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Memphis Refinery River Dock Operations Manual March 2008

River DockOperations Manual

Issued April 17, 2008

Valero Refining Company – Tennessee, L.L.C.

document.doc Revised: April 17, 2008 1

Table of Contents

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Memphis Refinery River Dock Operations Manual March 2008 Table of Contents

Table of ContentsSection

Sub-Section Description

100 General Description200 Process Overview -- Coast Guard Compliance Information

201 Process Overview – Marine Vapor Emission Control Unit300 Process Variables400 Process Chemistry500 Commissioning Activities600 Startup Procedures700 Normal Operations

701702703704705706707

River Dock GeneralBarge UnloadingBarge LoadingMarine Emissions Control SystemProduct TransfersEquipmentProhibited Activities

800 Shutdown Procedures900 Special Operations1000 Emergency Procedures

1001 River Dock Area Fire Response1002 Spill Response Procedure1003 Procedure for Electrical Power 1004 Procedure for Inclement Weather1005 Emergency Procedure for Handling Personnel Injuries1006 Security Procedures

1100 Health Safety and Environmental Information1101 River Dock Area safe work practices1102 Chemical Safety1103 River Dock leaks1104 Housekeeping1105 Safety systems and equipment1106 Static Electricity1107 Marine Vapor Emission Control Unit Safety

1200 Mechanical Description1300 Utilities1400 Chemicals1500 Appendices

1510 Tables1511 Forms and Log Sheets1512 Procedures Catalogue1513 Glossary1514 Drawings1515 MSDS

1600 Amendments


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Memphis Refinery River Dock Operations Manual March 2008 Sec 100 – General Description

Section 100 General Description

100.1 Introduction:

100.1.1 This River Dock Operations Manual describes the proper procedures for operation of the Barge Terminal Facility at the Memphis Refinery including the Marine Emission Control System.

100.2 Barge Terminal Facility {33 CFR Section 154.310.(a)(1)}

100.2.1 Memphis Refinery River Dock Marine Transfer Facility is located immediately north of the mouth of Nonconnah Creek on the east bank of McKellar Lake approximately 6.2 miles from the Mississippi River (mile 726) on the Tennessee Chute. ► The North Dock is located approximately 250 yards north of the mouth of

Nonconnah Creek. ► The South Dock is located approximately 125 yards south of the North Dock.

100.2.2 Memphis Refinery River Dock Marine Transfer Facility consists of two barge docks, the North Dock and the South Dock. {33 CFR Section 154.310.(a)(2)}► Each barge dock consists of a floating dock barge captured between two 16-foot

diameter sheet pile mooring cells. ► Each floating dock barge is connected to a fixed shore platform via a hinged pipe

bridge, which also contains a personnel access walkway. ► The design of each dock area allows the floating dock barge and pipe bridge

assembly to continuously and automatically adjust to varying river stage heights. ► Each dock has smaller mooring dolphins on either side of the 16-foot diameter cells

for securing moored barges during transfer operations.► The docks are located approximately 6.2 miles from the Tennessee Chute (mile 726)

of the Mississippi River. ► Both docks have shelters available on the dock barge with viewing windows and

both docks have all-weather offices located on shore. The North Dock office has telephone, water, and restroom facilities. {33 CFR Section 154.310.(a)(10)}

100.2.3 Terminal operation schedule {33 CFR Section 154.310.(a)(3)}► The barge terminal operates 24 hours a day, 7 days a week.

100.2.4 Terminal operating capacity {33 CFR Section 154.310.(a)(4)}► The River Dock facility is composed of a North Dock and a South Dock.► The two docks allow a maximum of six (6) 300-foot deep well pump barges to be

loaded simultaneously. The maximum of six barges would be accomplished by having four (4) at one dock and two (2) at the other.


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► The North Dock can accommodate up to four (4) 300-foot deep well pump barges simultaneously.

► The South Dock can accommodate up to four (4) 300-foot deep well pump barges simultaneously with the south end of the North Dock open.

100.2.5 Terminal personnel responsibilities {33 CFR Section 154.310.(a)(6)}► The minimum number of people on duty during any transfer operation is three: a

Dock PIC, a Tankerman PIC and a Pumper. The Dock PIC coordinates the transfer operations, operates the loading metering systems and supervises all activities at the dock. Other Dock PIC duties include:♦ Ensuring that all vessels are properly docked and securely moored ♦ Assisting the Tankerman PIC in making the product and vapor hose

connections♦ Coordinating with inspection companies and shore Tankerman PIC companies♦ Ensuring that any required barge gauges are completed♦ Start-up and operation of the vapor emission control system♦ Notifying the Pumper to begin the transfer of product♦ Ensures all safety and environmental regulations are met

► River Dock responsibilities♦ The Dock PIC and Tankerman PIC must complete a pre-transfer conference

and sign the Declaration of Inspection prior to beginning any oil transfer. At least one Tankerman PIC must be present during the product transfers, and can only be responsible for one transfer operation. Each barge is assigned a Tankerman PIC except when using a dummy line on one barge to load a barge abreast of it. All piping on a barge that is involved in the transfer must have a valve on each end. The Tankerman PIC is responsible for all transfer activities on the barges. These activities include the following:

All barge paperwork is present and up to date Hooking up transfer hoses from the dock to the barge Switching of product from one compartment to another Ensuring barges are loaded to the proper draft as required Closing the transfer to the barge Sealing barge compartments for shipment as required

♦ The River Dock PIC is also responsible for recording all inspections, transfers and activities using the appropriate Logs and Forms. In particular:

Every transfer is recorded using the Form RD-6 River Dock Daily Log. All dock activities are recorded in the Form RD-7 River Dock Log Book. Other forms are noted in Section 1511 Forms and Log Sheets.

► Tankerman PIC in charge of the loading and unloading operations at the river dock must meet the requirements of the USCG for a licensed Tankerman for handling Class “A” products. Tankermen not on Memphis Refinery payroll are required to hold a valid Tankerman license for handling Class “A” products.


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► The Pumper at the refinery tank field works with the Dock PIC, ensuring that the proper tank is lined up for the transfer, and obtaining tank gauge readings before and after the transfer. If the pump start is not automatic from the dock, the Pumper is also responsible for starting and stopping the transfer pump. The Pumper and Dock PIC are in constant radio communications during the transfer operations.

100.2.6 Responsibilities of Watchmen {33 CFR Section 154.310.(a)(8)}► Surveillance of vessels involved in loading or unloading operations at this facility

will be maintained by the on duty Tankerman PIC for each barge involved in a transfer operation.

► The Dock PIC will be responsible for the security of the vessel and for keeping unauthorized persons off the vessel.

► Whenever an unmanned vessel containing more than the normal clingage, unpumpable bilge, or sump residues in any compartment is moored at the facility, security of that vessel will be maintained as follows:♦ Dock PIC will be on duty at all times at the facility and will be responsible for

the security of such vessels.♦ Security camera:

A Security camera is available to the Dock PIC in the Control room for remote monitoring of any dock activities.

During such times that a Dock PIC is not present at the facility, the facility will be kept under surveillance with a video camera, which has a monitor at the manned security gate at the entrance to the refinery. If the security guard monitors any breach of security at the facility, the Oil Movement Superintendent or Refinery Shift Superintendent will be immediately notified and respond to the situation accordingly.

100.2.7 Communications {33 CFR Section 154.310.(a)(9)}► Two-way voice communication between the Tankerman, the Dock PIC, and the

Pumper involved in the transfer operation is maintained via intrinsically safe portable two-way radios. A radio is issued to the Tankerman by the Dock PIC prior to transfer operations and remains with the Tankerman until the transfer is complete.

► Telephone communication is available in the Dock Office as is a marine radio, which can be used by the Dock PIC to communicate with marine vessels.

100.2.8 Any product movement line that can move product to the River Dock area must be separated from the refinery by a series of in-line valves. ► The location of the valves is such that in the event of a significant equipment failure

at the River Dock area, product flow can be quickly controlled. ► All valves are in-line, and each line is clearly marked to indicate the product that the

line contains.


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♦ The first such valve is at the refinery’s loading / unloading stations. A 90º high – performance, quick shut-off butterfly valve, controls the flow at the North Dock Facility.

♦ The valves to the South Dock are 90º, quick shut-off ball valves. ♦ In either case, line flow control can be managed promptly and any discharge can

be minimized.

100.2.9 There are nine different lines that can transfer products from the refinery to the River Dock area. There is one line that is dedicated to transferring spent caustic to the loading facility. ► Each of these transfer lines has a valve at the short platform that can be quickly

closed to stop the flow of product in case of a line rupture. ► The transfer lines vary in size from 6” – 12” at the River Dock area. The barge-

loading rate varies from 2500 – 5000 bbl/hr.

100.3 Marine Emission Control System {33 CFR Section 154.310.(b)(2)}

100.3.1 The Marine Emission Control System (MECS) operates in conjunction with loading and unloading operations on the North Dock. At this time the South Dock does not have a MECS and therefore is limited in the type of cargo that may be loaded or unloaded at that facility.

100.3.2 This manual describes the proper procedures for start-up, normal operation and shut-down of the Marine Emission Control System (MECS). Included are descriptions of the MECS equipment and processes, components, start-up procedures, and key safety concerns.

100.3.3 Marine Emission Control System training, start-up, operation and shut-down:► The services of a competent on-site technical consultant are essential for initial

training, start-up and operation of the system.► This manual is provided as a guide for qualified personnel trained in the operation of

the MECS. A copy of the manual must always be on hand at the equipment site.

100.4 Applicable federal, state, and local oil or hazardous material pollution laws and regulations: {33 CFR Section 154.310.(a)(19)}

100.4.1 FEDERAL:► OIL Pollution Act of 1990 (OPA 90)

♦ Any oil or hazardous material spill that can reach navigable waters of the United States must be reported immediately to the National Response Center (NRC) and the U.S. Coast Guard.

♦ Elements of liability: The responsible party for each vessel or facility from which oil is discharged, or which poses the substantial threat of a discharge of oil,


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or upon the navigable waters or adjoining shorelines or the exclusive economic zone is liable for the removal costs and damages.

♦ Limits of liability: $75,000,000 plus unlimited removal costs: onshore facilities, and deep water ports.

♦ Failure to report: The fines for failure of timely reporting have been raised from $10,000 and one year in prison to $250,000 for individuals and $500,00 for corporations. The potential jail term has been extended to 5 years.

► The Federal Water Pollution Control Act (FWPCA):♦ As amended, prohibits the discharge of oil or oily waste into or upon the

navigable waters of the United States, or the water of the contiguous zone, if such discharge causes a film or sheen upon or a discoloration of the surface of the water, or causes a sludge or emulsion beneath the surface of the water. Violators are subject to a penalty of at least $5,000.

► The Refuse Act of 1989:♦ Prohibits the discharge from ship or shore of any refuse matter of any kind,

except liquid sewage, into U.S. waters. A violation of the law is a criminal offense and is punishable by a fine from $500 to $2,500 and/or 30 days to one year imprisonment.

100.4.2 STATE:► The Water Control Act of 1971, State of Tennessee:

♦ Sets forth, that an operator of a facility discharging water into streams of the state must obtain a permit. The quality of water is identified with “oil” being listed under the term of “other water.” This act is applicable for any operator that, as a result of that operation, discharges effluent into a stream.

► We are also required to notify the State of Tennessee regarding any event which requires reporting to other agencies.

100.4.3 LOCAL:► There are no local laws other than state and federal laws that are directed to oil

spills. The Memphis Fire Department requires that they be notified if there is a spill that presents a fire hazard.

100.5 Shielding portable lighting authorized by the COTP under 154.570(c): {33 CFR Section 154.310.(a)(20)}100.5.1 Stationary and portable lighting is properly shielded and located so as not to interfere

with navigation.

100.6 Facilities that conduct tank cleaning or stripping operations, a description of their procedures: {33 CFT Section 154.310.(a)(23)}100.6.1 Valero Refining Corporation does not conduct tank cleaning or stripping operations at

its marine facility.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 200 –Process Overview

Coast Guard Compliance Information

Section 200 Process Overview – Coast Guard Compliance Information

200.1 The following information has been provided in accordance with 33 CFR Section 154.310 Operations Manual. In order to ensure connection to the appropriate requirements, the text of the regulations are included in the left column below (italics) and the compliance information in the right column. In some cases, the compliance information will reference another portion of this manual both electronically (when computer document is viewed) or by section reference.

Sec. 154.310 Operations manual: Contents.(a) Each operations manual required by Sec. 154.300 must contain:

(a)(1) The geographic location of the facility; Refer to 100.2 Barge Terminal Facility

(a)(2) A physical description of the facility including a plan and/or plans, maps, drawings, aerial photographs or diagrams, showing the boundaries of the facility subject to Coast Guard jurisdiction, mooring areas, transfer locations, control stations, wharfs, the extent and scope of the piping subject to the tests required by Sec. 6.170(c)(4) of this chapter, and the locations of safety equipment. For mobile facilities, a physical description of the facility;

Refer to Refer to 100.2 Barge Terminal Facility for Physical DescriptionRefer to Section 1514 Drawings for associated maps and diagrams.Refer to River Dock Facility USCG Jurisdiction for an Aerial Photograph of Dock Area showing USCG boundaries of the facility.

(a)(3) The hours of operation of the facility; Refer to 100.2.3 Terminal Operation Schedule

(a)(4) The sizes, types, and number of vessels that the facility can transfer oil or hazardous material to or from simultaneously;

Refer to 100.2.4 Terminal Operating Capacity

(a)(5) For each product transferred at the facility:(a)(5)(i) Generic or chemical name; and(a)(5)(ii) The following cargo information:(a)(5)(ii)(a) The name of the cargo as listed under

appendix II of annex II of MARPOL 73/78, Table 30.25-1 of 46 CFR 30.25-1, Table 151.05 of 46 CFR 151.05-1, or Table 1 of 46 CFR part 153.

(a)(5)(ii)(b) A description of the appearance of the cargo;

(a)(5)(ii)(c) A description of the odor of the cargo;(a)(5)(ii)(d) The hazards involved in handling the

cargo;

See the table Table RD-A Products Transferred at River Dock Terminal

The Material Safety Data Sheets that identify the hazards involved in handling each cargo are also referenced in table Table RD-A Products Transferred at River Dock Terminal and attached in Section 1515 MSDS.

a)(5)(ii)(e) Instructions for safe handling of the cargo;

Refer to Section 1100 Health Safety and Environmental and 1100.3 Precautions for the Safe Handling of Cargo


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(a)(5)(ii)(f) The procedures to be followed if the cargo spills or leaks, or if a person is exposed to the cargo; and

Refer to 1002 Spill Response ProcedureAlso Refer to:

Table RD-A Products Transferred at River Dock Terminal for specific information about a particular cargo involved.

Forms\Form RD-2 Spill Response Notification.doc

(a)(5)(ii)(g) A list of fire fighting procedures and extinguishing agents effective with fires involving the cargo.

Refer to 1001 Fire Response

(a)(6) The minimum number of persons on duty during transfer operations and their duties;

Refer to 100.2.5 Terminal Personnel Responsibilities

(a)(7) The name and telephone number of the qualified individual identified under Sec. 154.1026 of this part and the title and/or position and telephone number of the Coast Guard, State, local, and other personnel who may be called by the employees of the facility in an emergency;

Refer to Table RD-B Emergency Notification

(a)(8) The duties of watchmen, required by Sec. 155.810 of this chapter and 46 CFR 35.05-15, for unmanned vessels moored at the facility;

Refer to 100.2.6 Responsibilities of Watchmen

(a)(9) A description of each communication system required by this part;

Refer to 100.2.7 Communications

(a)(10) The location and facilities of each personnel shelter, if any;

Refer to 100.2.2 Barge Terminal Facility

(a)(11) A description and instructions for the use of drip and discharge collection and vessel slop reception facilities, if any;

Procedures for the use of drip collection are included in the Loading and Unloading Procedures referenced in: Section 702 Barge Unloading , Section 703 Barge Loading

This facility does not receive vessel slop from loading/unloading vessels.

(a)(12) A description and the location of each emergency shutdown system;

Refer to: Section 1000.6 Description and location of each Emergency Shutdown system/divide

(a)(13) Quantity, types, locations, and instructions for use of monitoring devices if required by Sec. 154.525;

No monitoring devices required at this facility.


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(a)(14) Quantity, type, location, instructions for use, and time limits for gaining access to the containment equipment required by Sec. 154.545;

Refer to 1002 Spill Response Procedure

Also refer to Table RD-C Emergency Dock Equipment List

(a)(15) Quantity, type, location, and instructions for use of fire extinguishing equipment required by Sec. 154.735(d) of this part;

Refer to 1001.3 Material and Equipment in Section 1001 River Dock Area Fire Response

(a)(16) The maximum allowable working pressure (MAWP) of each loading arm, transfer pipe system, and hose assembly required to be tested by Sec. 156.170 of this chapter, including the maximum relief valve setting (or maximum system pressure when relief valves are not provided) for each transfer system;

The maximum allowable working pressure of each transfer pipe system and hose assembly (Valero Energy Corporation has no loading arms) is 150 psig.

The maximum system pressure for each transfer system is less than 150 psig. The static head, which can be developed by all barge-loading pumps in the tank farm, is less than 150 psig.Refer to procedure: RD Hose Inspection and Replacementfor information on the specific inspection and record keeping process.

(a)(17) Procedures for:(a)(17)(i) Operating each loading arm including

the limitations of each loading arm;

Valero Energy Corporation’s marine facility contains no loading arms.

(a)(17)(ii) Transferring oil or hazardous material; Procedures for transferring oil or hazardous materials are included in the Loading and Unloading Procedures referenced in: Section 702 Barge Unloading , Section 703 Barge Loading

Also refer to specific procedures: RD Barge Loading North DockRD Barge Loading South DockRD Barge Unloading North DockRD Barge Unloading South Dock

(a)(17)(iii) Completion of pumping; and Procedures for completion of pumping in the transferring of oil or hazardous materials are included in the Loading and Unloading Procedures referenced in: Section 702 Barge Unloading , Section 703 Barge Loading

Also refer to specific procedures: RD Barge Loading North DockRD Barge Loading South DockRD Barge Unloading North DockRD Barge Unloading South Dock


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(a)(17)(iv) Emergencies; Refer to: Section 1000 Emergencies(a)(18) Procedures for reporting and initial

containment of oil or hazardous material discharges;

Refer to: 1002 Spill Response Procedure and Form RD-2 Spill Response Notification

(a)(19) A brief summary of applicable Federal, state, and local oil or hazardous material pollution laws and regulations;

Refer to: 100.4 Applicable Federal, State, and Local Oil or Hazardous Material Pollution Laws and Regulations:

(a)(20) Procedures for shielding portable lighting authorized by the COTP under Sec. 154.570(c); and

Refer to: 100.5 Shielding Portable Lighting

(a)(21) A description of the training and qualification program for persons in charge.

Refer to procedure RD Training and Qualification for PIC

(a)(22) Statements explaining that each hazardous materials transfer hose is marked with either the name of each product which may be transferred through the hose or with letters, numbers, symbols, color codes or other system acceptable to the COTP representing all such products and the location in the Operations Manual where a chart or list of symbols utilized is located and a list of the compatible products which may be transferred through the hose can be found for consultation before each transfer; and

Each chemical service transfer hose at Valero Energy Corporation’s marine facility is marked with the words “HAZMAT Service.”.

Each transfer hose, which is intended to handle oil products, is marked with the words “Oil Service.”

(a)(23) For facilities that conduct tank cleaning or stripping operations, a description of their procedures.

Valero Energy Corporation does not conduct tank cleaning or stripping operations at its marine facility (Section 100.6).

(b) lf a facility collects vapors emitted from vessel cargo tanks for recovery, destruction, or dispersion, the operations manual must contain a description of the vapor collection system at the facility which includes:

(b)(1) A line diagram or simplified piping and instrumentation diagram (P&ID) of the facility's vapor control system piping, including the location of each valve, control device, pressure-vacuum relief valve, pressure indicator, flame arrester, and detonation arrester; and

Refer to P&ID Diagram: MECS P&ID

(b)(2) A description of the vapor control system's design and operation including the:

Refer to: 100.3 Marine Emission Control System Section 704 Marine Emissions Control System

(MECS) Operation


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(b)(2)(i) Vapor line connection; Refer to: RD MECS Equipment Design Table

(b)(2)(ii) Startup and shutdown procedures; Procedures for MECS Startup and Shutdown are referenced in: Section 704 Marine Emissions Control System

(MECS) Operation

Also refer to specific procedures: RD MECS StartupRD MECS Pre Start Checklist RD MECS System Startup Interlocks

(b)(2)(iii) Steady state operating procedures; Procedures for MECS Steady state operation are referenced in: Section 704 Marine Emissions Control System

(MECS) Operation

Also refer to specific procedures: RD MECS Equipment ListRD MECS Instrument SetpointsRD MECS OperationRD MECS Maximum Flow RatesRD MECS Panel DescriptionRD MECS Troubleshooting

(b)(2)(iv) Provisions for dealing with pyrophoric sulfide (for facilities which handle inerted vapors of cargoes containing sulfur);

This facility does not handle pyrophoric sulfide cargoes.

(b)(2)(v) Alarms and shutdown devices; and Procedures for Alarms and shutdown devices are referenced in: Section 704 Marine Emissions Control System

(MECS) Operation

Also refer to specific procedures: RD MECS Shutdown AlarmsRD MECS Analyzer Alarm Shutdown

(b)(2)(vi) Pre-transfer equipment inspection requirements.

Procedures for Pre-transfer equipment inspection are referenced in: Section 704 Marine Emissions Control System

(MECS) Operation

Also refer to specific procedures: RD MECS Pre Transfer ChecklistRD MECS Supplemental Declaration of InspectionRD MECS Annual Tests


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(c) The facility operator shall incorporate a copy of each amendment to the operations manual under Sec. 154.320 in each copy of the manual with the related existing requirement, or add the amendment at the end of each manual if not related to an existing requirement.

All amendments to this manual will be identified in Section 1600 Amendments.

(d) The operations manual must be written in the order specified in paragraph (a) of this section, or contain a cross-referenced index page in that order.

This operating manual has been written in a format and order consistent with other operating manuals developed for the Valero Energy Corporation – Memphis Refinery. As noted this outline has been cross-referenced and electronically hyperlinked to corresponding sections of the manual.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 201 Process Overview

Section 201 Process Overview – Marine Emission Control System

201.1 Introduction

201.1.1 The Marine Emission Control System (MECS) operates in conjunction with loading and unloading operations on the North Dock. At this time the South Dock does not have a MECS and therefore is limited in the type of cargo that may be loaded or unloaded at that facility.

201.1.2 This manual describes the proper procedures for startup, normal operation and shut-down of the Marine Emission Control System (MECS). Included are descriptions of the MECS equipment and processes, components, start-up procedures, and key safety concerns.

201.1.3 Caution:► If the Marine Emission Control System (MECS) is to be used while loading

gasoline, the River Dock PIC shall perform a series of pre-transfer checks on the MECS Programmable Logic Controller (PLC) and the system as a whole, and the system will be started up. Refer to MECS Operation section for details of the MECS operation.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 300 Process Variables

Section 300 Process Variables

300.1 General:

300.1.1 There are no River Dock area variables; however, they must ensure that the facility is operational, the loading meters are accurately measuring the volume of product loaded into the barges and the correct amount of additive is being added to the products.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 400 –Process Chemistry

Section 400 Process Chemistry

400.1 Process chemistry:400.1.1 There is no chemistry involved in the loading or unloading processes at the River Dock

area. There are several simple mixing processes - i.e. additive injection into gasoline, but no real chemistry.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 500 –Commissioning Activities

Section 500 Commissioning Activities

Table of Contents and Links for this Section500.1 INTRODUCTION:500.2 PRE-STARTUP SAFETY REVIEW:500.3 PRECOMMISSIONING PLANNING:500.3.2 GENERAL RESPONSIBILITY:500.3.3 HYDROSTATIC TESTING:500.3.4 TANK / EQUIPMENT INSPECTION:500.3.5 UTILITY PREPARATION:500.3.6 LINE FLUSHING:500.3.7 INSTRUMENT CHECKOUT:500.3.8 PUMP AND DRIVER RUN IN:500.3.9 PRE-STARTUP CHECKLIST:

500.1 INTRODUCTION:500.1.1 The information contained in this section is mostly general information to address pre-

commissioning activities required for the initial startup of a facility; however, it could apply to new or modified equipment (i.e. tankage) at the River Dock. The pre-startup checklist at the end of this section is designed for use prior to startup of equipment after it has been out of service for major maintenance. The use of activities in this section, along with any equipment startup procedures, could be used to form an initial equipment startup procedure.

500.1.2 General methods are presented for hydrostatic testing, vessel inspection, utility preparation, cleaning and flushing lines and equipment, instrument checkout, and rotating equipment run-in.

500.1.3 Contractor personnel will typically carry out many of the procedures presented in this section. This section should be used as a reference when meeting with contractor personnel as a checklist of activities that the contractor is responsible to perform. Valero personnel can then use the section as a reference to ensure that the contractor activities have been performed.

500.2 PRE-STARTUP SAFETY REVIEW:500.2.1 A pre-startup safety review must be performed prior to commissioning when

modifications have been made to equipment. The pre-startup safety review helps ensure that the equipment can be started and operated safely. The review includes the following:► Construction is in accordance with design specifications.► Adequate procedures are in place.► Process Hazard Analysis has been completed.► Personnel training has been completed and documented.


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500.3 PRECOMMISSIONING PLANNING:500.3.1 Careful preparation will minimize delays and help ensure trouble-free equipment

startup. Detailed "checklists" help in making sure that the preparatory work is complete and that nothing has been overlooked. These lists should include the following:► Lines and equipment to be cleaned and inspected to ensure that the equipment is free

of debris and possible contaminants.► Machinery requiring run-in such as new or significantly modified pumps and

drivers.► A list of equipment requiring special preparation. Existing procedures must be

reviewed and modified as necessary or new procedures written for the special preparations.

► A list of the utilities and support facilities to ensure they are operational prior to the equipment startup.

► The pre-startup checklist (included at the end of this section) should be reviewed and modified as necessary.

500.3.2 GENERAL RESPONSIBILITY:► Many of the items noted in this section will require the coordinated efforts of River

Dock personnel, maintenance, inspection and possibly outside contractor personnel.

500.3.3 HYDROSTATIC TESTING:► Hydrostatic tests are made on new or repaired equipment to prove strength of

materials and welds. This test is made by completely water-filling the equipment to be tested, then increasing the pressure to the specified test pressure, generally with a portable test pump. The test is often made at 1½ times the design pressure of the equipment. This hydrostatic test should not be confused with other and less severe tests usually carried out in the startup procedure to check tightness of flanged or screwed connections.

► Construction or maintenance personnel ordinarily do hydrostatic testing. If for any reason it should become necessary for the River Dock personnel to carry out such a test, the hydrostatic test pressure should be specified by the Inspection Department. Equipment to be tested can be divided into groups of similar test pressures and isolated from the other sections by suitable (specification) blinds. Makeshift blinds sometimes used for isolation can fail under the higher pressures of a hydrostatic test. Some suggestions for making the test are:♦ Relief valves and/or rupture discs must be removed or blinded.♦ All items under test must be air-vented and liquid-filled.♦ Internals, such as level ball floats, not designed for the test pressures must be

removed.♦ Items, such as connecting piping to a vessel under test, capable of withstanding

the test pressure may be included in the test.


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♦ Items, such as Tank/Equipment connected to piping under test that are not capable of withstanding the test, must be isolated by blinding.

♦ A water-filled system must not be drained without proper venting. A vacuum condition can develop with serious consequences for equipment not designed for vacuum.

♦ Note that all pressure relief valves are bench-tested and set before final installation. This testing and setting may be done while the hydrotesting is in progress.

► After the hydrotest, record the test information for inspection records.

500.3.4 TANK/EQUIPMENT INSPECTION:► Tanks/Equipment and Tank/Equipment Internals should be inspected to ensure they

are cleaned of debris and have been installed and assembled as designed before they are closed for final bolting of manways. Generally, a vessel should be clean on completion and water flushing should not be required. However, water filling for hydrostatic testing or as supply for line flushing is customary. After draining of the water a final inspection should be made for cleanliness.

► Caution: Follow the plant confined space entry procedure prior to entering any vessel. Be certain that each vessel is air-purged prior to entering for inspection. Persons entering Tank/Equipment, which contain a poisonous or oxygen-deficient atmosphere, may be seriously endangered. Never enter any vessel when in doubt of the atmosphere.

► A list of items to check during inspection, if applicable, include:♦ Nozzles♦ Check orientation with vessel drawings♦ Check against vessel drawings and P&ID's that process nozzles are located at

correct positions on trays♦ Check thermowell locations and projections into the Tank/Equipment

► Distributors:♦ Check orientation and location against vessel drawings.♦ Checks drilled holes and/or spray nozzles against vessel drawings for size,

number and orientation.♦ Test distribution across spray headers with water. At flow rates ½ of process

requirements, the distribution should be even.♦ Headers should be no more than ¼" out of level.

► Miscellaneous♦ Check for cleanliness and foreign objects that may have been left by construction

personnel.♦ Inspect vortex breakers.♦ Check location of level control nozzles with vessel drawing.♦ Tank/Equipment that will remain idle for long periods after hydrotesting should

be left floating on a slight positive nitrogen pressure to exclude air and prevent rust formation.


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500.3.5 UTILITY PREPARATION:► Water and air systems► Water and air are often required in the pre-commissioning of equipment.

Accordingly, these services should be prepared for service as soon as they are available. Use the following general steps to commission these utilities:♦ Remove utility area limit blinds.♦ Remove strainers, orifice plates, control valves, and other restrictions.♦ Clean air lines piping by blowing with service fluid. ♦ Water lines may be flushed using their normal supply.♦ Flush or blow systems at high velocities for thorough scouring.♦ Make sure all temporary breaks are reconnected after flushing the systems.♦ Replace strainers, orifice plates, and control valves.♦ Pressure test with the service fluid at design operating pressure and check for

leaks.♦ Commission and line up for service as needed.

500.3.6 LINE FLUSHING:► All piping must be cleaned of debris and scale. Generally, lines handling liquids are

flushed with water, then thoroughly drained. Where practical, use clean water and flush in the direction away from Tank/Equipment or tankage. Care must be taken not to flush debris into equipment, i.e., pumps and control valves. Orifice plates must be removed. Water-flushed lines that do not drain freely should be blown clear with air. Piping handling gases may be water flushed or air blown. Water should be blown from gas lines after flushing. Instrument air headers should be carefully blown with dry, oil-free air. Do not use construction air supplies for cleaning the instrument air lines. Maximum volume and velocity will result in a thorough cleaning.

► Care must be taken to avoid a vacuum condition when flushing from a vessel or other equipment. Adequate venting must be provided.

► After flushing lines of a system, be sure all temporary breaks are reconnected, control valves, orifice plates, restriction orifices, mixing orifices, and check valve flappers are replaced.

► Thorough cleaning, prior to pump run-in minimizes suction screen cleaning with the attendant downtime.

► The following are general suggestions for effective flushing:♦ Orifice plates and restriction orifices must be removed.♦ Control valves should be removed.♦ Process instrument leads should be closed or disconnected.♦ Flush pump suction and discharge piping while disconnected.♦ Flush through open ended lines. Do not restrict flow.♦ Flush through all drains and vents.♦ Flush main headers prior to flushing laterals.


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♦ Always flush through available bypasses to an open end before flushing through equipment.

500.3.7 INSTRUMENT CHECKOUT:► Before initial startup, instrumentation must be checked for completion. The

following list may be used as a guide of items to verify as completed:♦ Test and set all pressure relief valves (if any) prior to startup.♦ Check out all instrument transmission systems after installation.♦ Measurement signal to the field transmitter.♦ Field transmitter to the controller, recorders, alarms, and/or interlocks.♦ Controller to the field transducers.♦ Transducers to the control valves.♦ Test air lines to all control valves. Control valves are removed while line

flushing. When reinstalled, the connections should be retested.♦ Check control valves operability:

Smoothness of action Stem travel Action on air failure Correct response to control unit Direction of flow through the valve

♦ Check solenoid valves for proper action and operability of latching mechanisms.♦ Check instrument lead lines for leaks.♦ Install sealing fluid in instrument lines if required. Label clearly.♦ Calibrate all instruments and verify correct transmitter-receiver action.♦ Obtain meter factors for flow meters.♦ After line flushing, check to see that all orifice plates are installed correctly.♦ Check orifice meters and restriction orifices for:

Proper orifice diameter Proper orientation to the direction of flow Check that the upstream and down stream orifice taps are hooked up to the

proper side of the transducer.♦ Check all alarms for proper setting and record these settings.

500.3.8 PUMP AND DRIVER RUN IN:► The dependability of the machinery associated with the facilities should be

established before startup. The following are suggested procedures:♦ Motors:

Initially operate these uncoupled from their loads. Check direction of rotation, bearing performance, and shaft vibrations. Verify that lubrication is adequate. Verify that the speed is correct.

♦ Pumps: Run in with water.



Tank/Equipment, and piping are flushed and clean. Ensure that startup suction screens are installed.


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► Caution:♦ Since the pumps that handle hydrocarbons normally handle liquids of a lesser

density than water, the motor drivers may easily be overloaded. To avoid this condition, the pump flows must be limited by throttling the discharge valves.

► The following list should serve as a guide to initial run-in preparation for pumps and drivers coupled:♦ Check that overall installation is complete.♦ Verify that pump and driver have been aligned for cold operation. There must be

no undue strain on the pump, turbine, or motor.♦ Check cooling water piping. Verify that water piping is connected where

specified (bearing jackets, pedestals, or packing glands).♦ Check seal oil piping. Verify that the installation is correct and complete. ♦ When pump is furnished with a mechanical seal, verify that all of the

components of the flushing system, such as strainers, separators, restriction orifices, and coolers have been correctly installed and cleaned.

♦ Ensure that packing or seals are installed.♦ Ensure that temporary strainers are installed in suction piping.♦ Check that pump and driver are properly lubricated.

500.3.9 PRE-STARTUP CHECKLIST:► This walk-down can be completed by a team that includes supervision, Inspection

and River Dock personnel. Some checklist items recommend an audit of records. This should consist of reviewing a representative sample of records to help ensure that items represented in these records were addressed adequately and accurately.

► Area safety - ensure the following:♦ Access ways for emergency equipment are not blocked.♦ Scaffolding not required during the startup has been taken down and removed

from the area.♦ Cranes, manlifts, portable compressors and other equipment not required for the

startup has been removed.♦ Purged cabinets are:

Sealed Pressurized Low pressure alarms (if any) are working

♦ Turnaround lighting has been removed.♦ Vapor proof lighting is intact.♦ Excess personnel are removed from the area.♦ Open flame and hot work is stopped.♦ Explosion proof electric boxes are bolted up tight.

► Terminal safety♦ Audit blind list sign off to ensure blinds have been removed (except for those

needed during the startup procedure).


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♦ Audit all appropriate sections of the operating manual to ensure that any modifications made during the shutdown have been addressed in the manual.

♦ Audit the drawings to confirm modifications have been updated to these drawings.

♦ Check the Pre-startup Safety Review and confirm that the recommendations have been adequately addressed.

♦ All caps, plugs, and blinds installed - except those needed for startup.♦ Check flange locations for gaskets.♦ Confirm that hydrotesting was completed on all new and modified

Tank/Equipment♦ Prove critical alarm loops.

► Fire & safety equipment ♦ Review the fire equipment identified in the safety section of this manual. Ensure

that the equipment is in place and operable, including:♦ Fire hydrants♦ Fire extinguishers♦ Wheeled dry chemical extinguishers

► Utilities are available for service.♦ Process operability

Sewers are lined up and draining freely. Strainers cleaned.

♦ Confirm the readiness of the relief system.♦ Check all PSV’s and ensure that relief valves are not isolated by a block valve or

a blind.♦ Audit the safety/relief valve shutdown inspection records to help confirm that all

scheduled relief valve inspections and/or rebuilding were completed.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 600 –Startup Procedures

Section 600 Startup Procedures

600.1 General600.1.1 Step-by-step instructions for the startup and shutdown of the Marine Emission Control

System (MECS) at the River Dock is contained in the procedure RD MECS Startup.► A pre-transfer check procedure is described and an overview of the system’s

automatic steady-state operation is given.600.1.2 Startup procedures for the River Dock Terminal Facility are included as part of normal

loading and unloading operations and detailed in Section 700.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 700 –Normal Operations

Section 700 Normal Operations

700.1 Introduction700.1.1 This section of the River Dock Operations Manual describes the general operating

procedures, general monitoring and control necessary for maintaining a normal operation.

700.1.2 Sections that follow include:► 701 -- River Dock General► 702 -- Barge Unloading► 703 -- Barge Loading► 704 -- Vapor Recovery► 705 -- Product Transfers► 706 -- Equipment► 707 -- Prohibited Activities

700.1.3 During normal operation, the River Dock should be monitored and controlled to achieve the following three principal objectives:► Safe operation► Environmentally sound operation► Maximization of profit

700.1.4 To help achieve the desired objectives, operating variables should be kept in their normal ranges. Any local instrumentation (temperatures, pressures, etc.) should be checked during routine outside rounds.

700.1.5 Valero River Dock office hours are:► Monday – Friday: 7:00 A.M. to 4:00 P.M for supervisor personnel at the River

Dock, but the facility is manned and operated 24 hours per day-365 days per year by the River Dock staff.

700.2 Monitoring activities:700.2.1 A number of routine operating activities contribute significantly to maintaining normal

operations. These activities include the following:► Outside equipment monitoring► Housekeeping► Preparing equipment for maintenance

700.2.2 If above activities are not performed satisfactorily one can expect problems, sooner or later. These items must always be completed if the River Dock objectives are to be fully accomplished.

700.2.3 Outside monitoring activities:► River Dock personnel should make a thorough inspection of the facilities every

couple of days.


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♦ They should check for unusual occurrences, unusual noises, product leakage, high or unusual vibrations and any potential hazards to personnel and/or equipment.

♦ Current conditions should be compared to normal (or efficient) conditions. ♦ If anything unusual is noted it should be corrected or appropriate personnel

notified. ♦ The River Dock personnel must immediately investigate and resolve any

differences from normal conditions that may result in a safety hazard or equipment damage.

♦ Other differences and substandard conditions must be noted and resolved after completing the rounds.

♦ The River Dock personnel should use all the resources needed to investigate and resolve unusual problems including: past training and experience, other River Dock personnel and the work order system.

700.3 Critical Process Parameters and Consequences of Deviation700.3.1 Critical Process Parameters for the Marine Emissions Control System (MECS) are

identified in Section 704 Marine Emissions Control System (MECS)700.3.2 Dock Operations have been reviewed for Critical Process Parameters and found only

the parameters listed below:

Critical Process Parameter

Maximum Allowable

Potential Consequences Required Action

Transfer Hose Pressure 150 mawp

Hose rupture and resulting Hydrocarbon or Hazardous material spill

Section 1002 Spill Response Procedure


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Section 701 River Dock General

701.1 Dock inspection

701.1.1 Each day the River Dock PIC conducts a thorough inspection of each River Dock facility. A checklist for this inspection is provided below:► RD North Dock Daily Checklist ► RD South Dock Daily Checklist ► RD Hose Inspection and Replacement

701.1.2 Barges arriving to be loaded or unloaded must also be inspected. ► General instructions are included in the RD Barge Loading Unloading Checklist. ► Specific forms for tracking Loading and unloading of barge products are included

below:♦ Form RD-4 Declaration of Inspection ♦ Form RD-5 Declaration of Inspection Supplemental ♦ Form B Jet A Barge Loading QC Check List ♦ Form A Jet A Barge Receipt Quality Assurance Check List ♦ Form T ULSD Barge Receipt Quality Checklist

701.1.3 Gauging and/or sampling of barges may also be required. These guidelines are more fully discussed in the Valero Quality Management System manuals. Specific procedures for sampling and gauging are noted below:► General Gauging a Tank or Barge ► General Sampling Procedure


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Section 702 Barge Unloading{33 CFR Section 154.310.(a)(11)}{33 CFR Section 154.310.(a)(17)(ii)}{33 CFR Section 154.310.(a)(17)(iii)}

702.1 North Dock unloading

702.1.1 Products that may be unloaded at the North Dock include the following:► GASOLINE► GASOLINE BLEND STOCK► ULSD► NAPHTHA

702.1.2 Unloading products at the North Dock will be accomplished in a safe, environmentally sound and efficient method and guided by the following Standard Operating Procedures. ► Primary River Dock personnel operating guidelines for all loading is identified in

procedure:► RD Barge Unloading North Dock

702.1.3 The Valero Memphis Refinery Quality Management System contains specific procedures for the unloading of products at the River Dock. These procedures are product specific.

♦ Gasoline Barge Unloading to Tks 58-59-71-76 or 80 ♦ Gasoline Barge Unloading to Tk 002 ♦ Gasoline Blend Component Barge Unloading ♦ Jet A Barge Unloading ♦ ULSD Barge Unloading

702.1.4 NOTE: Permanent drip pans are located underneath the flanged hose connection area at each end of the floating dock barge and on the hose flange to cross-over piping connection areas on spacer barges (when used). ► Each of these drip pans will contain approximately 250 gallons. These drip pans are

pumped out as required via an air operated diaphragm pump, which discharges into the Refinery oil recovery system.

► At the conclusion of any transfer operation, the hose is drained into the drip pan or collection facilities on the cargo vessel.

► The free end of all cargo hoses, are placed in a portable drip pan when the hoses are not in use.

702.2 South Dock unloading


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702.2.1 Products that may be unloaded at the South Dock include the following:► VGO ► ETHANOL► HSD BLEND ► LCO► JET A ► BLEND STOCK

702.2.2 Unloading products at the South Dock will be accomplished in a safe, environmentally sound and efficient method and guided by the following Standard Operating Procedures. ► Primary River Dock personnel operating guidelines for all loading is identified in

procedure:► RD Barge Loading South Dock

702.2.3 The Valero Memphis Refinery Quality Management System contains specific procedures for the unloading of products at the River Dock. These procedures are product specific.

♦ Ethanlol Barge Unloading Tk 80 ♦ Jet A Barge Unloading ♦ Gasoline Blend Component Barge Unloading ♦ Ethanol Barge Unloading Tk 80

702.2.4 NOTE: The work area on the floating dock barge is diked (metal curbing) to prevent any product leakage from the flanges and dockside hose connections into the water. ► This diked area will contain approximately 250 gallons and is a back-up

containment should portable drip pans leak or overflow. ► At the conclusion of any transfer operation, the hose is drained into the drip pan or

collection facilities on the cargo vessel. ► The free end of all cargo hoses, are placed in a portable drip pan when the hoses are

not in use.


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Section 703 Barge Loading{33 CFR Section 154.310.(a)(11)}{33 CFR Section 154.310.(a)(17)(ii)}{33 CFR Section 154.310.(a)(17)(iii)}

703.1 North Dock loading

703.1.1 Products that may be loaded at the North Dock include the following:► GASOLINE► GASOLINE BLEND STOCK► ULSD► CAUSTIC (Non-metered)► NAPHTHA

703.1.2 Loading products at the North Dock will be accomplished in a safe, environmentally sound and efficient method and guided by the following Standard Operating Procedures. ► Primary River Dock personnel operating guidelines for all loading is identified in

procedures:♦ RD Barge Loading North Dock ♦ RD Barge Loading Rotating Blinds

703.1.3 The Valero Memphis Refinery Quality Management System contains specific procedures for the loading of products at the River Dock. These procedures are product specific.

♦ Gasoline Barge Loading 58 59 71 76 80 Tanks ♦ Gasoline Barge Loading from Tk 002 ♦ General Loading Barge From Dead Tank

703.1.4 At the North Dock, several additives may be injected into the product during loading as specified by the customer and other requirements. In the event additives are required, the Pumpers are notified and are responsible for lining up the appropriate tanks providing the additives. ► The only exception to this is when adding red dye to diesel products. Red dye is

stored in the River Dock area and it is the responsibility of the River Dock PIC that it be added according to procedure: ♦ RD Adding Red Dye

703.1.5 At the North Dock, loading of gasoline or gasoline blend stock may also be accomplished directly from the refinery blender. These specific procedures are included below:


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► RD Barge Loading Blend Stock from Blender 703.1.6 The work area on the main floating dock barge is diked (metal curbing) to prevent any

product leakage from the flanges and dockside hose connections into the water. ► This diked area will contain approximately 250 gallons and is a back-up



not in use.

703.2 South Dock Loading

703.2.1 Products that may be loaded at the South Dock include the following:► VGO ► SLURRY► LCO► JET A

703.2.2 Loading products at the South Dock will be accomplished in a safe, environmentally sound and efficient method and guided by the following Standard Operating Procedures ► Primary River Dock personnel operating guidelines for all loading is identified in

procedure:♦ RD Barge Loading South Dock

► The Valero Memphis Refinery Quality Management System contains specific procedures for the loading of products at the River Dock. These procedures are product specific. ♦ Jet A Barge Loading from Tanks 101, 102 and 115 ♦ Gasoline Blending to a Barge ♦ Gasoline Line Wash for Blending to Barge or WMTP ♦ ULSD Barge Loading

703.2.3 The work area on the floating dock barge is diked (metal curbing) to prevent any product leakage from the flanges and dockside hose connections into the water. ► This diked area will contain approximately 250 gallons and is a back-up



not in use.


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Section 704 Marine Emissions Control System (MECS) Operation{33 CFR Section 154.310.(b)(2)} {33 CFR Section 154.310.(b)(2(ii)} {33 CFR Section 154.310.(b)(2)(iii)} {33 CFR Section 154.310.(b)(2)(v)}{33 CFR Section 154.310.(b)(2)(vi)}

704.1 System summary:704.1.1 This Marine Emission Control System (MECS) is designed to capture and destroy

hydrocarbon vapors generated and displaced from cargo tanks during the loading of gasoline and fuel oils into non-inert barges.

704.1.2 The facility is capable of pumping a maximum flow rate of 10,000 barrels/hour. There are two vapor connections for the MECS. The maximum loading rate for each loading line is 5,000 barrels/hour. The combined total loading rate is 10,000 barrels/hour.

704.1.3 No products containing pyrophoric sulfides or sulfur compounds will be loaded with this MECS.

704.1.4 The vapor is drawn into the MECS safety spools through loading hoses from the vessel’s non-inert cargo tank. It is placed in a non-explosive state by adding additional hydrocarbon (natural gas) to lower the oxygen concentration in the vapor line to below 15.5%.

704.1.5 Water that has condensed out in the vapor line is collected in knockout pots and is discharged for disposal. Detonation arresters and a hydraulic seal protect against a fire or explosion in the vapor line spreading to other parts of the system or to the barge.

704.1.6 At a distance from the loading site, a flare burns the hydrocarbon vapors to break them down by oxidation into a mixture of carbon dioxide, nitrogen, oxygen, water, and various other compounds which fall within the emission type and quantity limits set by regulating agencies.

704.1.7 Key parts of this section include:► 704.2 -- Individual Operating Procedures ► 704.3 -- System Description► 704.4 -- Vapor Blower Skid► 704.5 -- Flare With Hydraulic Seal And Molecular Seal

704.2 Individual operating procedures have been developed for each phase of operation of the Marine Emission Control System (MECS) or Vapor Recovery System. The phases of operation and the procedures are identified below:

704.2.1 Start-up► RD MECS Pre Start Checklist ► RD MECS Startup ► RD MECS System Startup Interlocks


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704.2.2 Shutdown► RD MECS Analyzer Alarm Shutdown ► RD MECS Shutdown Alarms

704.2.3 Operation► RD MECS Pre Start Checklist ► RD MECS Pre Transfer Checklist ► RD MECS Operation ► RD MECS Maximum Flow Rates ► RD MECS Panel Description ► RD MECS Troubleshooting

704.2.4 Barge compliance checklist► RD MECS Supplemental Declaration of Inspection ► RD MECS Equipment Design Table

704.2.5 Calibration► RD MECS Annual Tests ► RD MECS Instrument Setpoints ► RD MECS Equipment List

704.3 System description704.3.1 Equipment control panels:

► Control panels associated with major equipment systems are located throughout the MECS. These contain various indicator lights and switches associated with the equipment and processes described below.

704.3.2 Programmable Logic Controller (PLC):► An Allen-Bradley SLC S/04 industrial computer controls the automated processes of

the MECS. The PLC is preprogrammed and provided with an Allen-Bradley panel view man-machine interface with which all processes and operations can be monitored and controlled. However, daily operation is normally controlled from the safety spool control panels.

704.4 Safety spool skid:704.4.1 Two safety spool assemblies are located at the barge-loading site. The safety spool

helps protect the barge, loading facility, and tank farm from flashbacks originating from either side of the safety spool. Vapor hoses from the cargo tank connect to the safety spool vapor intake line. Adequate hose handling equipment is provided to prevent kinking of the vapor hose. Each facility vapor connection has a permanently attached ½” diameter stud 1” long projecting outward from the flange face. These


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studs are located at the top of the flange, midway between the bolt holes, and in line with the bolt hole pattern. Each vapor connection is painted “red/yellow/red” and labeled “Vapor” in accordance with 33CFR 154.81(b)&(c). The insulating device must be used on the vapor hose and care must be taken to ensure the insulating device is not short circuited or bypassed. If grounding is used, proper connection of the grounding cable must be made to the barge.

704.4.2 Pressure relief valve with flame screens (PSV 121A, 121B):► The pressure relief valve pair provides protection from both excessive vacuum and

excessive pressure to protect against damage to the barge in the event of a control malfunction. If pressure is low, one valve opens to allow air to be drawn in and so reduces the vacuum. If pressure is excessive, the other valve opens to release vapor to the atmosphere and so lowers the line pressure.

► A flame screen on the positive pressure relief valve protects against combustion of released hydrocarbons flashing back into the vapor lines. A flame screen in the vacuum relief valve protects against flame being drawn in. These devices protect against flame propagation back into the line by reducing flame temperature below the ignition point of the vapor.

704.4.3 Intake vapor pressure transmitter and switches (PT125A,125B) (PSLL123A,123B) (PSHH124A,124B):► These switches trigger high and low pressure alarms for operator attention, and high-

high and low-low alarms for a safety spool shutdown.

704.4.4 Large capacity in-line filters (23-40-028 & 23-40-029) with differential pressure indicators have been added to the vapor headers to collect particles before they can plug the detonation arrestors.

704.4.5 Vacuum pressure control valve (PCV 125A,125B):► In accordance with Coast Guard regulations, a pressure control valve on the safety

spool is modulated by the PLC to maintain the pressure within the vessel’s cargo tank within 80% of the positive and negative relief valve settings. This also enhances pressure regulation throughout the system.

704.4.6 Detonation arrester (DA 23-21-001,23-21-002):► This Coast Guard-accepted device (type 2 with MESG ratings of 0.9 mm or greater)

restricts flashback by reducing the flame temperature below the ignition point of the vapor. Slowing the propagation of the flame-front to subsonic velocity halts a detonation. Both functions are accomplished by routing the vapors through a fine honeycomb of vapors channels, which serve to absorb heat and decrease vapor pressure/velocity.

► These devices are identified as 23—21-001 and 23-21-002 respectively on safety spools A and B. The nominal size of each device is 6”.


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704.4.7 Differential pressure transmitter (PDIT 127A,127B):► A differential pressure transmitter measures the line pressure difference between the

inlet and outlet of the detonation arrestor and is triggered when a backflow of vapor toward the barge causes a specific pressure difference between the inlet and outlet. Its signal initiates an alarm and a spool/blower shutdown.

704.4.8 Differential pressure gauge (PDI 126A,127B):► A differential pressure gauge measures the line pressure or both sides of the

detonation arrester and allows the operator to determine if the detonation arrester is becoming plugged. By observing the trend of increasing differential pressure the operator can plan ahead when scheduling maintenance downtime.

704.4.9 Temperature sensor (TE 128A,128B) (TE129A,129B):► Thermocouples placed at both the inlet and the outlet of each safety spool detonation

arrester (23-21-001, 23-21-002) trigger a spool/blower/flare shutdown if a high temperature is sensed.

704.4.10 Vapor enrichment gas pressure (PSHH 136A, 136B)(PSLL 135A, 135B):► Vapor flow is measured and a predetermined proportion of natural gas added to the

vapor line to maintain a vapor concentration of at least 200% of the Upper Explosive Limit (UEL) of the enrichment gas. Methane (the major component of natural gas) has a UEL of 15%; therefore, the vapors are enriched to a total concentration of 30% by volume. In effect, this decreases the proportion of oxygen in the vapor to a level below the combustion limit.

► Enrichment gas supply pressure is monitored and a safety spool shutdown triggered by an excessive insufficient pressure.

704.4.11 Oxygen analyzer (AE 132A, AFSL 132A)(AE 132B, AFSL 132B):► To avoid having an explosive mixture of vapors in the system, the oxygen content of

the vapor must remain below 16.5%. To check the success of the vapor enrichment process, the oxygen content of the enriched vapor is measured to ensure that the concentration remains below 15.5%. An alarm is triggered above this level. A safety spools shutdown is triggered if the oxygen concentration reaches 16.5%, if the gas flow to the analyzer is blocked, or if an analyzer fault occurs.

► A pair of Servomex 1100A Oxygen Analyzer elements are located at a point far enough downstream of both the enrichment gas injection site flow mixers to allow adequate mixing of the gases prior to sampling. The Coast Guard requires the sampling point be no further than 30 pipe diameters from the enrichment point.

► The enriched vapor from both safety spools is combined and monitored by the oxygen analyzers. The Servomex 1100A analyzers have a warm-up period of 12 hours during which the readings are invalid. Therefore, the Servomex 1100A analyzers must be turned on at least 12 hours before pre-transfer calibration is to be performed.


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704.5 Vapor blower skid704.5.1 Knock out Pot (23-10-002) (LSH/LSHH 420) (LSL 421):

► A knock out pot removes condensed hydrocarbons that may be carried through the system as a fine mist in the vapor. These liquid droplets must be removed from the vapor to protect against pooling of the condensate in the lines and to protect the blower from liquids.

► The knock out chamber allows suspended droplets to fall out of the vapor stream by slowing the vapor within the vessel. Level switches monitor the liquid level, and the accumulated condensate is discharged through a drain valve.

► High liquid level switch opens valve LV-411, and a low liquid level switch closes the valve. After a one-minute delay, if a high level still exists, an alarm is sounded. The high-high and low-low liquid levels trigger an alarm and a spools/blower shutdown. These alarms may result from a control failure, a blockage, or a leak.

704.5.2 PRESSURE INDICATING CONTROLLER 9PIC 423, PT 423):► This PIC subroutine of the PLC modulates a pressure control valve to allow the

system to be turned up and down to accommodate the range of design loading rates.

704.5.3 DETONATION ARRESTER (23-21-003):► The device restricts flashback by reducing the flame temperature to below the

ignition point of the vapor. Slowing propagation of the flame-front to subsonic velocity halts a detonation. Both functions are accomplished by routing the vapors through a fine honeycomb of vapor channels, which serve to absorb heat and decrease vapor pressure/velocity.

704.5.4 TEMPERATURE SENSOR:► A thermocouple placed at the outlet of detonation arrester 23-21-003 will trigger a

spools/blower/flare shutdown if a high temperature is sensed.

704.5.5 VAPOR BLOWER:► The vapor blower creates a vacuum on its intake side to draw the vapor from the

loading site, and it pressurizes the vapor lines on its outlet side to feed the flare.► The blower discharge temperature is monitored and a spools/blower/flare shutdown

is triggered if the temperature reaches a set maximum. High blower discharge temperature may indicate inadequate flow rate through the blower. This blower has a capacity of 1126 scfm, -47.0” WC inlet pressure at 3550 rpm.

704.5.6 ENRICHED VAPOR SHUTDOWN VALVE (SDV 434):► Prevents enriched vapor from entering the hydraulic seal portion of the flare vessel.

704.6 Flare with hydraulic seal and molecular seal (23-05-001):704.6.1 The flare has dimension of 2’-0 OD x 60’-0” OAH


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704.6.2 HYDRAULIC SEAL IN BASE OF FLARE:► The hydraulic (water) seal downstream of the blower provides flashback protection

by passing the vapors through a layer of water as fine bubbles. By eliminating a continuous vapor path, a flashback is prevented from passing through the seal as long as the water level is maintained. Vapor passing through the upper portion of the seal units slows enough to “drop-out” any water droplets picked up from the seal water and prevent these from being carried out the flare stack.

► A low-level switch will add water to normally maintain the seal integrity, and a high level switch stops water addition. High-high and low-low liquid level switches trigger shutdowns in case of liquid level control failure.

► Hydrocarbon will condense out and form a layer on top the water. This hydrocarbon layer should be removed periodically by draining the vessel while the MECS is not processing vapor, then allowing the automatic controls to refill it with water.

704.6.3 MOLECULAR SEAL ON FLARE STACK:► This chamber near the top of the flare prevents air infiltration during periods when

the flare is not burning, and during periods of low turndown. A baffle system, in the chamber traps, fuel gas which acts as a barrier to air movement into the stack. Air mixing in the stack could result in a potentially explosive gas mixture, which would require purging with a significant volume of fuel vapor prior to prior ignition. A molecular seal eliminates the need for purging.

704.6.4 PILOT IGNITION:► An electric spark generated ignition system is used. The equipment consists of

ignition junction box, manual block valves, automatic solenoid valves, and thermocouple pilot monitors the ignition process repeats every few seconds until flame is detected on the pilot or until the three ignition period expires.

704.6.5 PILOT MONITORING:► A pilot flame failure alarm is triggered when either of two thermocouples

monitoring the pilot flame fails to signal a temperature above set-point. If both thermocouples fail to detect flame, then a spools/blower/flare shutdown is performed.

704.6.6 FLARE TIP:► This flare tip is a John Zink design, which meets API requirements. The flare tip is

mounted on a flanged connection. For high temperature corrosion resistance, the upper half of the flare tip is made of 309 stainless steel, and the lower half is carbon steel. All portion of the flare tip which are exposed to heat are constructed of stainless steel, including the flame holder, pilot assemblies, pilot flame front ignition tubes, and upper steam manifold/steam jet assemblies.

704.6.7 STEAM MANIFOLD:



► High-pressure steam can be injected into the flame to draw in additional air (oxygen) to prevent smoke formation. A valve on the blower skid is set by hand to supply steam to the flare based on visual inspection of the flame by the operator. Even when steam is not required to prevent smoke formation, a minimum steam flow is required to prevent condensation from forming in the steam header, and to cool the steam manifold while it is exposed to flame.


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Section 705 Product Transfers

705.1 The River Dock may be involved in product transfers between the Refinery and the West Memphis Pipeline (WMT) and also between storage tanks.

705.2 WMT Pipeline transfers will be accomplished in a safe, environmentally sound and efficient method and guided by the following Standard Operating Procedures. 705.2.1 Primary River Dock personnel operating guidelines for transfer of product via the

West Memphis Pipeline is identified in procedure:► RD Transferring Product to WMT Pipeline

705.2.2 The Valero Memphis Refinery Quality Management System contains specific procedures for the transfer of product via the West Memphis Pipeline including: ► WMT Pipeline Batch Switch ► WMT Pipeline Receipt Alignment to a Tank ► Gasoline Line Wash for Blending to Barge or WMTP ► Gasoline Blending WMT Pipeline Alignment ► Gasoline Receive Gasoline from WMT via Pipeline ► ULSD Refinery Tank to WMT Pipeline Align and Switch

705.3 Tank to tank transfers will be accomplished in a safe, environmentally sound and efficient method and guided by the following Standard Operating Procedures.

705.3.1 Primary River Dock personnel operating guidelines for tank to tank transfers are identified in procedure:► RD Transferring Product Tank to Tank

705.3.2 The Valero Memphis Refinery Quality Management System contains specific procedures for the tank to tank transfer of products at the River Dock. ► Gasoline Riverline Line Wash from 58 59 71 76 80 Tks ► Gasoline Riverline Line Wash from Tk 002


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Section 706 Equipment

706.1 Equipment details706.1.1 Red dye injection system

► The red dye system consists of the following:♦ 4000 gal tank inside a concrete diked area♦ Two (2) injection pumps for moving red dye into diesel product during product

transfer♦ Associated piping to allow delivery

► Red dye injection is accomplished following procedure RD Adding Red Dye

706.1.2 Dock cranes► Three dock cranes are used to assist in loading

♦ Two (2) cranes are available at the North Dock♦ One (1) crane is available at the South Dock

► Each crane has:♦ 1100 lbs capacity♦ 40 ft. telescopic boom

► Dock cranes will be operated based on procedure RD Coastal Hydraulic Crane Operation

706.1.3 Waste oil sump operation► This system is designed to:

♦ Collect excess water from the MECS hydraulic seal♦ Collect excess product drained during blind rotation for unloading or loading.

► This system consists of:♦ One (1) pump♦ Associated piping to allow collection of material

706.2 Dock maintenance706.2.1 When maintenance is required on a piece of equipment at the River Dock area, River

Dock personnel will ensure that appropriate work permits and safety considerations are met according to RD Work Permits procedures.

706.2.2 If hot-work is to be performed on the dock barges, the following Coast Guard hot work permit must also be completed. ► Form RD-3 Coast Guard Hot Work Permit


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Section 707 Prohibited Activities

707.1 The following activities are prohibited at the barge loading facility.

707.1.1 Barge Stripping:► Open hatched barge stripping is not allowed at the Memphis Refinery Dock. ► If a barge has a fully enclosed stripping system it can be used while barge is at the

dock.

707.1.2 Barge Heaters:► Barge heaters cannot be operated when barge is at Memphis Refinery Dock. No

exceptions.

707.1.3 Piping Systems Without Valves:► All parts of the transfer system must have valves. Any part of the system that does

not have a valve cannot be used at the Memphis Refinery Dock.

707.1.4 Barge to Barge Transfer (lightering)► Under normal operating conditions barge to barge transfers are not allowed at the

Memphis Refinery Dock. ► Exceptions may be made in order to prevent environmental damage or for some

unusual refinery conditions that may exist. Any exception must be approved by the Dock PIC and the Oil Movement Superintendent.

707.1.5 Motor Vessel► When a motor vessel (tow boat) is moored to the Refinery Dock the following

activities are prohibited: ♦ Grinding♦ Welding♦ Cleaning of vessel and barge♦ Re-supplying activities♦ Any type of maintenance work that would limit vessel mobility.

707.1.6 Unauthorized Dock Access► All personnel must sign the Unit Entry Log located inside the dock office before

going down to dock barges. USCG CFR 33.105.245 Declaration of Security is strictly enforced.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 800 –Shutdown Procedures

Section 800 Shutdown Procedures

800.1 System Shutdown for the MECS800.1.1 The four system shutdowns are: standby, power down, automatic, and emergency.

800.2 Shutdown to Standby: 800.2.1 For a routine daily shutdown while leaving power on the all subsystems and panel

heaters:► Turn all vapor loading valve Off/On switches to OFF (PNL 100A, 100B).► Turn all safety spool enrichment gas blower Off/On switches to OFF (PNL 100A,

100B).► Turn all safety spool flare system Off/On switches to OFF (PNL 100A, 100B).

800.3 Complete Power-Down: 800.3.1 To power down the MECS for maintenance or extended periods of non-use:

► Turn all vapor loading valve Off/On switches to OFF (PNL 100A, 100B).► Turn all safety spool enrichment gas blower Off/On switches to OFF (PNL 100A,

100B).► Turn all safety spool flare system Off/On switches to OFF (PNL 100A, 100B).

800.4 Emergency Shutdown is discussed in Section 1006.6.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 900 –Special Operations

Section 900 Special Operations

900.1 Introduction900.1.1 Some operations and practices are not a normal portion of the River Dock operation

and may require special precautions or communications in order to complete them safely and effectively. Procedures in the section are noted below:► Hydrogen Sulfide Handling -- RD H2S Handling


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Memphis Refinery River Dock Operations Manual March 2008 Sec 1000 – Emergency Procedures

Section 1000 Emergency Procedures {33 CFR Section 154.310.(a)(17)(iv)}

1000.1 Introduction1000.1.1 Emergency preparedness and response capability are essential elements of River Dock

operations. Below are basic guidelines for initial action in the event of emergencies. Additional emergency procedures and information are included in the following sections:► Section 1001 River Dock Area Fire Response ► Section 1002 Emergency Procedure for Handling Discharge of Product ► Section 1003 Procedure for Electrical Power ► Section 1004 Procedure for Inclement Weather ► Section 1005 Emergency Procedure for Handling Personnel Injuries ► Section 1006 Security Procedures

1000.2 Hydrocarbon or Hazardous material spill: 1000.2.1 In the event of an oil or hazardous material spill:

► Transfer operations will be shut down immediately► The source of the spill will be secured if possible to prevent further spillage► Containment procedures will be initiated if it is safe to do so► Proper notification shall be made including notification of Oil Spill Team.

♦ Document notifications using Form RD-2 Spill Response Notification► Clean up shall proceed as soon as possible. ► These procedures shall be carried out per Section 1002 Spill Response Procedure.

1000.3 Weather: 1000.3.1 When severe weather conditions are present, the River Dock PIC shall have the

authority to shut the transfer operation down if the weather conditions create or could potentially create a hazardous situation. In general, if there is cloud-to-ground lightening present in the immediate area, transfer operations will be shut down until the lightening hazard is no longer present.

1000.4 Fire: 1000.4.1 In the event of fire:

► The situation will be immediately communicated to refinery personnel via the two-way radio system

► The plant fire alarm will be sounded► The security guard at the front gate will be advised and will call the Memphis

Refinery Fire Department. ► If the fire involves the transfer facility or barges moored at the facility, the USCG

Marine Safety Office Memphis should also be notified as soon as possible.1000.5 Injuries:

1000.5.1 In the event of injury to personnel, the situation should be reported immediately to the Oil Movement Superintendent or the Refinery Shift Superintendent.


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► If the injury is serious or if there is a concern that the injury may be serious, an ambulance should be called. The security guard should either make the call or be informed so they may direct the ambulance when it arrives.

► If the injured person is not a Memphis Refinery employee, the individual’s employer should be notified.

► As soon as possible (same day) an injury report should also be filled out. If personnel from the Memphis Refinery Safety Department are on site, they should be notified

► The Refinery Nurse should also be notified.1000.6 Description and location of each emergency shutdown system and device {33 CFR Section

154.310.(a)(12)}1000.6.1 Cargo line valves

► All cargo lines have a manually operated quick close (90 degree turn operation) valve on the shore platform.

► The cargo line valves on the dock barge at the hose connection area are manually operated ball valves or gate valves for positive closure.

► The valves at either end of the crossover lines on the spacer barges (when used) are manually operated ball valves.

► The gasoline and diesel cargo lines at the North Dock contain meters and automated set-stop valves that provide positive closure at the end of the pre-selected batch volume.

1000.6.2 Emergency shutdown switches► North Dock

♦ There are several emergency shutdown switches at the North Dock that will shut down all automated loading of gasoline and diesel at the North Dock when activated. When activated, the tank farm loading pumps shut down and all automated set-stop valves close.

♦ One (1) Emergency Shutdown switch is located in the North River Dock office.♦ One (1) Emergency Shutdown is switch located at each end of the floating dock

near the drip pans.♦ One (1) Emergency Shutdown switch is located on the shore platform near the

set-stop meters.♦ Two (2) Emergency Shutdown switches are located at the safety spool skids and

can be used to shut down the Marine Emission Control System in an emergency.♦ These switches will also stop all gasoline loading, the loading pumps will shut

down, and the automated set-stop valve will close. ► South Dock

♦ There are two (2) Emergency Shutdown switches at the South Dock that will shut down all loading of diesel at the South Dock when activated.


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Section 1001 River Dock Area Fire Response {33 CFR Section 154.310.(a)(5)(ii)(g)} {33 CFR Section 154.310.(a)(15)}

1001.1 Purpose:1001.1.1 This procedure identifies the steps to limit the damage to the River Dock equipment, as

well as the major steps for fire control. This procedure is intended as a Guideline for River Dock operators, and is not intended to replace or supersede other fire control strategies, policies or training.

1001.2 Safety:1001.1.1 Special or unique hazards: personnel safety is the primary concern in a fire situation.

Fire control and minimization of equipment and/or product losses are subordinate to personnel safety concerns in the event of a fire.

1001.1.2 Property and hazards of materials used in this procedure, along with actions to take if exposed to these materials can be found in Section 1102.

1001.3 Material and equipment: {33 CFR Section 154.310.(a)(15)}1001.3.1 The River Dock area has some emergency equipment located in the area. This

emergency equipment is provided to prevent exposure to hazardous materials and to provide a method of control if any material is accidentally released. Refer to the MSDS sheets for further control measures to be taken if you have had physical contact or airborne exposure.

1001.3.2 The tables below show the emergency equipment located at the River Dock area (shaded). The River Dock operations staff maintains a master list of emergency equipment.► Fire extinguishers:North DockLocation ID # Type Location

DLT 04 30# -- Purple K, Dry Chemical Fire Extinguisher

Dock Barge North End


Dock Barge South End


Shore Platform Meter Platform


Shore Platform Meter Platform


Spacer Barge North End


Spacer Barge South End


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South DockLocation ID # Type LocationDLT 12 30# -- Purple K, Dry Chemical Fire

ExtinguisherDock Barge South End


Dock Barge North End


Shore Platform Top Of Ramp

30# -- Purple K, Dry Chemical Fire Extinguisher

Shore Platform


Spacer Barge North End


Spacer Barge South End

Office AreaLocation ID # Type LocationDLT 01 Portable, CO2, Dry Chemical, type

fire extinguisherOffice


Meter Proving

► Hydrants: ♦ There is one-fire hydrant located just south of the dock office.♦ Three (3) monitors will be located as follows:

(2) North of the dock office (1) at the South Dock

♦ Location maps for the monitors are included as follows: (See Section 1514 Drawings)

RIVERDOCK FIRE MONITOR 1 (North Dock location) SOUTH DOCK FIRE MONITOR (South Dock location)

1001.4 The following is a guideline of the major steps to consider in the event of a fire: 1001.4.1 The first priority in any fire situation is to ensure the safety of personnel. Once that has

been assured, use the following 3-step approach to fire response:► Control the source of the fire► Contain the fire► Recover spilled material.

1001.4.2 Immediate action in the event of a fire► Communicate the situation immediately to refinery personnel via the two-way radio

system. ► Sound the plant fire alarm.


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► Advise the security guard at the front gate to call the Memphis Refinery Fire Department. ♦ The security guard will then notify the Memphis City Fire Department of the fire

and status. ♦ If the fire involves the transfer facility or barges moored at the facility, the

USCG Marine Safety Office Memphis should also be notified as soon as possible.

► Initiate fire control by isolating the piece of equipment from which the fire is originating. This may include any or several of the following actions:♦ Shutting down the Barge Loading Pump by informing the Tank Farm Pumper.♦ Isolating the Loading pump or a section of line.♦ Decisive action will be required. A piece of equipment in the River Dock area

can always be restarted.► When water spray becomes available from the Refinery and Fire Department, Start

the water sprays to cool the area down that is on fire.► Initiate River Dock Management notifications. At the minimum, notify:

♦ River Dock Management ♦ Safety Department♦ Environmental Department♦ Public Affairs

Note:The Refinery Fire Chief has authority to take over command of fire control efforts when he arrives at the River Dock.

► Initiate call out of spill cleanup contractor, if required. The Oil Movement Superintendent has authority to commit River Dock resources in a spill emergency.

► Initiate agency notifications (US Coast Guard, EPA, DOT and Tennessee DEQ) as required by the specific incident. If possible delegate this responsibility to Environmental Department representatives who deal with response plans and agency personnel on a regular basis.♦ Use all available resources to control and extinguish the fire. A fully engulfed

fire area may be nearly impossible to extinguish.► Initiate product recovery operations. This activity should be started as soon as

possible. However, do not jeopardize efforts to control the fire source.

1001.4.3 Responsibilities for reporting the fire► River Dock Operators are responsible to report fire to refinery personnel and to

initiate defensive fire fighting procedures until help arrives.► Process unit operators will remain in their units – ► Other trained refinery employees will report to the area.

1001.4.4 Planning fire response► Size-up of fire. A responsible supervisor will determine the best tactics and strategy

needed to fight the fire and should do this quickly.


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♦ Tactics – Basically there are three types of tactics that can be used in a barge fire situation:

Passive – This is a no-win situation, that is, if there is no water in the area or if there is very little product to be saved in the barge involved in the fire and there are no other exposures.

Defensive – This means there are exposures that can be protected with available water supplies, but extinguishing the fire is not practical. The general operation in this scenario will consist of leaving the fire alone and concentrating on protecting exposures.

Aggressive attack – This is when cooling water can adequately protect exposures and an aggressive attack is either in progress or is being planned to extinguish the barge involved in the fire.

♦ Fire extinguishing agents will typically be one or more of the following agents: Cooling water Dry chemicals (potassium bicarbonate – Purple K) Aqueous film-forming foam (AFFF) Carbon dioxide (CO2) Refer to the Material Safety Data Sheet in Section 1515 MSDS for the

specific cargo involved in the fire for specific instructions and recommendations in case of fire and for the most effective extinguishing agent.

1001.5 Additional procedure information1001.5.1 Responsibility:

► The River Dock Supervisor and Pumpers are responsible for initiating notifications, call-outs and fire control activities in response to a fire involving the River Dock and Tank Farm areas.

1001.5.2 Engineering controls:► No engineering controls are required to complete this procedure.

1001.5.3 Administrative controls:► Fire response requirements, including notification commitments are included in

several River Dock plans. The commitments made in the following plans should be considered in the initial response to a tank fire:♦ Fire Response Agreement with City of Memphis♦ Spill Prevention, Control and Countermeasure (SPCC) Plan which have been

submitted to the U.S. Coast Guard♦ OPA 90 Emergency Response Plan♦ Facility Response Plans which have been submitted to the US EPA and DOT♦ Discharge Prevention and Contingency Plan which has been submitted to the

Tennessee Department of Environmental Conservation (TDEQ)1001.5.4 Procedure outline:

► No procedure outline is included for this procedure as it is intended as a general guideline only. Actual fire response will depend on the situation at hand.


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Section 1002 Spill Response Procedure {33 CFR Section 154.310.(a)(5)(ii)(f)} {33 CFR Section 154.310.(a)(14)}

1002.3 Purpose:1002.3.1 This procedure describes steps required to safely handle a product discharge at the

River Dock area.1002.4 Safety:

1002.4.1 Special or unique hazards: leaks of any gasoline and/or diesel should be handled per the Emergency Spill Response Policy.

1002.4.2 The procedure includes sign off lines that will help all personnel involved with the procedure know what steps have been completed. This will help prevent missed steps.

1002.4.3 Personal Protective Equipment (PPE):► Normal River Dock personal protective equipment must be worn while loading,

unloading and/or transferring product. This includes:♦ Hard Hat♦ Safety Glasses♦ Steel Toed Safety Shoes♦ Protective Gloves♦ Personal Flotation Device (if accessing the barge dock area beyond the top of the

gang plank)1002.5 Emergency procedure for handling a discharge of product from the River Dock area:

1002.5.1 Spills:► In the event of an oil or hazardous material spill:

♦ Transfer operations will be shut down immediately♦ The source of the spill will be secured if possible to prevent further spillage♦ Containment procedures shall be initiated if it is safe to do so♦ Proper notification shall be made including notifying the Refinery Oil

Spill/Hazmat Team♦ Clean up shall proceed as soon as possible. ♦ These procedures shall be carried out per the Facility Response Plan.

► Immediately shut down any equipment contributing to the discharge of product, and any emergency shutdown switches as necessary

► Close any valves that are necessary to stop the flow of product to the discharge area► Immediately notify the Shift Superintendent and Oil Movement Superintendent

of the emergency situation.► Initiate Spill Response Notification process:

♦ Document notifications using Form RD-2 Spill Response Notification♦ Refer to Table RD-B Emergency Notification for additional contact

information.


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► Conduct all possible actions necessary to contain the discharge and prevent spillage into the water through the use of the drip trough and portable containers.

► Deploy absorbent material as necessary as an initial response to the spill.

► Initiate clean up activities to prevent any further pollution from taking place after all agency notifications and response activations have been started.

► Post security guards at the entrance to the River Dock area to keep out any unauthorized visitors.

1002.6 Valero spill response equipment1002.6.1 Equipment which may be accessed for spill response is detailed in Table RD-C

Emergency Dock Equipment List


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Section 1003 Procedure for Electrical Power

1003.3 Purpose:1003.3.1 Loss of electrical power will not result in an emergency situation at the River Dock

area. The area will be effectively shutdown without electrical power. Normal operations should be restored when power becomes available.

1003.3.2 This procedure identifies the steps to take in response to a power interruption in the River Dock area. This procedure is intended as a guideline for River Dock Operators. The response to a power interruption will vary depending on the full extent and duration of the outage.

1003.4 Material and equipment:1003.4.1 No special materials or equipment are required.

1003.5 Safety:1003.5.1 Special or unique hazards:

► Personnel safety is the primary concern in any emergency situation. Priority should first be given to activities that will secure the area in the safest possible condition. Then the priority may be given to activities that will resume normal River Dock operations.



gang plank)

1003.5.3 Property and hazards of materials used in this procedure, along with actions to take if exposed to these materials, can be found in Section 1102.

1003.6 Procedure for River Dock area power interruption response:1003.6.1 The first priority in any emergency situation is to ensure the safety of all personnel in

the area of the emergency. Once that has been assured, the following steps should be considered. Other steps may be necessary, depending on the degree to which the power interruption has affected the rest of the River Dock.► Check the River Dock area for any signs of spills. Address these as necessary.► When power has been restored, restart or reboot all computer controlled systems so

that product loading can be restarted ASAP.


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1003.7 Responsibility:1003.7.1 The River Dock Supervisor and Operators are responsible for prioritizing,

coordinating, and carrying out the critical activities in response to a power interruption.

1003.8 Engineering controls:1003.8.1 No engineering controls are required to complete this procedure.

1003.9 Administrative controls:1003.9.1 Emergency response requirements, including notification commitments, are included

in several River Dock plans. Although not all may apply, the commitments made in the following plans should be considered in the initial response to a power failure:► Notify and call-out Memphis Refinery Fire Department► Notify and call-out Memphis Refinery Oil Spill/Hazmat Team► Fire Response Agreement with City of Memphis► Spill Prevention, Control and Countermeasure (SPCC) Plan which has been

submitted to the U.S. Coast Guard► Facility Response Plans which have been submitted to the US EPA and DOT► Discharge Prevention and Contingency Plan that has been submitted to the

Tennessee Department of Environmental Quality (TDEQ).

1003.10 Procedure outline:1003.10.1 No procedure outline is included for this procedure as it is intended as a general

guideline only. Actual response will depend on the situation at hand.


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Section 1004 Procedure for Inclement Weather

1004.3 Purpose1004.3.1 Inclement weather will not result in an emergency situation at the River Dock area.

The area can be effectively shutdown because of bad weather. Normal operations should be restored when “good” weather conditions exist.

1004.3.2 This procedure identifies the steps to take in response to inclement weather in the River Dock area. This procedure is intended as a guideline for River Dock Operators. The response to inclement weather will vary depending on climatic conditions.

1004.4 Material and equipment:1004.4.1 No special materials or equipment are required.


► Personnel safety is the primary concern in any emergency situation. Priority should first be given to activities that will secure the area in the safest possible condition. Then the priority may be given to activities that will resume normal River Dock operations.



gang plank)

1004.5.3 Property and hazards of materials used in this procedure, along with actions to take if exposed to these materials, can be found in Section 1102.

1004.6 Procedure for inclement weather response:1004.6.1 The first priority in any emergency situation is to ensure the safety of all personnel in

the area of the emergency. Once that has been assured, the following steps should be considered. Other steps may be necessary, depending on the degree to which the inclement weather has affected the rest of the River Dock.► When severe weather conditions are present, the Dock Supervisor shall have the

authority to shut the transfer operation down if the weather conditions create or could potentially create a hazardous situation. In general, if there is cloud-to-ground


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lightening present in the immediate area, transfer operations will be shut down until the lightening hazard is no longer present.

► Check the River Dock area for any signs of spills. Address these as necessary.► When “good weather” has come back into the area, loading operations should be

restarted ASAP.

1004.7 Responsibility:1004.7.1 The River Dock Supervisor and Operators are responsible for prioritizing,

coordinating, and carrying out the critical activities in response to inclement weather.1004.8 Engineering controls:

1004.8.1 No engineering controls are required to complete this procedure.1004.9 Administrative controls:

1004.9.1 Emergency response requirements, including notification commitments, are included in several River Dock plans. Although not all may apply, the commitments made in the following plans should be considered in the initial response to a power failure:► Notify and call-out Memphis Refinery Fire Department► Notify and call-out Memphis Refinery Oil Spill/Hazmat Team► Fire Response Agreement with the City of Memphis► Spill Prevention, Control and Countermeasure (SPCC) Plan which has been

submitted to the U.S. Coast Guard► Facility Response Plans which have been submitted to the US EPA and DOT► Discharge Prevention and Contingency Plan that has been submitted to the

Tennessee Department of Environmental Quality (TDEQ).

1004.10 Procedure outline:1004.10.1 No procedure outline is included for this procedure as it is intended as a general

guideline only. Actual response will depend on the situation at hand.


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Section 1005 Emergency Procedure for Handling Personnel Injuries

1005.3 Purpose:1005.3.1 This procedure describes steps required to safely handle an injury to personnel at the

River Dock Area.


► Leaks of any gasoline and / or diesel should be handled per the Emergency Spill Response Policy.



gang plank)1005.4.3 Emergency procedure for handling personnel injuries at the River Dock area:

► In the event of injury to personnel♦ Report the situation immediately to the Oil Movement Superintendent or the

Refinery Shift Superintendent. ♦ Call out Memphis Refinery First Responders and EMT’s as available.♦ Notify Plant Nurse as available.♦ If the injury is serious or if there is a concern that the injury may be serious, an

ambulance should be called. The security guard should either make the call or be informed so they may direct the ambulance when it arrives.

♦ If the injured person is not a Refinery employee, the individual’s employer should be notified. As soon as possible (same day) an injury report should also be filled out. If personnel from the Refinery Safety Department are on site, they should also be notified.

1005.5 Responsibility:1005.5.1 It is the responsibility of the River Dock personnel to carry out this procedure. The

procedure must be carried out in a safe manner.

1005.6 Materials & equipment:1005.6.1 First Aid kits until other material becomes available

1005.7 Engineering controls:1005.7.1 No unique engineering controls are applicable to this procedure


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1005.8 Shutdowns:1005.8.1 There are emergency shutdowns switches that can be activated in the event of an

emergency event either in the Tank Farm area or River Dock area. These emergency shutdowns can be activated at any time.

1005.9 Procedure:1005.9.1 This procedure contains steps to safely handle a personnel injury at the River Dock

area. However, specific circumstances may change from time to time and trained, qualified River Dock personnel are expected to recognize those circumstances and take appropriate actions after careful consideration of their impact. The River Dock PIC must be consulted if in doubt about the specifics of a step in the procedure. Deviations from the recommended procedure must be documented on the actual procedure.


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Section 1006 Security Procedures

1006.3 DECLARATION OF SECURITY1006.3.1 The Dock PIC must ensure the Form RD-8 Declaration of Security is completed in

accordance with USCG regulations and the Refinery security plan. Regulations are noted below:

TITLE 33--NAVIGATION AND NAVIGABLE WATERS CHAPTER I--COAST GUARD, DEPARTMENT OF HOMELAND SECURITY PART 105_MARITIME SECURITY: FACILITIES Subpart B_Facility security requirementsSec. 105.245 Declaration of Security (DoS). (a) Each facility owner or operator must ensure procedures are established for requesting a DoS and

for handling DoS requests from a vessel. (b) At MARSEC Level 1, a facility receiving a cruise ship or a manned vessel carrying certain

dangerous cargo, in bulk, must comply with the following:(1) Prior to the arrival of a vessel to the facility, the Facility Security Officer (FSO) and Master, Vessel Security Officer (VSO), or their designated representatives must coordinate security needs and procedures, and agree upon the contents of the DoS for the period of time the vessel is at the facility; and (2) Upon the arrival of the vessel at the facility, the FSO and Master, VSO, or their designated representative, must sign the written DoS.

(c) Neither the facility nor the vessel may embark or disembark passengers, nor transfer cargo or vessel stores until the DoS has been signed and implemented.

(d) At MARSEC Levels 2 and 3, the FSOs, or their designated representatives, of facilities interfacing with manned vessels subject to part 104, of this subchapter must sign and implement DoSs as required in (b)(1) and (2) of this section.

(e) At MARSEC Levels 1 and 2, FSOs of facilities that frequently interface with the same vessel may implement a continuing DoS for multiple visits, provided that:

(1) The DoS is valid for a specific MARSEC Level; (2) The effective period at MARSEC Level 1 does not exceed 90 days; and (3) The effective period at MARSEC Level 2 does not exceed 30 days.

(f) When the MARSEC Level increases beyond that contained in the DoS, the continuing DoS is void and a new DoS must be executed in accordance with this section.

(g) A copy of all currently valid continuing DoSs must be kept with the Facility Security Plan.(h) The COTP may require, at any time, at any MARSEC Level, any facility subject to this part to

implement a DoS with the VSO prior to any vessel-to-facility interface when he or she deems it necessary.

[USCG-2003-14732, 68 FR 39322, July 1, 2003, as amended at 68 FR 60541, Oct. 22, 2003]


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Memphis Refinery River Dock Operations Manual March 2008 Sec 1100 – Safety and Environmental Information

Section 1100 Health Safety and Environmental{33 CFR Section 154.310.(a)(5)(ii)(e)}

1100.1 Introduction:1100.1.1 The River Dock area contains materials that can be dangerous to one’s health and has

the potential to expose personnel to fires and explosions. It is important that all personnel in the River Dock area be aware of potential hazards, the precautions necessary to prevent exposure to these hazards as well as control measures to take if exposure occurs.

1100.1.2 This section provides information on hazards and their prevention and control at the River Dock area including:

Section 1101 River Dock Area safe work practicesSection 1102 Chemical SafetySection 1103 River Dock leaksSection 1104 HousekeepingSection 1105 Safety systems and equipmentSection 1106 Static ElectricitySection 1107 Marine Vapor Emission Control Unit Safety

1100.1.3 The safety policies, procedures and equipment are intended to supplement – rather than replace – common sense, alertness and good judgment that all personnel are expected to use in carrying out their work. If there is any doubt as to the safety aspect of a particular operation, observation or event, consult your supervisor immediately.

1100.1.4 Mechanical craftsmen, contractors and others working at the River Dock Area will be subject to many of the same hazards as River Dock area personnel. The River Dock area personnel should review the work of others in this area to help ensure that this work is being conducted safely.

1100.2 Safety guidelines, policies and procedures:1100.2.1 Safe Work Practices (SWP) have been developed to help prevent exposing workers to

the hazards of the River Dock. These documents can be found in the Safety Manual on the Memphis Refinery Computer Network under the PSM Section. These include:► Lockout/Tagout► Confined Space► Opening process equipment/piping► Hot Work► Facility access control► Other safe work practices as needed (recommendations from NFPA, API, SOCMA,

and others)1100.2.2 As stated in the “Instructions to Contractors”, Safe Work Practices must apply to

contractors as well as to Valero employees.1100.2.3 Carriers and their employees must comply with all applicable laws, governmental

regulations and rules including, but not limited to, those set out in the Department of Transportation - Hazardous Materials Regulations, the United States Environmental


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Protection Agency, and all state and local environmental agencies. In addition to such regulations and to the extent not consistent therewith, the following specific rules must be observed.

1100.2.4 There should be strict adherence with all of the safety precautions embodied in this procedure.

1100.3 Precautions for the safe handling of cargo {33 CFR Section 154.310.(a)(5)(ii)(e)}1100.3.1 General loading procedures

► All warnings shall be displayed as required.► All personnel must wear personal flotation devices (PFD’) beyond the top of the

gang plank when accessing any dock facilities. ► Tankerman PIC and Dock PIC on duty shall inquire about and make themselves

aware of any repairs being made on the cargo vessel and/or dock facility► All connections on transfer hoses and vapor hoses (when used) shall be properly

assembled.► The Tankerman and Dock PIC on duty shall ensure that no fires or sources of

ignition are present when loading Grades A, B, or C cargo.► All personnel directly involved in the cargo transfer shall wear personal protective

equipment as required (refer to Material Safety Data Sheets in Section 1515)► Prior to cargo transfer, the Tankerman and the Dock PIC shall have a pre-transfer

conference and ensure that the Declaration of Inspection Bulk Cargo Transfer check list is complete and that the tank farm Pumper involved in the transfer has reported readiness to begin transfer. The following forms must be used as required:♦ Form RD-4 Declaration of Inspection ♦ Form RD-5 Declaration of Inspection Supplemental

1100.3.2 Procedure in the event of loading difficulties:► In the event of an emergency loading can be stopped by pressing the “Emergency

STOP Button” at the Barge Loading areaNote: The River Dock PIC must not leave the loading area while loading/unloading and the Tankerman PIC must not leave the Barge during Loading/unloading.

1100.4 Equipment tests and Inspections1100.4.1 All hoses and equipment used in the transfer of Oil and Hazardous Materials must be

inspected and tested in accordance with 33 CFR 156.17 Equipment tests and Inspections.► Hoses and connections must be inspected daily per procedure RD Hose Inspection

and Replacement.► Hoses will be hydrotested annually to ensure safety and compliance.► All inspection and testing records will be maintained at the River Dock Office.

1100.4.2 All Hoses must also be specified and marked per 33 CFR 154.500 Hose Assemblies.► Hoses used in the transfer of products at the River Dock are specified and marked

per procedure RD Hose Inspection and Replacement.


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Section 1101 River Dock Area Safe Work Practices (hazards and control)

1101.1 Personal Protective Equipment (PPE):1101.1.1 Normal River Dock personal protective equipment must be worn while loading,

unloading and/or transferring product. This includes:► Hard Hat► Safety Glasses► Steel Toed Safety Shoes► Protective Gloves► Personal Flotation Device (if accessing the barge dock area beyond the top of the

gang plank)

1101.2 Barge Sampling:1101.2.1 All sampling must be done in accordance with General Sampling Procedures.1101.2.2 When taking any samples protective clothing should be worn.

1101.3 Opening equipment:1101.3.1 Opening equipment such as pipelines, tanks and pumps present special safety

concerns. ► Unless proper precautions are taken in preparing the equipment, mishaps may occur. ► The particular risk present in the River Dock area is exposure to flammable

materials. 1101.3.2 Treat all equipment as if it were under pressure to ensure safety, even if all steps have

been taken to relieve pressure from the equipment.1101.3.3 In opening flanges or cover plates:

► First loosen and remove the bolts on the far side, away from and downwind of the person doing the work.

► Do this with a sufficient number of bolts allowed to remain tight on the near side until the connection can be wedged open.

► Any unanticipated trapped pressure will then be released away from the person doing the work.

1101.3.4 Wear any necessary special protective equipment when opening lines or valves. ► If special protective equipment is required, this information should be indicated on

the work permit.

1101.3.5 Electrical shock:► Never touch loose hanging electrical wires. ► Do not attempt to connect electrical wiring. ► Seek out an electrician to reconnect or disconnect any electrical service. ► Treat all electrical wires as though they are energized.


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Section 1102 Chemical Hazards:

1102.1 When working in the River Dock area you may be exposed to hazardous materials. Hazards of these materials, along with the controls necessary to prevent exposure to these hazards, are identified in the River Dock area MSDS book. General information is provided here. Additional information is available from the MSDS sheets for individual chemicals.

Chemical Name Properties Hazards Actions if Exposed

Hydrocarbon Liquid, Diesel

A yellow to yellow-brown, oily liquid with a petroleum odor

Diesel is combustible, can irritate skin and respiratory tract. Concentrated vapors may cause nausea and dizziness.

See MSDS for additional information.

In case of skin contact, immediately wash with soap and water. Seek medical attention if irritation develops.In case of eye contact, immediately flush eyes with water for 15 minutes including under the eyelids, and seek medical attention.If swallowed seek medical attention immediately. Do not induce vomiting.If inhaled, remove to fresh air. If not breathing, give artificial respiration. Seek medical attention immediately.

Hydrocarbon Liquid, Gasoline

Flammable liquids

Vapors can burn or explode on contact with a source of ignition in the presence of air or oxygen.

Contact with liquid can be irritating to the skin and eyes. Ingestion or inhalation in severe cases may result in death.

See MSDS for additional information.

In case of skin contact, immediately wash with soap and water. Seek medical attention if irritation develops.In case of eye contact, immediately flush eyes with water for 15 minutes including under the eyelids, and seek medical attention.If swallowed seek medical attention immediately. Do not induce vomiting.If inhaled, remove to fresh air. If not breathing, give artificial respiration. Seek medical attention immediately.


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Chemical Name Properties Hazards Actions if Exposed

Benzene

Liquid -- colorless to pale yellow watery liquid with a gasoline-like odor

EXTREMELY FLAMMABLE LIQUID AND VAPOR. Cancer hazard. Contains material which can cause cancer. Causes damage to the following organs: blood, respiratory tract, skin, eyes, bone marrow, central nervous system, eye, lens or cornea. Contains material which causes damage to the following organs: kidneys, liver. VAPOR MAY CAUSE FLASH FIRE. MAY BE HARMFUL IF SWALLOWED.

In case of contact, immediately flush skin with plenty of water. Wash exposed area thoroughly with soap and water. Remove contaminated clothing promptly and launder before reuse. If irritation persists or symptoms described in the MSDS develop, seek medical attention. High pressure skin injections are SERIOUS MEDICAL EMERGENCIES. Get immediate medical attention.

1102.2 The primary hazard at the River Dock area is the risk of explosion and fire from flammables. Additives used can be dangerous to ones health if they are inhaled, swallowed or come into contact with one’s skin. There is a remote chance that H2S may be present in some of the cargos handled in the River Dock Area. It should be noted that there are no known hazards associated with mixing of chemicals at the River Dock area. Always refer to the MSDS for any questions.

Material Hazard ControlHydrogen Sulfide (H2S)

Flammable gas that is toxic and can be fatal if inhaled. Eye and respiratory irritant. Colorless gas with an offensive odor (rotten eggs) at low concentrations. Heat is generated on reaction with alkaline materials. Corrosive to many materials when moist. H2S is an irritant to all moist tissues. The sense of smell is immediately paralyzed on exposure at 200 ppm. At 1000 to 2000 ppm, collapse and death are imminent if removal to fresh air and restoration of breathing are not rapidly accomplished

An SCBA or breathing air is required while working with containable leaks. PPE (personal protective equipment) is required


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Material Hazard Control

Miscellaneous Hydrocarbons (gasoline and diesel fuels)

Flammable liquid. Vapor can be harmful and is a possible aspiration hazard. Can be irritating to the skin, eyes, and respiratory tract. Can release toxic H2S vapors.

Provide sufficient means of ventilation. PPE considerations include splash goggles or face shield, chemical-resistant gloves, respirator, and protective clothing to minimize skin exposure.

Sodium Hydroxide (Caustic Soda)

Corrosive Liquid. Vapors can be harmful if Spent Caustic is being handled, as it can contain H2S. Can cause severe burns/skin irritation upon skin contact. Can cause blindness if comes in contact with eyes.

Provide sufficient means of ventilation. PPE considerations include splash goggles or face shield, chemical-resistant gloves, respirator, and protective clothing to minimize skin exposure

Benzene

EXTREMELY FLAMMABLE LIQUID AND VAPOR. Cancer hazard. Contains material which can cause cancer. Causes damage to the following organs: blood, respiratory tract, skin, eyes, bone marrow, central nervous system, eye, lens or cornea. Contains material which causes damage to the following organs: kidneys, liver. VAPOR MAY CAUSE FLASH FIRE. MAY BE HARMFUL IF SWALLOWED. Do not ingest. Keep away from heat, sparks and flame. Keep container closed. Use only with adequate ventilation. Wash thoroughly after handling. Risk of cancer depends on duration and level of exposure.

Provide sufficient means of ventilation. PPE considerations include splash goggles or face shield, chemical-resistant gloves, respirator, and protective clothing to minimize skin exposureKeep away from heat, spark and flames. In case of fire, use water spray, foam, dry chemical or carbon dioxide as described in the Fire and Explosion Hazard Data section of the MSDS.


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Section 1103 River Dock Area Leaks:

1103.1 The possibility of leaks at the River Dock area always exists. Leaks are dangerous and should be repaired as soon as possible. The River Dock area does handle cargos that have contained H2S, and the possibility does exist that it could be present. Fresh air equipment should be used to isolate a leak that may be releasing H2S to the atmosphere. Review the MSDS for H2S for properties of H2S and required protective equipment.

1103.2 Responses to specific minor leaks are listed below:

Source Response

Leaking Hydrocarbon FlangesTry to tighten up flange to stop leak. Notify supervision. Fill out a work order. Clean up area as necessary.

Leaking Hydrocarbon from Bull Plug

Close down on the bleeder valve. Monitor the leak (should slow down) to verify valve has closed. Bleed off any remaining pressure by slowly loosening the bull plug. Clean and re-dope the threads and install. Clean up area as necessary.

Leaking Hydrocarbon Packing Glands

Tighten packing glands and nuts with a wrench. If packing cannot be adjusted, fill out a work order for supervision. Clean up area as necessary.

NOTE: Contact the Environmental Department for proper clean-up and disposal of material from any leak.

1103.3 Notify the Environmental Department of any leak that may be a recordable or reportable quantity of hazardous material.

1103.4 Follow procedures per Section 1002 for discharge of product into the water.


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Section 1104 Housekeeping:

1104.1 Housekeeping is an important part of a plant safety program. A clean workplace will be free of the hazards that cause a high percentage of work related accidents. Each person has the responsibility to see that everyone performing work in the area follows good housekeeping practices.

1104.2 Following are some simple guidelines used for proper housekeeping:1104.2.1 No job is complete until the work area has been cleaned.

► Tools and equipment must be returned to their proper place. ► All waste should be placed in trash containers. ► Tools, boards, wire, pipe and other types of debris, which may be lying around are

tripping hazards that could cause a serious injury.

1104.2.2 All aisles, stairs, passageways, and ladders should be kept clean and free of tripping hazards.

1104.2.3 All work areas should be kept clean and free of material that may fall (scaffold boards, wire, pipe insulation, conduit, etc.).

1104.2.4 Guards around moving shafts, couplings, etc., which have been removed for repairs to the equipment, must be replaced when repair work is completed, or before restarting equipment.

1104.2.5 Liquid spills must be contained and cleaned up immediately. This will eliminate the potential for slips and falls.

1104.2.6 Fire extinguishers must be recharged or replaced immediately after use. ► Access to such equipment must not be obstructed.► Fire extinguishers must be inspected monthly.

1104.2.7 Operating equipment should be checked frequently for signs of leakage, overheating, or corrosion so that unsafe conditions may be corrected before they result in serious consequences. ► Unusual conditions should be reported at once.


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Section 1105 Safety Systems and Equipment:

1105.1 Safety systems:1105.1.1 Relief systems:

► Thermal relief valves are provided for thermal expansion of the product in the lines. These are located on sections of line that can be blocked in. These relief valves discharge to a tank or a section of line that is vented.

1105.2 Fire and safety equipment: 1105.2.1 Safety equipment:

► All safety equipment should be checked to ensure it is in it’s proper location and functional. If it is not, the problem should be brought to the attention of a supervisor. Fire extinguishers must be fully charged and ready for immediate use. Access to all safety equipment must not be obstructed.


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Section 1106 Static Electricity:

1106.1 Introduction:

1106.1.1 Hazards from static electricity are present in a significant number of procedures followed in the River Dock area. The following general discussion is presented to explain how static electricity is generated and how to avoid potential hazards associated with static electricity. Static electricity generation is of most concern while loading lighter materials or when loading a heavier material into a compartment which previously contained a light material. Although the following discussion focuses around truck loading, similar hazards can be created while transferring product into barge compartments.

1106.1.2 Minimum hazard is associated with loading gasoline or other high vapor pressure products as long as:► Good bonding and grounding has been established before loading hatches have been

opened► As long as at least one minute has been allowed for static charge relaxation before

either spouts are withdrawn or load samples are taken.► NOTE; In loading lighter products (i.e. Gasoline), the compartments soon become

"too vapor rich" for ignition from static electrical charges that later reach a hazardous sparking potential.

1106.1.3 The hazard from static electrical ignition is not pronounced when loading distillates (diesel fuels):► At temperatures below their flash points► Into compartments previously containing these same products► NOTE; However, a serious hazard can exist when such products are being loaded

with excessive splashing or into a compartment that previously contained low flash volatile products

1106.1.4 The greatest exposure to serious fires and explosions at loading areas exists when:► Barge compartments are being "switch loaded" (filling a compartment with diesel oil

after it previously contained gasoline).

1106.1.5 All personnel connected with loading, from designers to loaders, should be thoroughly aware of the hazards of "switch loading" and the precautions that must be taken to reduce or eliminate the risk involved.


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1106.2 Static electrical ignition:1106.2.1 Static electrical charges of sufficient voltage to cause sparking in petroleum products

are built up as a result of turbulent flow through pipes and through filters using paper or cloth elements, and as the oil splashes into the compartments in the vessel being loaded.

1106.2.2 Some of the heavy fuels will quickly dissipate static charges due to good electrical conductivity of entrained moisture or impurities. Consequently, they present no significant static ignition potential. Other fuels, such as the diesel fuels, gasoline, etc., retain static charges on their surface long enough so that sparking to other objects such as fill pipes or barge structural parts readily takes place. When the energy of a spark is great enough in a vapor space containing hydrocarbons within the flammable and/or explosive range, ignition/fire/explosion will occur.

1106.2.3 In order to reduce or prevent fires caused by static electrical charges, it is necessary to carry out one or more of the following to be effective:► Control of static generation► Neutralization of static charges► Bonding► Grounding► Control of the atmosphere above the product being loaded► Switch loading comments

1106.2.4 Control of static generation:► Electrostatic generation (static charges) in hydrocarbons passing through piping is

usually not critical if turbulence is not excessive, allowing charges that have been generated to quickly dissipate to the metal piping. On the other hand, high transfer rates and hydrocarbons passing through product filters utilizing cotton, paper or felt elements generate strong static charges that require significant relaxation time to dissipate charges in the flow between the outlet of the filter and the tip of the loading tube. Additional relaxation time is achieved by utilizing special relaxation chambers or longer runs of pipe.

► With higher purity products, particularly as produced by hydrodesulfurization, a tyPICal relaxation time can range from 100 to 500 seconds or more under some conditions.

► Electrostatic charges are also generated as the oil enters the tank compartment with the intensity being proportional to the amount of flow turbulence which, in turn, is dependent upon the rate at which the product enters the compartment, as well as the design of the loading pipe tip.

► Loading tips of various designs have been investigated. The straight tips formed by a loading tube cut at right angles to its centerline would appear to be unsatisfactory from the standpoint of causing turbulence and its tendency to be thrown upward when loading is initiated. In contrast, a loading tube cut at a 45 degree angle to its centerline forms a loading tip which at moderate flow rates has satisfactory turbulence characteristics and is perhaps the least costly of the loading tips in


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common use. With all loading operations, the loading tube should be of all metal construction and of sufficient length to rest on the bottom of the tank compartment.

1106.2.5 Neutralization of static charges:► After loading has been completed, a static charge relaxation time of at least one-

minute should be allowed before the loading pipe is withdrawn and before any sampling devices are inserted. This period of time is essential to permit charges on the surface of the oil to migrate to the loading pipe or to the compartment structure where they are neutralized. Here again longer periods may be advisable when handling pure products, especially in colder weather when static dissipation takes place at a slower rate.

► Anti static additives have been developed for addition to distillates, which increases conductivity and consequently drastically reduces the hazard of static charge buildup: however, in less than recommended concentrations, these materials actually increase the hazard.

► In drier climates, there can be an appreciable buildup of static charge. Proper bonding and grounding before loading operations begin dissipates the static electricity build-up.

1106.2.6 Bonding:► Bonding is accomplished by joining two pieces of metal with a wire, which in effect

reduces the electrical potential to zero volts between the two pieces, thus eliminating the chance of a spark.

► Good bonding is essential between the loading pipe and the shell of the tank compartment in order to eliminate sparking at the hatch and should be established before the loading pipe is inserted into any compartment.

► Since bonding is effective only on electrically conductive material, it would have no effect in neutralizing the charge on the surface of oil within the tank compartment.

► Bonding is usually accomplished by means of heavy flexible stranded steel or copper cable securely attached to a fixed portion of product pipe riser on one end, and clamped to the shell of the compartment being loaded on the other end using a strong alligator clip or pressure clamp.

► Electrostatic bonding is considered adequate as long as resistance in the circuit does not exceed 1,000,000 ohms.

► Condition of the alligator (grounding) clips, especially the joint between the bonding wire and the clip, should be periodically examined by inspection to ensure effective bonding circuits.

► Loading arms that drop down to touch the “Barge Shell” should not be considered as effective electrical bonding for loading operations.

1106.2.7 Grounding:► In grounding, the bonding system is electrically connected to the earth so that any

static charges, as well as any stray electrical currents are led into a common grounding system.


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► The effectiveness of the grounding system should be checked regularly. Resistance of over 5 ohms is seldom encountered. Correction of grounding is recommended where readings are in excess of 10,000 ohms.

1106.2.8 Control of the atmosphere above the fuel:► This practice mostly involves reduction in oxygen level in the compartment being

loaded to a point where combustion cannot take place. Generally, with gasoline and other products having a Reid Vapor Pressure above 4.5 psi, the vapor in the compartment is "too rich" to burn and need only be properly bonded for safe loading operations. Intermediate products having Reid Vapor Pressures below 4.5 psi and also a flash point below 100°F produce vapor concentrations within the flammable range that can easily be ignited by static charges on the surface of the oil.

► Maximum safety in loading these products calls for reduction of the oxygen level in the compartment below concentrations necessary for the support of combustion. This can be accomplished by injecting sufficient quantities of CO2, nitrogen, or inert gas into the vapor space prior to loading. The same result can be accomplished by gas blanketing the compartment with fuel gas or heating the oil sufficiently to maintain a "rich" vapor condition over the oil. Due to the time consumed and the extra expense involved, these practices are not generally followed. The only alternative is to minimize static potential as outlined in the sections above.

1106.2.9 Switch loading:► This practice and the hazards associated with it accounts for 70% - 80% of serious

losses reported, consequently, switch loading merits special attention from all those connected with safety.

► Switch loading is the loading of low vapor pressure products into a compartment that previously contained a high vapor pressure product, such as loading kerosene or diesel fuel into a compartment previously containing gasoline.

► A flammable vapor space is present over the lower vapor pressure product because the compartment has been partially ventilated when unloading the previous load of gasoline, thus reducing the "over rich" condition to a flammable condition. The lower vapor pressure product usually retains static charges long enough to create a potential ignition source.

► Switch loading losses seem to occur most frequently when the compartments are one quarter to one-third full and when temperatures are close to 30°F.

► Proper bonding and grounding are not effective in preventing such losses, since the spark discharge in switch loading ignitions occurs between the surface of the charged oil and the metal of the fill pipe or barge compartment. The principal means of preventing switch loading fires would be to eliminate the practice altogether.

► If switch loading is necessary, the hazard can be eliminated by injecting sufficient quantities of CO2 or nitrogen into the vapor space prior to loading so as to eliminate the possibility of combustion. Air eduction to free the compartment of flammable vapors can be effective; however, if there are two or more baffles on each side of the loading hatch, or if there is too long a delay between eduction and subsequent filling,


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the effectiveness is diminished. This practice also adds to air pollution by hydrocarbons.

► Relative safety in switch loading can be accomplished by using a proper combination of the precautions listed below:♦ Reduced barge compartment fill rates - Initial rate of 3 feet / second, Then a final

rate of not over 15 feet / second.♦ Installation of static neutralizing devices on pipe risers handling intermediate oils

having Reid Vapor Pressures below 4.5 psi.♦ Provision of relaxation time for product flows between filters and loading tips.♦ The addition of neutralizing additive. (Conductivity improver)♦ Installation of loading arm tips that produce a minimum of flow turbulence.♦ Insertion of loading tip into the compartment until it touches the bottom of the

tank.


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Section 1107 Marine Vapor Emission Control Unit Safety

TABLE OF CONTENT1107.1 Safety1107.2 Blower Rotation & Operation1107.3 Explosion Hazards1107.4 Electrical Equipment1107.5 Mechanical Repair1107.6 Confined Spaces1107.7 Pressurized Gas

1107.1 Safety:1107.1.1 REPROGRAMMING WARNING: The Programmable Logic Controller (PLC) is the

computer controlling the MECS. The PLC is programmed to ensure proper MECS operation. Accidental or unauthorized reprogramming of the PLC may result in unsafe or dangerous operation of the MECS and/or void the MECS equipment warranty.

Note: It is the Memphis Refinery’s responsibility as the owner/user of this equipment to ensure that all persons around this equipment are thoroughly trained and familiar with its operation, maintenance, and safety requirements. Only qualified personnel knowledgeable in the operation, maintenance, and safety aspects of this equipment should approach and operate this equipment.

1107.2 Blower rotation and operation1107.2.1 Never operate the blower with either its suction and/or discharge line blocked. Blocked

vapor flow can cause damage to the blower wheel, which could allow hydrocarbon vapor to be released into the atmosphere.

Note: After MECS installation, before the system is placed into service, it is important to verify the rotation direction of the blower. Reverse rotation of the blower wheel may ultimately result in catastrophic mechanical failure and result in poor blower performance.

1107.3 Explosion hazards1107.3.1 If hydrocarbon vapors are released into the air, they may become explosive. Smoking

or other ignition sources must be prohibited anywhere in the vicinity of this equipment due to the risk of fire or explosion.


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1107.4 Electrical equipment1107.4.1 To reduce danger of electric shock, any circuit on which work is being performed

should be disconnected from the power source. Be sure all electrical equipment is adequately grounded prior to turning the power.

1107.5 Mechanical repair1107.5.1 During any mechanical repair or prolonged shutdowns, turn all panel switches OFF,

disconnect all power, and shut off all gas lines to the equipment. At all other times leave all panel power switches set to ON to provide power to the panel space heaters.

1107.6 Confined spaces1107.6.1 MECS vessels may at times require internal work. These spaces may contain oxygen

deficient, flammable, or toxic atmospheres, which must be adequately purged. Before any entry, lockout/tagout and confined space entry procedures are required. Do not enter any vessel until all owner specified safety procedures have been completed.

1107.7 Pressurized gas1107.7.1 Gas under pressure can be dangerous. The following guidelines for working around

pressurized equipment must be followed:► Never expose piping, vessels, or equipment to pressures higher than their design

pressure. Excessive pressure can result in vessels or lines leaking, bursting, or rupturing, or in other types of dangerous pressure release. Be aware of the design pressures of the equipment you are working with and the gas pressure present. Refer to RD MECS Equipment Design Table.

► Keep all gas connections tight. Leaking gas containing hydrocarbon vapors always presents the danger of fire or explosion. A flanged or threaded connection just tight enough to hold a vacuum or a few pounds pressure may leak at higher pressure. Always use an appropriate thread sealant on screw connections, and make sure gaskets are in good condition and properly positioned to provide full surface contact.

► Always be sure the pressure is relieved before opening any piping or vessel connections.

► Do not vent gas pressure by loosening a component connection. Use vent and drain valves provided for this purpose. Even at low pressure, the pressure on components can be great enough to pose a hazard.

► Protect your hearing. Pressurized gas being vented may produce a very loud, high frequency sound, which may not be uncomfortable but can cause damage. When working around such a vent, use ear-plugs or other suitable hearing protection.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 1200 – Mechanical Description

Section 1200 Mechanical Description

1200.1 Mechanical Integrity information is located in the Inspection Department files of the Memphis Refinery.

1200.2 Mechanical Descriptions, design data and other process safety information is located in the Engineering Department Equipment files at the Memphis Refinery.

1200.3 Information necessary for the operation of equipment at the River Dock is included in Section 700 of this Manual.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 1300 -- Utilities

Section 1300 Utilities

1300.1 The required utilities and respective sources for the facilities are shown below:

Utility SourceElectric Power Memphis RefineryAir Memphis RefineryFire Protection Water Memphis RefineryPotable Water Memphis RefineryNitrogen Memphis RefinerySteam Memphis Refinery

► Electrical equipment will meet standards for Electrical Class 1 Div 1 explosive atmosphere.

► Compressed air is provided by the refinery at 100 psig for the River Dock.► Nitrogen is provided by the refinery at 150 psig for the River Dock.► Steam is provided by the refinery 150 psig Steam Distribution System.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 1400 -- Chemicals

Section 1400 Chemicals

1400.1 Additives are used in the gasoline and some of the diesels that are loaded and shipped from the River Dock area. These additives contain several different chemicals. The additives stored at the River Dock area and the maximum volume stored at the facility are shown below:

Additive Package Use Max. Storage Volume (Gal.) Location

Red Dye Added to non-taxed diesel products 4000 South of North Dock

Office

1400.2 Safety and environmental information on the additives can be found on the MSDS kept at the River Dock office and can also be found on the Valero Computer Network - PSM area.

1400.3 There is no catalyst used at the River Dock area.

1400.4 Products transferred at the River Dock facility are noted in Table RD-A Products Transferred at River Dock Terminal.


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Memphis Refinery River Dock Operations Manual March 2008 Sec 1500 -- Appendices

Section 1500 Appendices

SectionSub-

Section Description1500 Appendices

1510 Tables1511 Forms and Log Sheets1512 Procedures Catalogue1513 Glossary1514 Drawings1515 MSDS


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Section 1510 Tables

Title Table refers to Coast Guard Reference:

Table RD-A Products Transferred at River Dock Terminal33 CFR Section 154.310.

(a)(5)Table RD-B Emergency Notification 33 CFR Section 154.310.

(a)(7)Table RD-C Emergency Dock Equipment List 33 CFR Section 154.310.

(a)(14)


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Section 1511 Forms and Log Sheets

Since some forms will change over time, please make sure to refer to the latest forms for your use.

Title ResponsibleForm RD-1 Daily Check List River Dock PICForm RD-2 Spill Response Notification River Dock PICForm RD-3 Coast Guard Hot Work Permit River Dock PIC

Form RD-4 Declaration of Inspection River Dock PICTankerman

Form RD-5 Declaration of Inspection Supplemental River Dock PICTankerman

Form RD-6 River Dock Daily Log River Dock PICForm RD-7 River Dock Log Book River Dock PICForm RD-8 Declaration of Security River Dock PICForm A Jet A Barge Receipt Quality Assurance Check List River Dock PICForm B Jet A Barge Loading QC Check List River Dock PICForm T ULSD Barge Receipt Quality Checklist River Dock PIC

Notes concerning forms use and records retention:All records must be self-explanatory and legible.The Refinery, Terminal and Pipeline Supervisors shall routinely, in a timely manner, review the completed forms for any abnormal conditions and for proper and timely entries. All records shall be dated and signed by the person(s) responsible for completing the forms.All records shall be kept for a minimum period of five (5) years or as required in the Corporate Records Retention Policy, whichever is longer.


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Section 1512 Procedures CatalogueThe standardized procedures utilized in this manual are listed below. Please make sure to refer to the PSM database for the most current version of these procedures.

Terminal Procedure and Link Marine Emission Control System ProceduresRD Adding Red Dye RD MECS Analyzer Alarm ShutdownRD Barge Loading Blend Stock from Blender RD MECS Annual TestsRD Barge Loading North Dock RD MECS Declaration of Inspection Supplemental RD Barge Loading Rotating Blinds RD MECS Equipment Design Table..RD Barge Loading South Dock RD MECS Equipment ListRD Barge Loading Unloading Checklist RD MECS Instrument SetpointsRD Barge Unloading North Dock RD MECS Maximum Flow Rates RD Barge Unloading South Dock RD MECS OperationRD Coastal Hydraulic Crane Operation RD MECS Panel DescriptionRD H2S Handling RD MECS Pre Start ChecklistRD Hose Inspection and Replacement RD MECS Pre Transfer Checklist RD North Dock Daily Checklist RD MECS Shutdown AlarmsRD South Dock Daily Checklist RD MECS Startup RD Training and Qualification for PIC RD MECS System Startup Interlocks RD Transferring Product Tank to Tank RD MECS TroubleshootingRD Transferring Product to WMT PipelineRD Work Permits

The Procedures below are associated referenced only for the River Dock. These procedures relate to the Valero Memphis Refinery Quality Management System and provide additional information for working with specific products and areas.

Gasoline Barge Loading 58 59 71 76 80 Tanks General Gauging a Tank or BargeGasoline Barge Loading from Tk 002 General Sampling ProcedureGasoline Barge Unloading to Tk 002 General Loading Barge From Dead TankGasoline Barge Unloading to Tks 58-59-71-76 or 80 Jet A Barge Loading from Tanks 101, 102 and 115 Gasoline Blend Component Barge Unloading Jet A Barge UnloadingGasoline Blending to a BargeGasoline Blending WMT Pipeline Alignment ULSD Barge Loading Gasoline Line Wash for Blending to Barge or WMTP ULSD Barge Unloading Gasoline Receive Gasoline from WMT via Pipeline ULSD Refinery Tank to WMT Pipeline Align and

Switch Gasoline Refinery Tank to WMT Pipeline Alignment WMT Pipeline Batch Switch Gasoline Riverline Line Wash from 58 59 71 76 80

TksWMT Pipeline Receipt Alignment to a Tank

Gasoline Riverline Line Wash from Tk 002 Ethanlol Barge Unloading Tk 80


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Section 1513 Glossary

The terms included in this glossary are those that have a meaning in the refining industry that is somewhat different from their dictionary definitions.

Acfm Actual cubic feet per minute

Adm Admiralty

AISC American Institute of Steel Construction

AMBIENT TEMPERATURE

The air temperature surrounding a specific area

API American Petroleum Institute

API DEGREES Units used for density measurement.

API GRAVITY The petroleum industry’s scale and method of measuring density of liquid petroleum products, including ULSD fuel

API Gravity A special gravity scale adopted by the API for expressing gravities of liquid hydrocarbon products:

API = ( 141.5 ) - 131.5Specific Gravity @ 60°F

ASME American Society of Mechanical Engineers

ASTM American Society for Testing Materials. An organization that sets up standards for testing industrial products.

ASTM COLOR A test method for determining the color of a wide variety of petroleum products such as: Lubricating oils, heating oils, diesel fuel oils, and petroleum waxes with a range of 0 (clear oils) - 8 (dark oils).

ASTM D 86 A test method used to obtain an assay of a mixture whose heaviest molecule boils at about 700oF (370oC).


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ASTM DISTILLATION Any one of several distillation tests made in accordance with specific ASTM distillation procedures. The most common distillation tests are the D 86 used on light products like gasoline and jet fuel, and the D 1160 used on heavier products like vacuum gas oils.

BASIC TESTS A selected set of tests carried out, during or after certain types of movement, to verify that the ULSD has not been contaminated or the quality of the fuel has not otherwise changed and remains within the specification limits for specified critical properties.

BAT Bed Average Temperature. A general measure of operating severity of the catalyst bed.

BATCH A batch of fuel is an identifiable quantity, produced at a refinery, tested and identified as a single entity. If product from two different batches is mixed, i.e., at a terminal, it is re-tested and re-identified as a new batch.

BOILING POINT The temperature at which a substance boils, that is, when the liquid is converted into vapor. The boiling point of a substance increases if the pressure on it is raised and decreases if the pressure is lowered. This term is usually restricted to pure substances. The corresponding term of mixtures that exhibit a boiling range is a bubble point.

BOILING RANGE The range of temperature, usually determined at boiling range. The range of temperature, usually determined at atmospheric pressure and by a distillation test, over which boiling or distillation of a liquid proceeds. Only a pure substance has one definite boiling temperature at a given pressure. Mixtures, such as petroleum products, exhibit a boiling range.

BONDING The physical connection of two metal objects by an electrical conductor, which equalizes the charge or electrical potential between the two objects. Example: tank truck bond to the loading rack with a metal cable to equalize the charge, thus reducing the possibility of generating sparks while loading.

BPD Barrels per day

BPH Barrels per hour

CATALYST A material that promotes a desired reaction (without itself undergoing a chemical change).


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CERTIFICATE OF ANALYSIS (C OF A)

A Certificate of Analysis should be prepared to document the full specification analyses performed at the refinery. The C of A normally shows the date, test methods, test results, batch number, batch quantity, tank number, and the type and quantity of additives, if used. A person responsible for the test results should sign the C of A.

CETANE NUMBER The percentage of pure Cetane in a blend of Cetane and alpha-methylnaphthalene, which matches the ignition quality of a diesel fuel sample. This quality, specified for middle distillate fuels, is analogous to the octane number for gasolines.

CHARGE Blend-stock to a refinery-processing unit.

CI Cast iron

CLOUD POINT The temperature of a liquid specimen when the smallest observable cluster of wax crystals first appears on cooling under prescribed conditions.

COLOR ULSD fuel is usually a “pale yellow” to “blue green” tint.

COMMINGLE The mixing of product from two different sources or batches so that each loses its original identity.

CONDUCTIVITY The capability to transmit electrostatic charges, normally expressed pico Siemens per meter (pS/m) for petroleum products. It is the reciprocal of electrical resistivity.

CONDUCTIVITY IMPROVER

A material added to a fuel in very small amounts to increase its electrical conductivity and thereby reduce relaxation time.

CONTAMINANTS Substances, either foreign or native, which may be present in ULSD fuel that may detract from its performance.

COOLER A heat exchanger whose primary purpose is to reduce the temperature of one of the passing fluids.

CORROSION Destruction of a metal surface as a result of a chemical reaction. Corrosion can be caused by acids or other corrosive agents.

CORROSION INHIBITOR

A chemical mixture, which is added to a corrosive system to reduce or eliminate corrosion problems.

CRUDE A short name that describes raw or unrefined petroleum or crude oil.


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CRUDE OIL A synonym for petroleum. A naturally occurring mixture consisting predominately of hydrocarbons and or sulfur, nitrogen, and oxygen derivatives of hydrocarbons. Crude oil is removed from the earth in a liquid state, or is capable of being so removed.

CS Carbon steel

CUT An individual product obtained during the distillation of oil.

CUT POINT The boiling temperature division, based on a distillation curve, between two cuts. The boiling ranges of two adjacent cuts overlap, so that the cut point is the temperature below which most of one cut boils and above which most of the next higher cut boils.

D 86 An ASTM test method used to determine the boiling point distribution of a cut with an endpoint lower than about 700oF (370oC).

DEDICATED A completely segregated system of tankage, pipes, vehicles, etc. which handles only ULSD product. Complete segregation can best be achieved by removing all interconnecting lines between pipelines which handle different products, and between pipelines that handle tested and untested product. If interconnecting piping must be left in place, dedicated segregation can be achieved by the use of blind spectacle flanges, double block valves with bleed valve or by a twin seal valve with body bleed.

DENSITY The amount of mass (weight) in a unit volume of material.

DESULFURIZATION The removal of sulfur compounds from oil. Desulfurization methods used include sweetening, amine treating, and hydrodesulfurization, and by reaction with hydrogen to form hydrogen sulfide.

DIESEL A combustible liquid hydrocarbon distilled from petroleum that has a boiling range of 400o - 650°F.

DIFFERENTIAL PRESSURE

The measured difference or Delta (ΔP) in pressure between any two points, generally between the inlet and outlet connections on filtration vessels.

DIRECT READING ∆P GAUGE

A pressure gauge that automatically displays the differential pressure between the inlet and outlet connections of a filtration vessel.

DISCHARGE LINE Product line usually under pressure due to a pumping force being applied.


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DISSOLVED WATER Water that is in solution in ULSD. This water is not free water and cannot be removed by normal means.

DISTILLATE The part of a liquid that is vaporized and then condensed during a distillation process. Any liquid stream from a distillation column other than the bottoms product.

DISTILLATION The process of heating a liquid mixture, forming vapors, and then condensing the vapors separately from the un-vaporized liquid. The purpose of distillation is to separate the mixture into fractions (cuts), distinguished mainly by their different boiling ranges. Distillation occurs only when vapor and liquid are brought into contact with each other, and then allowed to separate.

DISTILLATION COLUMN (TOWER)

A vertical, cylindrical vessel designed for continuous distillation of a mixture to separate it into various fractions (cuts), each covering a different boiling range. The column (tower) is constructed so that rising vapors are contacted with falling liquid on a series of trays. The vapor passes from one tray to the next above it by bubbling through the liquid on the tray. The high boiling point components of the vapor condense and overflow with the liquid to the tray below. This results in a separation of the feed from tray to tray into fractions in order of the condensing or boiling point temperatures. Products are removed from the top of the column as an overhead product, from various trays as side cuts, and from the bottom of the column as bottoms product.

DISTILLATION TEST Any of several laboratory tests used to characterize an oil with respect to the boiling points of its components. In tests, the oil is distilled and the temperature of the condensing vapor and the volume of liquid formed are recorded. The information is then used to construct a distillation curve of liquid volume percent (LV%) distilled versus condensing temperature. The condensing temperature of the vapor at any point in the test will be close to the boiling point of the material condensing at that point. For a pure substance, the boiling and condensing temperature are exactly the same. Hence, the distillation curve provides useful information as to the amount of materials in the oil that falls into various boiling ranges.

DOC TEST A very sensitive test for the detection of mercaptan and H2S in naphtha. A negative Doc Test indicates an extremely low concentration of mercaptan and H2S. The Doc Test is used primarily for motor gasoline.


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DOUBLE BLOCKS AND BLEEDER

Two consecutive block valves, separated by a short length of pipe with a third block valve off a tee. Used to give positive isolation between two systems. The third valve is usually kept open to detect if there is a leak through either of the two main valves.

EFFLUENT An outflow or stream flowing out. This is the opposite of feed.

ELEMENTS A generic term given to different types of decontamination media installed in various types of filtration vessels.

EMULSION An intimate mixture of two liquids, which are not miscible with each other, such as oil and water. Fine particles of one of the liquids are so thoroughly dispersed in the other liquid that they do not coalesce to form a separate phase. Oil-in-water emulsions have fine droplets of oil dispersed in a water phase. Water-in-oil emulsions have fine droplets of water dispersed in an oil phase.

END POINT The final temperature, determined by a distillation test, at which boiling or distillation of a liquid takes place (heavy ends).

ENIC Equipment not in commission

ENTRAINED WATER Small droplets of free water in suspension that may make ULSD appear hazy or cloudy.

ENTRAINMENT Vapor or liquid carried along in a dissimilar process stream. Also referred to as carry-over. Entrainment occurs when the velocity of the process stream becomes high enough to overcome the gravitational forces that would normally cause the dissimilar materials to separate. A variety of types of entrainment can occur. For example, overhead vapor leaving a distillation column may contain entrained liquid, water from a desalter may contain entrained oil, oil from the atmospheric column reflux drum may contain entrained water, or oil leaving the flash zone of a distillation column may contain entrained vapor bubble.

EPA Environmental Protection Agency — The federal agency responsible for enforcement of air and water quality regulations.

FCCU Fluid Catalytic Cracking Unit

FILTER A decontamination device to remove solid particles from ULSD.


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FILTER EFFICIENCY Filter manufacturers often refer to their products as “nominal 5 micron” filters, or as filtering down to 5 microns. This means that the filter should remove better than 90 to 95 % of all the 5 micron, or larger particles reaching it. It will usually remove a large percentage of particles smaller than 5 microns.

FILTER MEMBRANE TEST

A standard test in which ULSD fuel is passed through a small filter membrane housed in a plastic holder. The cleanliness of the ULSD fuel can be determined by measuring the residue or amount of solid contaminates left on the fuel or matching the color to color standards. (See Millipore)

FILTER/ SEPARATOR A vessel with two stages of filtration and water separation, through which ULSD fuel passes to remove dirt and water. The first stage coalescer removes dirt and coalesces water; and the second stage (separator) prevents residual water droplets, that have not yet settled, from leaving the filter vessel with the fuel.

FILTERING The separation of solids from a carrier liquid by allowing the liquid to pass through a porous medium. Typical filtering media are filter clay, chemically treated paper, felt, canvas, woven wire, and synthetic cloth.

FILTRATION The process of separating solids from a fluid by passage through a porous medium.

FLAMMABLE Capable of being easily set on fire or combustible.

FLASH POINT The lowest temperature at which an oil gives off enough vapor to make a small flash when a flame is passed over it. The flash point is an indication of the temperature below which the oil can be handled without the danger of fire. Flash points of distillation products like naphtha and heavier, are analyzed to make sure they are safe for storage.

FLOATING SUCTION Pump suction piping with floatation capability used to draw the cleanest fuel from the upper level of the fuel in a tank.

FRACTIONATING COLUMN

A column arranged to separate various fractions of petroleum by a single distillation. The column may be tapped at different points along its length to separate various fractions in the order of the condensing temperatures or boiling points.


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FRACTIONATION The separation, usually by distillation, of a mixture into fractions or cuts that condense at different boiling ranges. The degree of fractionation, or sharpness of separation, is indicated by the extent of overlay in the boiling range between the product fractions.

FREE WATER Water in fuel other than dissolved water. Free water may be in the form of droplets or haze suspended in the fuel (entrained water or an emulsion) and/or water layered at the bottom of the container holding the fuel.

FREEZING POINT The coldest fuel temperature at which the last fuel wax crystals disappear when fuel physically changes from a solid back to a liquid when warmed.

FREQUENCY The number of times an event repeats itself per unit time.

FRONT-END As applied to the lower boiling components in a cut, front-end is the components that are the first to boil in a distillation test.

GASOLINE A light petroleum fraction having an approximate boiling range of 100-400°F and obtained by distillation, cracking, polymerization, and other processes.

GATE VALVE A straight through flow design valve where the barrier to flow is a disk or wedge shaped dam sliding at right angles to the direction of the flow. Extremely large changes in area are produced from small changes in valve stem position, making gate valves undesirable for partial flow control. Gate valves are not suitable for service where the nature of the seat design may trap solid particles. In the open position, the valve will cause essentially no pressure drop. Significant valve trim erosion can occur if a gate valve is used to regulate flow.

GAUGE To measure, such as to gauge the level in a tank. Also, an instrument for measuring a process value, such as a pressure gauge.

GAUGE PRESSURE Normally referred to as psig. Gauge pressure is the difference between the total or absolute pressure at the point of measurement and atmospheric pressure (psi). Most pressure gauges read gauge pressure (psig), not absolute pressure.

GEMS General Equipment Materials Specifications

GPM Gallons per Minute. Used to describe the flow rate of liquid streams at process conditions such as pump suction. Unlike BPOD or BPSD, these units are not corrected to standard conditions.


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H2 Hydrogen. The lightest known naturally occurring scientific element.

H2S Chemical symbol for hydrogen sulfide.

H2SO4 Sulfuric Acid.

HC Hydrocarbon

HDS Hydrodesulfurization

HDT Hydrotreating

HEADER A common manifold in which a number of pipelines are united. The U-bend connections between two consecutive tubes in the coil.

HEAVY ENDS The highest boiling molecules in a mixture.

HFRR High Frequency Reciprocating Rig. Used to evaluate the lubricity of diesel fuels.

HYDROCARBON A class of molecules that contain only carbon and hydrogen atoms. In practice, molecules that contain only trace levels of sulfur, nitrogen, or metals are also called hydrocarbons. Crude oil and its refined products are hydrocarbons.

HYDROGEN (H2) The lightest of all elements and one of the basic components, along with carbon, of all hydrocarbon compounds. Hydrogen is produced in reforming reactions and is consumed in desulfurization reactions.

HYDROGEN PARTIAL PRESSURE (H2)

Partial Pressure of Hydrogen or average partial pressure (denoted with a line over the p). For Chevron’s kinetic estimates, the hydrogen partial pressure in the reactor is calculated by assuming all oil molecules are vaporized. The average partial pressure in the reactor generally refers to the linear average of the inlet and outlet.

HYDROGEN SULFIDE A compound with a molecular weight of 34 and the chemical formula of H2S. H2S is a gas under most conditions and is only slightly soluble in water. H2S is a deadly, foul-smelling gas. It has the odor of rotten eggs. H2S is a neurotoxin that reduces the stimulus to breathe.

HYDROTREATING The processing of oil in the presence of hydrogen, usually at high temperature and high pressure over a catalyst. Hydrotreating removes sulfur and nitrogen compounds and saturates olefins and aromatics.

I &T Inspection and Testing



IMMISCIBLE Not capable of mixing and tending to form two layers, as oil and water.

INFLUENT Stream of fluid at the inlet of filtration vessels. This is the opposite of effluent.

INTERFACE CUT A procedure used to isolate or segregate one product from another at the receiving end of a non-dedicated pipeline or unloading line, as the products go into tanks.

ISOTREATING The trade name of the hydrotreating process licensed by Chevron Lummus Global.

KEROSENE A refined petroleum distillate suitable for use as an illuminant when burned in a wick lamp. Products in the boiling range of kerosene are also used as jet fuels.

KINEMATIC VISCOSITY

The viscosity of a fluid divided by its density. The viscosity in cP divided by the density in g/cc equals the kinematic viscosity in centistokes (cSt).

KO Knock out (drum)

LIGHT ENDS The lowest boiling components of a mixture; those that boil first in a distillation test.

LOADING RACK A structure used for the purpose of loading railroad cars and tank trucks with products such as gasoline, lube oils, molten sulfur, or other refinery materials.

LUBRICITY A qualitative term describing the ability of a fluid to effect friction between, and wear to, surfaces in relative motion under load. Tests include HFRR, Wear Scar.

LUBRICITY ADDITIVE A product added to diesel fuels in small amounts to improve the lubricity of the fuel.

LV% Liquid volume percent.

MATERIAL SAFETY DATA SHEET (MSDS)

A refinery or supplier bulletin containing environmental, health, and toxicology information on chemical compounds (liquids, solids, and gases).


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MERCAPTAN A type of hydrocarbon with sulfur in its molecular structure. Causes very strong odors at less than 1-ppm concentration. Mercaptans are used to impart an odor on natural gas, which is odorless in nature. Mercaptans is a common name for Thiols. Thiols are a class of hydrocarbon molecules containing sulfur. The chemical structure of a mercaptan contains a sulfur atom bonded to one carbon atom and one hydrogen atom. These compounds tyPICally have a noxious odor. Skunk scent is butyl mercaptan.

MICROBIAL GROWTH A living organism, which requires water, a source of carbon (food), and various trace minerals for its existence. Microbial (or microbiological) growths are better able to survive in kerosene, ULSD, or heavy middle distillates, due the chemical composition of these fuels; however, gasoline and aviation gasoline systems are not immune to this contamination.

MICRON A unit of linear measurement. One micron is equal to 0.000039 inches and approximately 25,400 microns equals one inch. For comparison, a human hair is about 100 microns in diameter.

MICRONIC FILTER A filtration vessel equipped with pleated paper cartridges designed to remove solid particles from fuel.

MILLIPORE A test for solid contaminants in a sample of fuel that is passed through a filter membrane which is matched to a color standard (Millipore Color) or which is weighed (Millipore Weight or Gravimetric Test), to determine the degree of solid contamination.

MISCIBLE Liquids that are mutually soluble. Opposite of immiscible.

MMSCFD Millions of standard cubic feet per day

MSCFD Thousands of standard cubic feet per day

MSDS Material Safety Data Sheet

N/A Not applicable

NAPHTHA A cut that generally boils between 90oF (30oC) and about 338oF (170oC) and is used to make gasoline.

NON-DEDICATED A system of tankage, pipes, vehicles, etc. in which more than one product can or does flow through the same system; a system with single valve isolation is considered non-dedicated (also referred to as a “multi-product” system).


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OVERHEAD In a column, the lighter part of the feed that is vaporized and removed from the top of the column.

OWS Oily water sewer

P&ID Piping and Instrumentation Diagram

PARTIAL PRESSURE A term used to describe the concentration of a component in an oil or gas stream. The higher the partial pressure of a component, the greater the concentration. In a gas stream, hydrogen partial pressure is equal to the total pressures times the fraction of hydrogen in the stream. The proportionate share of the total vapor pressure attributed to a given molecule compound in a mixture of compounds.

PARTICLULATES Solid contaminates found in ULSD, i.e., dirt, rust, sand, fibers, etc.

PETROLEUM A material occurring naturally in the earth, predominantly composed of mixtures of chemical compounds of carbon and hydrogen, with or without other non-metallic elements such as sulfur, oxygen, and nitrogen, etc. Petroleum may contain or be composed of such compounds in the gaseous, liquid, and or solid state, depending on the nature of the compounds and the existent conditions of temperature and pressure.

PFD Process flow diagram

POUR POINT The lowest temperature at which an oil can be poured or will flow under specified ASTM or other test conditions.

POUR POINT DEPRESSANT

A product added to diesel fuels in small amounts to improve flow properties at lower temperatures. (Reduce the Pour Point).

PPE Personal protective equipment

PPM Parts per million. A designation used to express very low concentrations, 1% = 10,000 ppm. Parts per million by volume is used for gases, and parts per million of weight usually is used for liquids and solids.

PRESSURE DROP (∆P) The decrease in pressure usually due to friction, which occurs when a liquid or gas flows through a pipe, distillation column, or other piece of equipment.

PSI Pounds per Square Inch

PSIA Pounds per square inch absolute pressure.


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PSIG Pounds per square inch gauge pressure.

PSV Process Safety Valve - A pressure relieving device designed to protect equipment from overpressure

REACTOR The vessel in which all or at least the major part of a reaction or conversion takes place. On most units, this will be the place in which the catalyst is located. At some units within the refining industry, a vessel such as a reaction furnace is also referred to as a “thermal reactor.” The reaction furnace/thermal reactor does not contain catalyst, but instead provides large enough space in which a thermal reaction occurs to the hot gases flowing through the vessel.

REBOILER A heat exchanger used to supply heat to a fractionation/distillation tower. Liquid is withdrawn from the bottom of the tower and heated by a heating agent flowing through the tube side of the reboiler. The vapors formed by heat exchange in the reboiler shell are returned to the tower. The remaining liquid may or may not be returned to the tower. Reboiler heat may be furnished by oil circulated through a heater, bottoms from some other tower, by steam or gas fired furnaces.

RECYCLE A stream returned to a process after having been through it.

RECYCLE GAS Gas that is taken from a separator, compressed, and returned to a unit at some point within the process. At DHT-18, the portion of the discharge of the recycle compressor that is not used as quench gas.

REFLUX In distillation, the part of the distillate that is returned to the column to improve separation of the product. Reflux may be either circulating reflux or overhead reflux. Overhead reflux is the liquid that is formed by condensing the vapors that leave the top of the column and returned to the column. Circulating reflux is the liquid that is drawn from the column, cooled, and returned to the column. Pumparound is another name for a circulating reflux.

RELAXATION TIME The time provided by including volumetric capacity in a fuel handling system, which increases the residence time (downstream of any charge generating equipment such as filters) for the purpose of dissipating, or losing, static electricity charge, before the fuel discharges from the fuel system into a tank, truck or aircraft.

RESIDUE Heavy oil or bottoms left in the still after low boiling constituents have been removed.


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RON Research Octane Number

RUNDOWN TANK Receiving tanks for distillation products.

SCBA Self contained breathing apparatus

scfm Standard cubic feet per minute

SPACE VELOCITY The relative gas flow through a catalyst bed, expressed as cubic feet per hour of gas per cubic foot of catalyst. The flow definition varies. The rate can be based on liquid rate or gas rate and may not include all material entering the reactor.

SPECIFIC GRAVITY The specific gravity of a liquid or solid is the ratio of its density to the density of water at a specified reference temperature. The specific gravity of a gas is the ratio of its density to the density of air at the same temperature and pressure as those of the gas.

SS Stainless steel

STABILIZER A fractionating tower for removing light hydrocarbons from an oil to reduce vapor pressure particularly applied to gasoline.

STATIC DISSAPATION ADDITIVE

A product added to diesel fuel to improve the conductivity of the fuel.

STATIC STORAGE Storage tanks, which have had no new fuel movement (in or out) over a period of time. Static product inventory shall be All-levels or Composite sampled and tested for the Basic Tests.

STRAIGHT RUN OIL A material produced by the distillation of crude oil without appreciable cracking or alteration of the structure of the constituent hydrocarbons.

STRIPPER A vessel that fractionates the light ends of a sidecut from the main fractionating tower. Superheated steam can be injected into the stripper bottom to improve this separation. A steam reboiler can also be used to impart heat that will cause water in a stripper tower to flash to steam.

STRIPPING Removal of the lightest or lowest boiling point components of a mixture. Usually achieved by distillation or contacting with an up-flowing vapor. Usually the amount of liquid components removed is small compared to the total stream that is stripped.


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SUCTION The upstream or feed side of a pump or compressor. Also, the act of drawing a fluid into a pump or compressor.

SULFUR Sulfur shows up in a variety of forms. Operators see it generally as:Hydrogen Sulfide (H2S): a toxic gas.Sulfuric Acid (H2SO4): a corrosive acid.Sulfur Oxides (SO2 or SO3): also toxic gases.Elemental Sulfur (S): a yellow crystal.Mercaptan (RSH): combining sulfur with hydrocarbons

SULFUR RECOVERY A thermal and catalytic process used to produce sulfur from hydrogen sulfide gas (H2S). The gas is burned in air where one-third is converted to sulfur dioxide (SO2). The resulting mixture of H2S and SO2 is charged to a converter where it reacts to form sulfur and water.

SUMP A chamber or depression installed at the bottom of a storage tank or filtration vessel to facilitate the collection and removal of water and other contaminates.

SUPERFICIAL VELOCITY (AKA SPACE VELOCITY)

A fluid velocity based on the entire cross-sectional area of the flow channel. The superficial velocity is equal to the volumetric flow divided by the cross-sectional area even if the entire cross-section is not available for flow, such as in a fixed bed.

TANK A vessel designed for storage for all stocks (including raw, intermediate, and finished products) with an RVP 25 lbs or lower.

TEMPERATURE An arbitrary measurement of the amount of molecular energy of a body, or the degree of heat possessed by it. It should be distinguished from heat itself. Heat is a form of energy, while temperature is a measurement of its intensity.

THROUGHPUT The volume of feed that is processed in a piece of equipment or a plant.

VISCOSITY The resistance of a fluid to flow. The unit of viscosity is the Poise. A more convenient unit is 1/100th of a Poise, the centipoise (cP). Water has a viscosity of 1 cP at 68oF (20oC).

WATER CUT A water sensitive paste applied to the end of a stick or rod or tank gauge plumb to check for the presence of water, as determined by a change in color of the paste.

WEAR SCAR A scar produced on an oscillating ball (during a test to evaluate the lubricity of diesel fuel) from contact with a stationary disc immersed in the test fluid operating under defined and controlled conditions.


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Section 1514 Drawings

1514.1 The following Key Drawings are included in this manual.

River Dock Drawings MECS DrawingsRiver Dock Area Marine Emissions Control System Drawings

MECS P&ID

Memphis Refinery Aerial Photograph Refinery Photo overheadNorth River Dock Drawing North Dock Layout 740D220South River Dock Drawing South Dock Layout 740D221North Dock Fire Water Plan RIVERDOCK FIRE MONITORSouth Dock Fire Water Plan SOUTH DOCK FIRE MONITORMemphis River Dock Facility Aerial Photo River Dock Facility USCG Jurisdiction


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Section 1515 Material Safety Data Sheets – MSDS {33 CFR Section 154.310.(a)(5)}

1515.1 Material Safety Data Sheets for Products Transferred at this facility are catalogued in Table RD-A Products Transferred at River Dock Terminal. Please refer to this table for a list of all required MSDS.


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Section 1600 Amendments {33 CFR Section 154.310.(c)}

Amendment # Date Description


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