Introduction
The ConocoPhillips San Francisco Refinery (SFR) operates two crude distillation units and several separate downstream units to produce a variety of petroleum products. These products include butane, various grades of gasoline, diesel fuel, jet fuel, fuel oils, sulfur, and petroleum coke. The fuels produced are used for numerous transportation applications, including automobiles, heavy trucks, ships, and aircraft. The petroleum coke produced is sent offsite either as fuel or for further processing at the Carbon Plant. The refinery processes several different types of crudes. The crudes are delivered to the refinery by pipeline and tanker. Built in 1896, Rodeo Refinery was the first major oil refinery in the Bay Area. The original site occupied only 22 acres and processed 1,600 barrels of crude oil per day. Today, the site occupies approximately 1,100 acres and employs about 470 people. The refinery is located on approximately 320 acres of land adjacent to the Marine Terminal and is bisected by San Pablo Avenue.

Major Products and Capacities
Refinery throughput data for crude, cracking/coking and reforming/alkylation processes is approximately 73,000 barrels of per day. Crude oil and intermediate streams are refined at the facility to produce gasoline, diesel and jet fuel. In addition, Plant #A0016 also produces petroleum coke and sulfur as a co-products.

As part of the Bay Area Air Quality Management District's 2001 Clean Air Plan, the District, in cooperation with the California Air Resources Board (ARB) and the United States Environmental Protection Agency (U.S. EPA), is examining the wastewater systems for each of the Bay Area refineries to determine whether there are significant potential emission reductions from control of any remaining uncontrolled components of the wastewater systems, or through other measures. Most components of refinery wastewater systems are already controlled through compliance with District Regulation 8, Rule 8 (8-8), District New Source Review requirements, and EPA's National Emission Standard for Benzene Waste Operations (40 CFR Part 61, Subpart FF).

As part of this project a two day site visit (5/1/02 and 5/2/02) was conducted at Plant #A0016 to assess the availability of information related to the waste water system and to review the on-site collection and treatment of water which may have Volatile Organic Compounds (VOC) emissions impacts.

Refinery Areas
At Plant #A0016, process water trunk lines originate in four geographic areas that flow through separate trunk lines to the Wastewater Treatment Plant. These areas may be conveniently referred to as "West Refinery" "East Refinery/Tormey Hill", "Lower Tank Farm", and "Sulfur/MP-30/Seasonal Storage". Each area includes units of varying construction dates.

West Refinery
The oldest area is the West Refinery located west of San Pablo Avenue. Existing construction in this area ranges from 1940 to 1994. This area includes a Marine Terminal, butane storage, railcar loading, crude oil and product storage, hydrogen plant Unit 110, a Cogeneration steam/power plant, shop areas, warehouse, laboratory, and administration buildings. This area also has a number of decommissioned units including Unit 32 (wax processing), Unit 67 (crude processing), Unit 105 (lubrication oil and wax processing).

The decommissioned areas typically have open drain channels with below-grade sumps covered by grates or platforms and no underground wastewater structures. The decommissioned areas appear to be abandoned in place.

The primary sources of wastewater from the West Refinery include:

• Stormwater runoff
• Rainwater drained from tank blocks
• Flow from decommissioned Unit 210 in the East Refinery/Tormey Hill area that runs under San Pablo Avenue to the West Refinery area
• A cogeneration steam/power plant
• Groundwater remediation water
• Sewer discharge from buildings, e.g. lab, administration, warehouse, and shop.

Combined wastewater (e.g. stormwater runoff, process water, sanitary sewage, and groundwater remediation) is discharged from the West Refinery area via a 48-inch underground pipe. This drainage pipe connects to the main refinery wastewater collection and storage system. All refinery wastewater is collected and pumped to tanks 130, 104, 105 prior to treatment.

All drains inspected (except for those installed in the hydrogen plant, Unit 110) in the West Refinery area were open and typically varied in size from 3 to 4 inches. Refinery drawings suggest that drains flow to water sealed junction boxes. Confirmation of junction box design will occur during future visits.

Also, located in the West Refinery area is the inlet for a 42 million gallon per day (MGD) saltwater single pass cooling system. This inlet is located just north of the Marine Terminal causeway. Discharge of the single pass saltwater cooling occurs in two outfall locations, E-001 and E-003. The E-001 outfall is at the southern boundary of the West Refinery area near butane tank 302. The E-003 outfall is located approximately 700 feet south of E-001.The Rodeo refinery is the only Bay Area refinery currently using single pass saltwater cooling in refinery operations.

South of the West Refinery area is an area containing equipment salvage, parking, the saltwater "safety basin" and the associated "safety basin" bypass channel. The safety basin and channel are located in the southern tip of the refinery bounded by San Pablo Avenue and the Union Pacific Railroad tracks. The open safety basin and bypass channel are holding structures for single pass saltwater discharge that is regulated by a National Pollution Discharge Elimination Permit (NPDES) permit issued by the San Francisco Bay Regional Water Quality Control Board.

The most recent refinery process construction at the West Refinery area is the hydrogen production plant, Unit 110.

This area appears to be the only major process area in West Refinery Area equipped with water seal drains. These drains are equipped with box type water seal inserts draining to below grade 3'x3' sumps. However, one of these sumps appeared to be an open sump without a water seal. Other drains in active refinery areas appear to be open units without water seals. These open drains connect to a variety of sumps, junction boxes and manholes. Some of these sumps appear to be open collection units without water seals.

East Refinery/Tormey Hill
East Refinery/Tormey Hill is located east of San Pablo Avenue. This area contains the refinery's major petroleum processing areas. Construction in this area ranges from 1940 to present. This area generates process wastewaters from product storage, product shipping via pipeline, delayed coking, crude distillation, desalting, gas fractionation, catalytic reforming, prefractionation, hydrogen production, hydrotreating, fractionation and utility operations. This area also has a number of decommissioned units including Unit 210 (dewaxing), Unit 212 (deoiling), and Unit 220 (Duo Sol). Surface runoff at the decommissioned Duo Sol unit currently flows through a concrete structure that was used historically to contain and pump out process liquids that could not be discharged to directly the process sewer. Sources of wastewater in this area also include stormwater runoff, domestic sewage, and drainage from tank blocks.

The decommissioned units typically have open drains connected to below-grade sumps covered by grates. The decommissioned areas appear to be abandoned in place.

Product storage is located on the northeastern boundary of the East Refinery/Tormey Hill area and east of Highway 80. Wastewater and stormwater drains in these areas are open and connected to sumps or manholes. These sumps or manholes are in or adjacent to the perimeter impoundment structures surrounding the product storage tanks. Some of the sumps or manholes in this area appeared to be without water seals.

Manually operated valves regulate discharges from large tank impoundment areas. Water draws and tank cleanout from product tanks discharge into open sumps immediately adjacent to tanks. Pipeline shipping operations occur at Unit 80 , which is located near San Pablo Avenue in the East Refinery/Tormey Hill area. Most of the refinery's liquid product is distributed through this unit to northern California pipelines. The unit has open 4" drains connected to below grade open sumps,

The coking unit (Unit 200), crude oil desalter (Unit 267), fuel gas recovery (Unit 233), and butane fractionator (Unit 215) are located in the lower center portion of the East Refinery/Tormey Hill area. Most if not all of the drains in these units were open and connected to below grade sumps. Drain size ranged from 4" to 6". Some of the sumps appear to be open and without water seals. Horizontal dimensions for sumps were typically 3'x3'. The desalter 6" open drain is the location of the initial refinery NESHAP sampling point for Benzene.

The coking unit uses the MOSC process (Mobil Oil Sludge Coking) and is the primary destination for oily sludge from the API separator and residual oils left from refining crude petroleum byproduct materials. These materials are converted to delayed or "green" petroleum coke via the MOSC process. Discharge from the coking drums is carried out via hydraulic cutting using oily water routed from the de-coking process. Green coke and oily hydraulic cutting water discharges to a large open pit below the coke unit. Oily cutting water is recycled to a storage tank adjacent to the coke unit. Green coke is removed from the pit via clamshell and sold as a direct product or shipped to the refinery Carbon Plant. The Carbon Plant is a petroleum coke calciner that makes anode grade calcined coke from green coke. The Carbon Plant is located approximately five miles from the main refinery. The Carbon Plant was not surveyed during the May inspection due to time constraints.

Units 240 (prefractionation, hydrotreating, fractionation and hydrogen production), 244 (catalytic reforming) and 248 (aromatic saturation) are located in the southern portion of the East Refinery/Tormey Hill area. These units were constructed during the 1970's. Most if not all of the drains in these units were open and connected to below grade sumps. Size of the drains range from 4" to 6". Some of the sumps appear to be open and without water seals. Typical horizontal dimensions for sumps were 3'x3'.

Sulfur/MP-30/Seasonal Storage
The Sulfur/MP-30/Seasonal Storage area is adjacent to East Refinery/Tormey Hill. This area includes Units 234, 236 and 238 (sulfur recovery), MP-30 consisting of Units 228 (isomerization), 229 (catalytic hydrotreating), 230 (distillation and olefin saturation), 231 (catalytic reforming), and Seasonal Storage (i.e. finished product storage) located east of Interstate Highway 80. Primary design and construction of this area occurred from 1940 to 1970. The primary sources of wastewater in the Sulfur/MP-30/Seasonal Storage area are:

• Product storage
• Seasonal Storage wastewater (connects to the Sulfur/MP-30area wastewater system via an underground pipe below Interstate Highway 80)
• Stretford process sulfur removal
• Incoming pipeline operations
• Units 228, 229, 230 and 231

This area is reported to be similar to all other refinery product storage areas. The Seasonal Storage area was not inspected due to time constraints. Wastewater and stormwater drains in the product storage areas inspected were typically 4" open drains connected to sumps or manholes. These sumps or manholes are in or adjacent to the perimeter impoundment structures surrounding the product storage tanks.

Refinery sulfur removal uses the Stretford process. The Stretford Process is a wet-type desulfurization process where hydrogen sulfide is removed from gas streams and fine particle sulfur is recovered.

Drains in the sulfur units (units 234, 238, 236) were typically 4" open drains connected to open sumps. Concrete berms and paving in the sulfur units appeared highly corroded most likely due to acidic properties associated with biological breakdown of fine particle sulfur. Incoming pipeline operations and MP-30, were closed due to process operations during the inspection. The area will be inspected in the future. The MP-30 units (Units 228, 229, 230, 231), typically contained 4" open drains connected to open sumps.

Lower Tank Farm
Interstate Highway 80 runs parallel to the eastern boundary of the Lower Tank Farm. Sulfur/MP-30/Seasonal Storage forms the northern boundary and the refinery wastewater treatment system is located to the southwest. This area includes product storage, gasoline blending (Unit 76), and wastewater storage. The primary sources of wastewater from the Lower Tank Farm are from:

• Stormwater runoff
• Product storage
• Gasoline blending
• Raw materials receiving (Unit 40)
• Fire Training area

Product storage is located throughout the Lower Tank Farm area. Wastewater and stormwater drains in these areas are typically 4" open drains connected to sumps or manholes. These sumps or manholes are in or adjacent to the perimeter impoundment structures surrounding the product storage tanks. The east main trunk line (a 42" underground pipe) connects all refinery wastewater discharge and lies along the western boundary of the Lower Tank Farm area. Primary design and construction of this area occurred from 1950 to 1970. Current operations in this area include product storage, tank water draws, tank cleanout, and wastewater storage, tanks 130, 104, and 105). Gasoline and mid-barrel blending at Unit 76 produces finished gasoline and diesel fuels. Some additional retail gasoline product blending occurs off site.

On-Site Waste Water Treatment
Selenium treatment occurs on the western boundary of the Lower Tank Farm area. The refinery segregates sour water from process units, strips out hydrogen sulfide, and hard pipes this stripped sour water to the Selenium Removal Plant (SRP). This treatment unit uses primary copper and secondary ferrous precipitation to remove selenium and excess copper from stripped sour water. Precipitated selenium and copper containing solids are dewatered in a filter press and disposed as hazardous waste. The filter press system does not need to use vapor recovery. Treated effluent from the SRP is routed to the main refinery wastewater storage and treated through the wastewater system.

The waste water collection system (Unit 100) at Plant #A0016 flows by gravity to dry and wet weather sumps, from which it is pumped to the three-tank wastewater storage system, equalization tanks 130, 104, 105. Total volume of tank storage is approximately 18 million gallons. During periods of extreme rainfall, if the equalization tanks are full, wastewater is diverted to a surface impoundment, the "Primary Basin" (2.3 million gallons capacity). The primary basin is permitted as a RCRA secondary containment structure since it may contain hazardous petroleum constituents. If the Primary Basin reaches capacity it will overflow into a second surface impoundment, the "Main Basin" (7.2 million gallons capacity).

All onsite wastewaters (process, stormwater runoff and sanitary waste) are combined for treatment at Unit 100. Wastewater from the equalization tanks is gravity fed to a four-cell oil/water separator (API) at ambient temperature. The API does not use screens to remove gross debris from the effluent stream since trash is removed at the inlets to the dry and wet weather sumps. The API is completely enclosed. These cells allow product from process waters to settle out via gravity. Oily surface waters and oily solids are removed from the cells by top and bottom chain driven skimmers for oil recovery or conversion to delayed petroleum coke via the MOSC process. From the API cells, water flows under gravity into a four-cell Dissolved Air Flotation (DAF) unit to remove additional oil and suspended solids. This unit is also completely enclosed. Here air bubbles are used to remove any suspended product from the effluent prior to PACT treatment.

Biological treatment occurs in a Powdered Activated Carbon Treatment (PACT) unit followed by clarification and sand filtration. The PACT treatment unit biologically oxidizes organic materials with aggressive aeration and adsorbs toxics using powdered activated carbon. Carbon is recycled from the PACT system and is regenerated using a Wet Air Regeneration (WAR) unit. The WAR unit reactivates the carbon and oxidizes biological growth. Makeup carbon is supplied from tankage adjacent to the PACT system. Biosolids generated in the PACT unit are settled out in the clarifiers. Discharge from the clarifiers is filtered through sand media, disinfected with chlorine, dechlorinated with sodium bisulfite, and discharged to San Pablo Bay

Solid Waste
Off-site removal of solid waste from the wastewater treatment system at this facility occurs primarily at the Selenium Reduction Plant. Solids separation of selenium filter cake does not require vapor control. It is estimated that 250 tons of sludge (70 to 75% moisture content) were removed for landfilling in 2001. All organic waste is destroyed via WAR unit or transferred to the Coker.

Storm Water
As well as treating process wastewater, stormwater runoff from process and industrial areas is routed through the on-site wastewater treatment plant prior to being discharged to San Pablo Bay through a 6,000-foot, 18-inch diameter outfall pipe. The outfall, referred to as E-002, terminates with a multi-port diffuser. Permitted discharges of stormwater runoff flow to San Pablo Bay from the refinery's Marine Terminal and causeway. Stormwater runoff from these areas is estimated at 0.006 MGD.

Sumps, Junction Boxes and Drains
As part of this site visit, an extensive tour of the various operating units was conducted at Plant #A0016 that incorporated construction from all phases of building. A range of drain, sump and junction box designs were observed at the facility and these components varied with construction date and location. However, most drains and sumps were open without water seals.