MEMPHIS REFINERYSTANDARD PROCEDURES

Revision Date
Original Date: Sept. 2001
2008
2009
2010
2011 / River Dock
Hydrogen Sulfide Handling
H2S / Annual Certification Date
2008
2009
2010
2011

It is the Dock PIC responsibility to inform barge personnel of the possibility of high H2S in certain products being transferred. All barge personnel are responsible to monitor H2S levels in product being transferred and to inform the Dock PIC of any reading at or above 10ppm. It is the barge company’s responsibility to provide standby personnel and breathing air if needed. The riverdock will follow the refinery policy pertaining to H2S exposure

I. PURPOSE:

  • This guideline defines the minimum requirements that must be in place to protect Valero employees, visitors and contractor personnel from potential exposure to hydrogen sulfide (H2S) while in the Operating Area of the Memphis Refinery.

II. SCOPE :

  • This policy applies to all Valero refining employees, contractors and visitors within the operating area of the Memphis Refinery.
  • This policy does not apply to Memphis Fire Department emergency response personnel.
  • This policy does not apply to non-contracted services from railroad or municipal personnel.
  • This policy provides information about
  • Properties of Hydrogen Sulfide.
  • Personal H2S monitors in the operating area.
  • Safe work requirements when potential exposure to H2S exists
  • Fixed area H2S monitors
  • Response to H2S alarms
  • Training requirements
  • First Aid

III. REFERENCES

  • Valero Corporate Safety & Health Hydrogen Sulfide Safety Guideline
  • Valero Memphis Refinery Plant Wide Emergency Alarm System Policy
  • ANSI Z390.1-1995 (R2001) Accepted Practices for H2S Safety Training Program

Pg. 1

RD H2S Handling.doc March 26, 2008

MEMPHIS REFINERY STANDARD PROCEDURES

VI. DEFINITIONS:

  • Operating Area –All areas within processing units, oil movement areas, docks, and designated loading racks. The exceptions are:
  • Inside or around the Valero Fire Station
  • New construction sites, which are physically separated from the operating units, i.e., not intermingled with operating equipment.
  • Contractor –Any employee of a company that Valero has a contract with. This includes contractors and sub-contractors. Contract companies with personnel within the Operating Area of the refinery will be required to provide their own personal H2S monitors to their employees and provide calibration records to Valero upon request.
  • Visitor – A person that Valero or its contractors or sub-contractors have a written contract with. A Valero Manager or their designee may loan an H2S monitor to a visitor.

V. PROPERTIES OF H2S

  • Hydrogen sulfide is a flammable, toxic, colorless, and corrosive gas. When first encountered, low concentrations of H2S are recognized by the smell of rotten eggs. However, prolonged exposure to low concentrations can decrease the sense of smell and may irritate the eyes. Also, the odor is not more intense with higher concentrations. Sense of smell should NOT be depended upon to detect any level of H2S.
  • H2S gas is soluble in water and oil and may be present in any equipment. A release may occur when equipment is drained. Proper precautions (i.e. breathing air and barricading) shall be taken when draining equipment known to contain H2S.
  • The Occupational Safety and Health Administration (OSHA) has established the permissible exposure limit (PEL) of 10 ppm for the 8-hour time-weighted average, and the short-term exposure limit (STEL) of 15 ppm for 15 minutes with an IDLH of 100 ppm.
  • Human physical responses to various PPM concentrations of hydrogen sulfide have been reported as follows:
  • 10-ppm Eye irritation.
  • 100 Coughing, headache, dizziness, eye irritation, loss of sense of smell.
  • 200-300 Marked eye inflammation and respiratory tract irritation after 1 hour.
  • 500-700 Loss of consciousness and possibly death in 30 minutes to one hour.
  • 700-1000 Rapid loss of consciousness, cessation of respiration and death.
  • >1000 Unconsciousness in seconds, with early cessation of respiration and death in a few minutes unless victim is removed from exposure and breathing restored. Death may result regardless.

VI.PERSONAL H2S MONITORS

  • All persons in the operating area of the refinery must wear a personal H2S monitor. Monitors must be worn in the breathing zone of the user (i.e., within 18 inches of the nose) with the sensor clear of any obstructions. The devices must be intrinsically safe for use in Class I, Division I locations and must have both audible and visual alarms that activate at 10 parts per million H2S.
  • Valero has selected the BW Technologies Gas Alert Clip Extreme 3-year H2S monitor as its monitor of choice. This monitor is not the only acceptable monitor at the Memphis Refinery. Contractors are allowed to choose a monitor that meets or exceeds Valero expectations.
  • Department Directors may waive the requirement for personal monitor use particularly during new construction projects or turnarounds, once a unit has been gas freed and tested, potential H2S hazards have been eliminated, and a program is in place to monitor the area for H2S. However, during non-routine operations, special precautions should be taken to prepare for the presence of H2S in unexpected areas. The deviation from safe work practice form must be completed to document the decision to waive the requirement. During off-shift hours, the Shift Foreman is authorized to sign the deviation form with a verbal approval from management.
  • Personal H2S monitors must be bump tested, function tested, calibrated, and maintained as per original equipment manufacturer (OEM) specifications. It is the responsibility of individuals to test their monitor according to the manufacturer’s recommendations and Valero Memphis Refinery policy. The Memphis Refinery requires the user to bump test the sensor’s response by exposing the detector to a target gas concentration that exceeds the low alarm set point. As a minimum bump testing is required every 30 days. Function testing is required prior to each day’s use.
  • Test stations are available in every control room for use by Valero employees. Additional test gas for the test stations is available in the Warehouse. The BW Tech Gas Alert Extreme H2S monitors also have a test button to perform a function test before each day’s use.
  • Valero employees will obtain their personal H2S monitors from the Warehouse. Valero employees are not allowed to loan or provide H2S monitors to a contractor. Contractors are not authorized to use the Valero bump test stations or calibration gas. Contractors are expected to provide their own bump testing capabilities for their employees in accordance with the manufacturer’s specification for their monitors.

VII. SAFE WORK REQUIREMENTS

  • Operations
  • When taking samples with a potential exposure to high concentrations of H2S, where the concentration in the breathing zone would be 10 ppm or greater, hose line breathing air units with egress hip pack must be used.
  • When performing work that may cause a release of H2S or when working on open equipment containing H2S, hose line breathing air units with egress hip pack must be used. Temporary barricades utilizing red “Danger, Do Not Enter”, barricade tape must be hung on all four sides of the area. No one is to enter the barricaded area without proper respiratory protective equipment.
  • Maintenance and Contractors
  • Prior to performing any work in the Memphis Refinery the Valero permit policy must be complied with. When performing work that may cause a release of H2S or when working on open equipment containing H2S, hose line breathing air units with egress hip pack must be used. This could include tightening a leak or opening a line or equipment that is known to, or may contain, H2S. Temporary barricades utilizing red “Danger, Do Not Enter”, barricade tape must be hung on all four sides of the area. No one is to enter the barricaded area without proper respiratory protective equipment.
  • NOTE: Efforts to purge or drain equipment to a closed system should be considered prior to opening equipment to the atmosphere and maintenance being performed.
  • Other Personnel
  • All others will notify the unit operator working the board before entering an operating unit and obtain the proper permit or permission before entering or performing work in the operating area.

VIII. FIXED AREA H2S MONITORS

  • Fixed area H2S monitors are located in the Cryo, SRU I & II, and Sats Gas Units. The H2S Alarm on the fixed monitors are set to activate at 10 ppm with an electronic wail that alternates followed by a voice message – “H2S has been detected in the area. Leave this unit and go to the upwind side.” This alarm is a local alarm. This may be sounded in the Cryo, SRU I & II, or the Sats Gas units. In addition control rooms equipped with E2010 control panels (Alky, Crude, CCR, FCC) can manually trigger the unit H2S alarms.
  • These fixed area H2S monitors are calibrated and maintained by the Valero Maintenance Department as per original equipment manufacturer (OEM) specifications.

IX. RESPONSE TO H2S ALARMS

  • Personal Monitors
  • If a personal H2S alarm is activated the person wearing the monitor and anyone in their immediate area should evacuate the area by going cross wind and then upwind to a safe location to notify their supervisor. Personnel will wait for operations to check the area with a hand held meter and approve the work to continue.
  • Fixed Area Monitors
  • Whenever a concentration of H2S above 10 ppm is detected in a unit with fixed monitors, a unit alarm is sounded in the affected unit(s). If a fixed area H2S alarm is activated, all non-operational personnel in the unit should evacuate the area by going cross wind and then upwind to a safe location and notify their supervisor that they are safe. Unit operators will evacuate to the control room and notify the Shift Foreman when all Operation personnel are safe and accounted for.
  • The personnel working in the unit will notify their supervisor so their supervisor can notify the Shift Superintendent that their personnel are accounted for. Personnel will wait for operations to check the area with a hand held meter and approve the work to continue by sounding the All Clear Alarm.
  • Response to a confirmed H2S leak above the PEL
  • Unit Operators / Unit Superintendents and / or Emergency Response Personnel (minimum 2) will enter an area found to be above the PEL using thirty (30) minute Self Contained Breathing Apparatus (SCBA) and a hand held meter. One person with breathing air is to remain a safe distance up wind as back up. No one is to enter an area in alarm condition with out a back up. Once the area is clear of H2S the Lead Operator working the board will notify the Shift Supervisor and all units that may be affected that the area is clear by sounding the All Clear Alarm, by telephone and radio.

X. TRAINING REQUIREMENTS

  • The Valero Memphis Refinery will ensure that Valero employees in the operating areas receive pre-employment, annual and as-needed training for H2S and the use of the personal H2S monitors. This training will meet or exceed the ANSI Z390.1-1995 (R2001) Accepted Practices for Hydrogen Sulfide (H2S) Safety Training Program.
  • Contractors at the Memphis Refinery will be expected to meet or exceed Valero policy for H2S training. Contractor employees will be expected to provide documentation upon request to verify H2S awareness training and training on the proper use of their personal H2S monitors.

XI. FIRST AID

  • Victims exposed to hydrogen sulfide gas do not pose substantial risks of secondary contamination to personnel outside the Hot Zone. However, contacting or breathing vapors from clothing heavily soaked with hydrogen sulfide-containing solution could contaminate personnel.
  • Hydrogen sulfide is a highly toxic gas that can produce extremely rapid central nervous system and respiratory suppression. It is also an irritant affecting skin and mucous membranes. There is no proven antidote for hydrogen sulfide poisoning.
  • Treatment generally consists of support of respiratory and cardiovascular functions. Immediately remove victim from H2S source to a well-ventilated area. Call for medical assistance to administer Oxygen as needed and to transport the victim to a Medical Facility. Check airway, breathing, and circulation of victim. If breathing and circulation are absent, immediately start CPR. If breathing only is absent, start rescue breathing. If victim is breathing place fresh breathing air on victim until Oxygen is available.
  • The Valero Medical Department and Refinery Industrial Hygienist will communicate with the outside Medical Personnel and Ambulance personnel in the event of a Valero employee, contractor or visitor exposure.

Pg 1

RD H2S Handling.docMarch 26, 2008