ExxonMobil

Process Hazard Analysis Protocol

JOLIET REFINERY

safety procedures
December 2011

PROCESS HAZARD ANALYSIS PROTOCOL PURPOSE This protocol contains requirements for preventing or minimizing the consequences of catastrophic releases of toxic, reactive or flammable chemicals. These releases may result in toxic, fire or explosion hazards. The protocol will reference or provide procedures for conducting and documenting a PHA for a Capital Project, MOC project, initial Unit PHA for an existing refinery unit, and the revalidation of a Unit PHA. SCOPE A Process Hazard Analysis (PHA) will be conducted on all new facilities and on all existing refinery units. The application of PHA will be considered for modifications to existing units, but is not mandatory. PHA is performed at the Joliet Refinery in accordance with OIMS 2.1, GMOP 2.1, ExxonMobil HAZOP Application Guide, and the Risk Assessment and Management Guide. This procedure details the site-specific activities and details regarding preparing for, conducting, documenting, and tracking PHA activities onsite. Revision & Review Record Date of Review &/or Revision
9/27/99 11/9/99

Name of Reviewer
C. Patschke T. Jennings

Reviewers Position
SH&E Advisor SH&E Advisor

Comment(s)
Updated procedure to address PSM Audit findings and observations. Minor Change Replaced term Process Representative with Unit Console Qualified Process Control Technician; formatting; updated PHA Schedule; updated to reflect EPAs RMP Rule. Changed Production to Process; Facilities to Mechanical; Engineering to Technical and EHS to SH&E. Updated PHA schedule; added PHA Facilitator knowledge requirements; minor wording changes for clarity. Major revision. Reflects adoption of EM OIMS Greenbook requirements, EM Refining Americas PHA Program and OIMS Internal Assessments 2002 & 2003. This document was reduced in length from 36 pages to 13 pages excluding endnotes. Outline formatting was deleted.

Mary R. Morrison R. Todd Jennings

Administrative Asst. SHE Advisor

4/00 9/00

R. Todd Jennings

SHE Advisor

12/03

M. Miri

Safety Engineer

7/08

Minor Changes. Updated reference documents. Updated Attachment 1 PHA Schedule. Added requirements for additional documentation. Added requirements for safety engineering review of all HAZOP item closure.

A. Kidd

Loss Prevention Group Leader

6/11

Revised procedure to include workflow changes associated with moving to IMPACT for tracking of assessment follow-ups.

K. Arrington

Safety Engineer

12/11

Minor changes. Employee input request methods added & RC1 approval clarification

Section 43 -- Process Hazard Analysis Protocol

1-

ExxonMobil
Process Hazard Analysis Protocol

JOLIET REFINERY

safety procedures
December 2011

I.

OVERVIEW

Process Hazard Analyses (PHAs) are performed in compliance with OSHA Process Safety Management (PSM) and EPA Risk Management Plan (RMP) regulations. The goal is to identify potential deviations from current process design, maintenance, inspection, and operating standards and procedures that could lead to a serious injury or catastrophic event, including events which could have offsite impacts. All Joliet Refinery PHAs are performed using the Knowledge-Based HAZOP technique as outlined in the ExxonMobil HAZOP Application Guide. All deviations are categorized, prioritized, and tracked to ensure resolution. PHA Frequency is defined as below, consistent with GMOP 2.1: Capital Project PHA Initial Unit PHA A PHA is required for each Capital Project prior to start-up. All existing refinery units were complete by May 26, 1997. See Long Range PHA Schedule for history. All Unit PHAs must be revalidated every five (5) years.

Unit PHA Revalidations

The minimum required PHA team composition is as follows: 1. 2. 3. PHA Leader* Cold Eyes Process Design Engineer Operations Representative, with a minimum of five years experience on the unit

The following refinery personnel should also expect to be called during a Unit PHA to answer job-specific questions. The required time commitment maybe be large or small as determined by the PHA Leader. Unit Process Complex Engineer or Process Contact Engineer Unit Mechanical I&E Representative CADD Draftsman (Responsible for noting drawing updates) Unit Mechanical Plant Engineer Unit I/E Engineer SH&E Representative Control System Representative Mechanical Representative Rotating Equipment Specialist Unit Inspector Unit Materials Engineer Reliability Representative Environmental Advisor Industrial Hygienist *NOTE: The PHA Leader must be an approved HAZOP leader per the guidelines provided by GMOP 2.1. II. PREPARATION PHAs Associated with Changes A key stakeholder for the change, typically the Process Design Engineer for Capital Projects and the Mechanical Contact Engineer for expense projects, is responsible for coordinating a PHA review when needed as part of the Management of Change (MOC) Process. Non-process area projects, replacement in kind projects, minor changes to MFDs and changes to isometric drawings require at a minimum a review by a local or EMRE Safety Engineer. The safety engineer will determine if a full PHA review is necessary. For guidance on safety reviews, refer to the ISHER checklist in TMEE082 Section 1 Appendix 2.

Section 43 -- Process Hazard Analysis Protocol

2-

ExxonMobil
Process Hazard Analysis Protocol

JOLIET REFINERY

safety procedures
December 2011

All other projects both expense and capital, require a full PHA review of the Issued for Construction (IFC) drawings.

If a formal PHA review is required, the project representative performs the following tasks: 1. Coordinates the schedules of an appropriate PHA team (contact Loss Prevention Group Leader for a PHA Leader resource) and location. 2. Provides copies of IFC drawings and other documentation for all PHA team members. Unit HAZOPs The OIMS 2.1 Coordinator is responsible for coordinating the preparation for Unit HAZOPs. The following tasks are required. 1. Contact EMRE to coordinate the schedules of a PHA Leader and a Cold Eyes Process Design Engineer with the Unit HAZOP schedule. (6 - 12 months prior to the HAZOP) 2. Send reminder email to CADD to prompt drawing reviews. (6 months prior to HAZOP) 3. Send out Meeting Notices and Kickoff Letter to the affected personnel (8 - 12 weeks prior to the HAZOP) 4. Schedule close-out meeting with Complex Coordinator and Process Manager. (6 8 week prior to the HAZOP) 5. Request employee input from unit operations personnel (6 8 weeks prior to the HAZOP) via one of the following methods: a. E-mail notification with sign-off sheet at the control board b. Field visit to each crew to solicit feedback with sign-off sheet. 6. Prepare HAZOP Binder (4 6 weeks prior to the HAZOP) to include: a. HAZOP Application Guide (may include TOH Application Guide) b. HAZOP Reference List c. DP & GP Index d. Existing Facilities Risk Consideration e. Joliet Safety Procedure Section 43 (PHA Protocol) f. Joliet Safety Procedure Section 53 (Ad Hoc Risk Assessment Procedure) g. Previous Unit HAZOP Final Report h. Previous Unit HAZOP Findings Status List (IMPACT report) i. Employee Input j. Critical Equipment List k. PSV List l. CSO/CLO List m. Unit Material Safety Data Sheets n. Incident History since last Unit HAZOP o. List of Previously Accepted Category 2 and 3 Risks p. CADD Drawing List 7. Send incident history since previous HAZOP to PHA Leader and Cold Eyes Design Engineer (2 4 weeks prior to the HAZOP) 8. Send out meeting reminders to affected personnel (2 weeks prior to the HAZOP) 9. Arrange for location, meals, and entrance permits (for PHA leader and designer) III. CONDUCTING AND DOCUMENTING THE PHA PHAs Associated with Changes All findings and responses from project PHAs shall be documented and attached to the eMOC. Unit HAZOPs The OIMS 2.1 Coordinator shall serve as the PHA Scribe, documenting all findings, risk assessment information, and cover letter. The HAZOP findings are documented in WinHAZOP and tracked in IMPACT.

Section 43 -- Process Hazard Analysis Protocol

3-

ExxonMobil
Process Hazard Analysis Protocol

JOLIET REFINERY

safety procedures
December 2011

After concluding the risk identification portion of the HAZOP, the following tasks are performed by the OIMS 2.1 Coordinator: 1. Prepare final report and review with Complex Coordinator and Process Department Manager. 2. Conduct Ad Hoc Risk Assessments, as necessary, to confirm risk level of findings and develop mitigation plans. a. Regulatory items will not be risk assessed for acceptance b. Prepare Approval To Operate or Risk Acceptance paperwork 3. Set initial due dates for all follow-up action items. a. Next turnaround date for all items requiring a turnaround b. Six months from HAZOP Report Date for Do Items or Submission of project requests c. Two years from HAZOP Report Date or Project Request Submission for all other items 4. Obtain Process Department Manager signature on final HAZOP report, including finding resolution plans and timing. a. If a finding is determined to be a Risk Category 1 the Refinery Managers signature is required on the HAZOP report b. If the resolution plans will miss the next opportunity, the next level up of approval is required (ie. approving risk to second T/A or beyond a period of due diligence). 5. Distribute copies of signed report to applicable L3s and post on Loss Prevention Sharepoint site. 6. Give report to IMPACT Clerk for data entry into IMPACT to track findings. See next section for details on IMPACT. IV. IMPACT System Each Action Item is automatically given a unique identifying number when it is entered, which serves as a reference for documenting resolution to the recommendation for the life of the process. Each Action Item entry documents the Action Item, a target completion date, records the assigned risk level and identifies the person responsible for completing the Action Item. Each Action Item entry has software provisions for updating with a status report, or for indicating completion and submitting for approval by the assigned responsible person. The Action Item is Approved by the PHA Coordinator and the associated finding closed. Provisions are included to notify the responsible person of the expected completion date. Should the Action Item not be closed by the expected completion date, the responsible person will receive daily reminders via email. Only Department Managers or above may approve extending the due date for an Action Item. The IMPACT Database is accessible to all Joliet Refinery Employees. The status of the resolution of PHA Action Items can easily be reviewed by all affected employees. Stewardship of the status of PHA findings is addressed by the Refining Quarterly Process Safety Stewardship and monthly MLT business review. V. PHA File Management PHA recommendations and their resolutions shall be maintained per XOM Retention Guidelines. Retention of PHA Worksheets An electronic copy of all Initial Unit PHAs and Unit PHA Revalidations will be stored on the Loss Prevention Sharepoint site. Hard copies of Unit PHAs and Unit PHA Revalidations are maintained in the SHE Building. An electronic copy of Capital Project PHAs will be attached to the project eMOC (since 2010) and/or in the projects files maintained by the Technical Information Group. Retention of documented resolutions An electronic record of all documented resolutions of PHA recommendations is maintained in the IMPACT database (since 2010) and/or Rectrack (prior to 2010). Each Unit PHA completion date is recorded on the Joliet Long Range PHA Schedule, which is kept on file by the Loss Prevention Group.

Section 43 -- Process Hazard Analysis Protocol

4-

ExxonMobil
Process Hazard Analysis Protocol

JOLIET REFINERY

safety procedures
December 2011

VI. DEVIATIONS Deviations from this procedure and its requirements must be in written form stating why the deviation is necessary and what will be done to ensure equivalent protections. The request must be reviewed and approved by the requesting departments manager and an SH&E Representative or their designee. The Joliet Safety Procedure, Section 48 - Deviation / Variance Procedure provides specific guidance and forms.

Section 43 -- Process Hazard Analysis Protocol

5-