for rarely response tolocal=it remotecommon trouble 4/30/2006 the Oxygen enrichment skid at the Sulfur slates for Main and Mini Blowers.(addresses Additional Finding#2) 7 Evaluate mechanical trip systems and determine best means for reducing the Main Blower—3/31/07 recovery unit (SRU). The loss of the possibility that mechanical malfunction could prevent an over-speed trip for both oxygen enrichment skid resulted in the Main and Mini Blowers. addresses Root Cause 43 Mini Blower Complete Sulfur Dioxide in the chemical plant g Consider fail-safe energise-to-close configuration for over-speed trap solenoids for Main Blower—3/31/07 both Main and Mini Blowers.(addresses Root Cause#1) stack plume. Mini Blower Complete 9 Consider additional means to prevent or mitigate a deadhead operation ofthe Mini Complete Blower.Include consideration ofoption to trip Mini Blower during ESD as means Initially, a CWS level 0 was declared to mitigate possible deadhead operation.(addresxs Root Cause 42) 10 Consider mitigating pmsimityofMini Blower mp/threttlevalve oil line toliars Complete for this incident. However, a plume source on prevent potential plugging.(addresses Roe Cause 43) 11 Evaluate installation ofredmdan[comolsystem inlieu ofthe Tnsen"it Fieldpak 3/31/2007 from the chemical plant stack was for speed control.(addresses Root Cause#1) visible from off site and it potentially 12 Determine whether Main Blower Tinen speed pickup alarm(bad probe)label can Complete be made more descriptive,(addresses Additional Finding 42) contained Sulfur Dioxide; therefore the 13 Consider removing TrisetasaMain Blow ortrip initiator after altemateWmeam 3/31/2007 jnC'dent was a raded to a CWS level 2. have been secured(related to#I1).(addresses Root Cause k I) pg 14. Consider surge pratectionfor the Mini Blowegincluding asurge valve upsrmam 3/31/2007 Golden Eagle Operations personnel took of the check valva faddreases Root Cause#2) Is Review applicability ofthisinvestigation finding toother meeting equipment 12/312007 immediate action to either reduce unit throughout the refinery.(addresses Additional Finding 46) rate or shutdown the process units. The 16 Consider means to routinely update docks of process and mechanical data Complete historians throughout the refinery.(addresses Additional Finding 43) Emergency Operations Center (EOC) 17 Consider addition ofS)stem I(data historian)toall Bentley Nevada Syswmsof.1112/312006 was activated and notifications were critical rotating equipment.(addresses Additional Finding 44) ]g Evahma,procedure for triptesting majmosetingequipment. Updaleprocedureto 4/302006 made to required outside agencies and to clarify when trip tests should be conducted on tmspared equipment Communicate Golden Eagle personnel. Golden Eagle requirements to Maintenance and Operations.(addresses Additional Finding#5) g p g dispatched Odor Science and Engineering personnel to Clyde to assess possible community impact; no community impact was detected or reported. The Ground Level Monitors (GLMs) did not detect any Sulfur Dioxide or Hydrogen Sulfide. Industrial Hygiene monitoring (by Tesoro personnel and CCHS personnel) was 56 conducted and no chemicals of concern were Material Released: detected offsite. A brief timeline follows: A visible plume was emitting from the Sulfur Plant stack,which contained Sulfur Dioxide and Sulfur 23:50 hrs: Power outage at the refinery Trioxide. An estimated amount of 1860 pounds of 23:50 hrs: CWS level 0 notification issued over CWS Sulfur Dioxide and 24 pounds of Sulfur Trioxide terminal was released. 00:07 hrs: Ammonia Recovery Unit(ARU) shutdown to reduce acid gas load to SulfurMeteorological Conditions: plant The weather was partly cloudy on 10/26-27/05, with wind from the West at 5-12 MPH. The 00:15 hrs: CWS level 2 notification issued CWS temperature was about 54 degrees F. terminal 00:40 his: Contra Costa County Sheriff personnel Injuries: arrive No injuries were reported on or offsite. 00:45 hrs: BAAQMD notified 00:46 hrs: CCHS reports that their personnel detect Community Impact: no odors/chemicals of concern A CWS level 2 incident was declared due to the 01:00 hrs: Oxygen ratios reestablished to units in visibility of the plume from the chemical plant chemical plant stack and it potentially contained Sulfur Dioxide. 01:07 hrs: CWS level 0 notification issued over CWS Odor Science and Engineer personnel indicated terminal that there were no odors found in the surrounding communities during the incident (Clyde, Concord, 01:20 hrs: Refinery personnel detect no chemicals of Bay Point areas). The GLMs did not detect any concern in downwind area Sulfur Dioxide or Hydrogen Sulfide. In addition, 01:35 hrs: OS&E personnel detect no odors in the Tesoro personnel and CCHS conducted Industrial community of Clyde Hygiene monitoring and detected no chemicals of concern offsite. Agency Notification and Response: The following agencies were immediately notified: Focus of the incident investigation: Contra Costa Health Services (CCHS) via the CWS, The incident investigation focused on two primary the Bay Area Air Quality Management District areas,the cause of the power outage and the impact (BAAQMD) via the CWS and phone, Contra of the power dip on the oxygen enrichment skid at Costa Fire Protection District, and the Contra the chemical plant. Costa County Office of Emergency Services. Agencies responding with personnel to the site An investigation by Foster Wheeler concluded that included CCHS and Contra Costa Sheriff. [Note: the most likely initiating event was an electrical Notifications over the CWS terminal: CWS level arc-over on two insulators in their switchyard 0 notifies Contra Costa Health Services (CCHS). on Structure #3. These insulators are in the two CWS level 2 notifies CCHS, Contra Costa OES, circuits that feed power from Switching Station Contra Costa Sheriff and BAAQMD with a #7 to Switching Station#1 and are located on the message. Additional notice informs Contra Costa downstream side of the reactors in these circuits. Fire Protection District, California Highway Patrol, This arc over may have been caused by moisture California Dept. of Health, San Ramon Valley Fire, in the atmosphere from rain earlier in the day. All Martinez Police, Antioch Police, Pinole Police and maintenance procedures for these insulators were Richmond Police.] appropriate as specified by industry standards and had been followed. These insulators had been Emergency Response Actions: cleaned and spray coated with silicon grease 18 Golden Eagle Operations personnel took immediate months prior to the incident. Normal industry action to either reduce unit rate or shutdown the practice is to conduct this operation every 3-5 years. process units. 57 This failure should have only interrupted the Coirecttx�*Acts€isfl icter]�T>at of electrical power to Switching Station#1, it should , cvmptezttn , not have affected Switching Station #7 (SS#7). The 1 1 Evaluate electrical controls for the 9/1/2006 reverse current relays in the feeder circuits from oxygen enrichment skid at the the Foster Wheeler bus to SS #7 had operated and chemical plant and determine if opened both feeders even though the fault was improvements can be made. downstream from them. The loss of the oxygen 2 Review procedures with operators 6/1/2006 enrichment skid was most likely due to a system on taking timely and appropriate action on these units when there is wide power dip from 12.47 KV to approximately an exceedance of environmental 10.3 KV. permit limits. 3 Replace reverse relays with ones complete Root Cause # 1: The oxygen enrichment system with less sensitive relay settings. unexpectedly tripped due to a power dip. 4 Replace insulators. Change complete maintenance practice to eliminate greasing and clean insulators more Root Cause#2: Upon loss of the oxygen skid, unit frequently. (This is Foster rate was not reduced quickly at the SRU and ARU. wheelers action item) 5 Consider improvements to back up 12/31/2006 Root Cause#3: The reverse current relay settings power supply in the VAX room in were too sensitive. the warehouse. Root Cause#4: There was an electric arc over in Foster Wheeler's switch yard most likely due to dirty insulators. Root Cause#5: There is no additional backup power beyond the UPS batteries for the equipment that contains the PI system. As a result, it took longer than expected to stabilize the units due to the loss of the PI system. 58 N >1c _U :3 C •N C R N C 0 C d a) Q. C N E a) � E a) `L' + OlN E _ ° .- 0 Edo E = cnv, EU N N v y 0 Q N ,F N E U =° N �r a 0) CLE a� s E a.S o a E •- CL 3 C m c'm m �� m o m asi a0 m oCo = 300 3 '> Ea� 3 0 +. co-'acma) ° c ccnE cm (D = w .- c a m o30 ° 0a' -ao -'a3 � n -oE d Y UO N c E U Y 'U N ° = N Q ° N O.'p :r Y d Y N .N +-� > Y ° ° Y. N U (6 Y (6 - N 76 0 CL M CL m CD 0 A` O Q. 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N � .: Cl � a) o- o- m m aE aa) c E � ao -o a � 'C E a � o fir°? Q a) Q a) Q 'cn ate) d E Q w Q a) ¢ m s� is ry 0 d W r •1 aa. a a a a a a a Ev :fa n, tr. Y W d H O �. > > > > > > > L a) i nm (n CC W -N N O O O L N O O O r W �t (D If N O `� O O O �' O to O IVy-"' V�' tt O Cl O O I O N O O O N N N O O O N C 7 C O a d Z Cb op co M J J J a co co F— N o 0 o Q Q Q 60 � � w v a> E a' E m = = roar N' D N a y Co �.H c L Ql .0 N D ) N w .a 0) N N L C y � N _ N f6 2 2 m ,ka a a E.r a Q N �I cn d 0 '� (6 w co W ua i M I�t LO LO LO W �►- d t O M o 0 cq CN 0 CO co 00 F N d Y •z ;, 61 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION CONTRA COSTA Document No.: Date Effective: Page: 1 of 2 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 Annual Performance Review and Evaluation Submittal June 22, 2006 *Attach additional pages as necessary 1) Name and address of Stationary Source: Air Products Tract 1, Tesoro Refinery(Golden Eaele-Avon). Solano Way,Martinez,CA 94553 2) Contact name and telephone number(should CCHS have questions): Michael Cabral. (925) 372-9302 3) Summarize the status of the Stationary Source's Safety Plan and Program(450-8.030(B)(2)(i)): The Stationary Source's SaLtE Plan is complete per CCHS requirements and submitted to CCHS for review. The Program has been implementedd, as required. 4) Summarize Safety Plan updates(i.e.,brief explanation of update and corresponding date)(450- 8.030(13)(2)(ii)): Date: 22 June 2006-update: Section 7(Annual Accident History and Section 8(Annual Per Review and Evaluation Submittal) 5) List of locations where Safety Plans are/will be available for review, including contact telephone numbers if the source will provide individuals with copies of the document(450-8.030(B)(2)(ii)): CCHS Office, 4333 Pacheco Boulevard Martinez: Bay Point Librya (library closest to the stationary source);Air Products—See contact in#2, above. 6) Provide any additions to the annual accident history reports(i.e.updates)submitted pursuant to Section 450- 8.016(E)(2)of County Ordinance 98-48(450-8.030(13)(2)(iii))(i.e.,provide information identified in Section 450-8.016(E)(1)for all major chemical accidents or releases occurring between the last accident history report submittal(January 15)and the annual performance review and evaluation submittal(June 30)): None 7) Summary of each Root Cause Analysis(Section 450-8.016(C))including the status of the analysis and the status of implementation of recommendations formulated during the analysis(450-8.030(B)(2)(iv)): No events triggered this requirement since the previous Annual Performance Review and Evaluation submittal. 8) Summary of the status of implementation of recommendations formulated during audits,inspections,Root Cause Analyses,or Incident Investigations conducted by the Department(450-8.030(B)(2)(v)): APCI submitted proposed remedies to the audit findings to Contra Costa County before 16 August 2004. All outstanding actions of this audit were completed by 16 August 2005. In addition, CCCHS completed an unannounced inspection on 18 January 2006. A response to proposed remedies from three Action Items was accepted by CCCHS on March 27`h 2006. APCI has completed the remedies asoposed for each Action Item. 9) Summary of inherently safer systems implemented by the source including but not limited to inventory reduction(i.e., intensification)and substitution(450-8.030(B)(2)(vi)): (1) Plant uses aqueous ammonia rather than anhydrous ammonia in its emission control system. This he reduce the offsite consequence of an ammonia release. (22)Plant is designed without a liquid hydrogen backup system. This reduces the inventory of hazardous chemicals on-site. 10) Summarize the enforcement actions (including Notice of Deficiencies, Audit Reports, and any actions turned over to the Contra Costa County District Attorney's Office) taken with the Stationary Source pursuant to Section 450-8.028 of County Ordinance 98-48(450-8.030(13)(2)(vii)): No enforcement actions were taken since the revious Annual Performance Review and Evaluation Submittal. 62 Title: INDUSTRIAL SAFETY ORDINANCE ANNUAL PERFORMANCE REVIEW AND EVALUATION C O f� T R A COSTA Document No.: Date Effective: Page: 2 of 2 HEALTH SERVICES HAZARDOUS MATERIALS PROGRAMS Policy Document Owner: Approved By: Revision No.: 1 11) Summarize total penalties assessed as a result of enforcement of this Chapter (450-8.030(3)): No penalities have been assessed against this facility since the previous Annual Performance Review and Evaluation Submittal. 12) Summarize the total fees, service charges, and other assessments collected specifically for the support of the ISO(450-8.030(B)(4)): CalARP Program fees for these eight facilities are-$325,581 the Risk Management Chapter of the Industrial Safety Ordinance fees are- $296,179. 1 ) Summarize total personnel and personnel years utilized by the jurisdiction to directly implement or administer this Chapter (450-8.030(B)(5)): 4000 hours were used to auditlinspect and issue reports on the Risk Management Chapter of the Industrial Safety Ordinance. 14) Copies of any comments received by the source (that may not have been received by the Department) regarding the effectiveness of the local program that raise public safety issues(450-8.030(B)(6)): None 15) Summarize how this Chapter improves industrial safety at your stationary source(450-8.030(B)(7)): Air Products is committed to the safe operation of our facilities and has implemented applicable reguirements outlined in the ISO, as well as the CaIARP regulation. The Human Factors pro am is implemented, and has helped the site maintain a salty record ofno recordable or Lost Time Iniuries since the last plan submittal. Likewise, there have been no events that resulted in offsite impact. This Chapter has helped reinforce the need to maintain and follow a structured sa(etyprogram to help ensure the safety of our employees and the communities in which we operate. v. 16)List examples of changes made at your stationary source due to implementation of the;industrial Safety Ordinance(e.g.,recommendations from PHA's,Compliance Audits,and Incident Investigations in units not subject to CaIARP regulations;recommendations from RCA's)that significantly decrease the severity or likelihood of accidental releases: Air Products has developed and implemented a Human Factors Program as required by the Industrial SafeN Ordinance. Per the request ofCCCHS. the site clarified issues associated with the Management of Change by creating a site-specific Tier IV document. In addition, the Air Products Corporate Assurance Department formulated an internal audit template developed specifically to verify compliance to the elements of the CCC ISO program. 17) Summarize the emergency response activities conducted at the source(e.g.,CWS or CAN activation)in response to major chemical accidents or releases: There were no emergency response activities to this site since the previous Annual Performance Review and Evaluation Submittal. 63