Text For Citation: 01 Item/Group: 006 Hazard:

29 CFR 1910.119(e)(1): The process hazard analysis did not identify the hazards involved in the process: (a) On or about May 12, 2021, at Limetree Bay Refining, LLC., Delayed Coker Unit (DCU) - The employer's 2020 UNIT 8500 Coker Unit Re-do Process Hazard Analysis Final Report failed to identify, evaluate, and control the hazards of quenching coke drums. The PHA did not identify, evaluate and control the hazard of high levels in Coke Drums (D-8501/2/3/4) during quenching. Failure to control hazards of excessive quench water resulted in overfill/overpressure of Coker Unit equipment, and liquid carryover to flare, exposing employees to fire, explosion, and toxic release hazards. (b) On or about May 12, 2021, at Limetree Bay Refining, LLC., Delayed Coker Unit (DCU) - The employer's 2020 UNIT 8500 Coker Unit Re-do Process Hazard Analysis Final Report failed to evaluate and control the hazards of quenching coke drums. The PHA identified the hazard of adding too much quench water to the Coke Drums but did not evaluate and specify controls for the hazards of leaving the 3-inch bypass valve around the quench water valve (FV-4067) open. Failure to control hazards of excessive quench water resulted in overfill/overpressure of Coker Unit and liquid carryover to flare, exposing employees to fire, explosion, and toxic release hazards. (c) On or about May 12, 2021, at Limetree Bay Refining, LLC., Delayed Coker Unit (DCU) - The employer's 2020 UNIT 8500 Coker Unit Re-do Process Hazard Analysis Final Report failed to evaluate and control the hazards of the DCU process. The PHA identifies low temperature and loss of feed to Coke Drums (D-8501A/B/C/D) upon Coker Feed Furnace (H-8501A/B) trip but did not evaluate and specify controls for the hazards of an abnormal Coke Drum. Failure to evaluate and control hazards of abnormal coke drum caused overfill/overpressure of Coker Drum, liquid carryover to flare, and exposed employees, contractors, and off-site communities to fire explosion, and toxic release hazards. (d) On or about May 12, 2021, at Limetree Bay Refining, LLC., Delayed Coker Unit (DCU) - The employer's 2020 UNIT 8500 Coker Unit Re-do Process Hazard Analysis Final Report failed to identify, evaluate, and control the hazards of processing lighter crude. Failure to evaluate changes to crude on DCU unit affected safe operation of the unit, and exposed employees and contractors to fire explosion, and toxic release hazards. (e) On or about May 12, 2021, at Limetree Bay Refining, LLC., Flare No. 8 - the employer's 2020 UNIT 7940 - No. 8 Flare FINAL Re-do Process Hazard Analysis Report failed to evaluate and control the hazards involved in the Flare No. 8 process. The PHA failed to evaluate high flow overpressure scenarios from the upstream Coker Unit, and specify controls for hazards of overfilling of FCC LP Flare Knockout Drum (D-7941), and Coker Flare Knockout Drum (D-8702). Failure to control hazards of liquid carryover to flare during abnormal coke operations exposed employees to flare rainout, fire, and toxic release hazards.