California Accidental Release Prevention (CalARP) Program Guidance Revised May 2020 Preface ..................................................................................................................................................... 6 About This Document ......................................................................................................................... 6 Acknowledgements............................................................................................................................ 6 About the 2020 Revision ..................................................................................................................... 6 Introduction .............................................................................................................................................. 6 The California Accidental Release Prevention (CalARP) Program ............................................. 6 Unified Program Agencies (UPAs) ..................................................................................................... 7 Intent of Guidance Document ......................................................................................................... 7 General Duty Clause .......................................................................................................................... 9 Recommended Initial Actions for UPAs to Establish a CalARP Program .................................... 9 Chapter 1. General (Article 1) ............................................................................................................ 13 Definitions (Section 2735.3) .............................................................................................................. 13 Applicability (Section 2735.4) .......................................................................................................... 15 General Requirements (Section 2735.5) ........................................................................................ 22 CalARP Program Management System (Section 2735.6) ........................................................... 24 Emergency Information Access (Section 2735.7) ........................................................................ 25 Chapter 2. Registration (Article 2) ...................................................................................................... 26 Registration (Section 2740.1) ........................................................................................................... 26 Chapter 3. RMP Components and Submission Requirements (Article 3) .................................... 27 Submission (Section 2745.1) ............................................................................................................. 27 RMP Review Process (Section 2745.2) ............................................................................................ 29 RMP Executive Summary Component (Section 2745.3) ............................................................. 35 RMP Offsite Consequence Analysis and Five-Year History Components (Section 2745.4 and Section 2745.5) ................................................................................................................................... 36 RMP Program 2 Prevention Program Component (Section 2745.6) ......................................... 36 RMP Program 3 Prevention Program Component (Section 2745.7) ......................................... 36 RMP Program 4 Prevention Program Component (Section 2745.7.5) ...................................... 37 RMP Emergency Response Program Component (Section 2745.8) ......................................... 37 RMP Certification (Section 2745.9) ................................................................................................. 40 RMP Updates (Section 2745.10) ...................................................................................................... 40 Required RMP Corrections (Section 2745.10.5) ............................................................................ 42 Covered Process Modification (Section 2745.11) ........................................................................ 42 Certificate of Occupancy (Section 2745.12) ................................................................................ 43 2 Chapter 4. Hazard Assessment (Article 4) ......................................................................................... 44 Hazard Assessment Applicability (Section 2750.1) ....................................................................... 44 Off-Site Consequence Analysis Parameters (Section 2750.2) .................................................... 44 Worst-Case Release Scenario Analysis (Section 2750.3) ............................................................. 46 Alternative Release Scenario Analysis (Section 2750.4) .............................................................. 49 Defining Offsite Impacts to the Population (Section 2750.5) ...................................................... 50 Defining Offsite Impacts to the Environment (Section 2750.6) ................................................... 50 Offsite Consequence Analysis Review and Update (Section 2750.7) ...................................... 50 Offsite Consequence Analysis Documentation (Section 2750.8) .............................................. 51 Five-year Accident History (Section 2750.9) .................................................................................. 51 Chapter 5. Program 2 Prevention Program (Article 5) .................................................................... 52 Process Safety Information (Section 2755.1) ................................................................................. 52 Hazard Review (Section 2755.2)...................................................................................................... 52 Operating Procedures (Section 2755.3) ........................................................................................ 54 Training (Section 2755.4) ................................................................................................................... 54 Maintenance (Section 2755.5) ........................................................................................................ 56 Compliance Audits (Section 2755.6) .............................................................................................. 57 Incident Investigation (Section 2755.7) .......................................................................................... 58 Chapter 6. Program 3 Prevention Program (Article 6) .................................................................... 59 Process Safety Information (Section 2760.1) ................................................................................. 59 Process Hazard Analysis (PHA) (Section 2760.2) ........................................................................... 61 Operating Procedures (Section 2760.3) ........................................................................................ 63 Training (Section 2760.4) ................................................................................................................... 64 Mechanical Integrity (Section 2760.5) ........................................................................................... 65 Management to Change (Section 2760.6) ................................................................................... 68 Pre-Startup Review (Section 2760.7) ............................................................................................... 69 Compliance Audits (Section 2760.8) .............................................................................................. 70 Incident Investigation (Section 2760.9) .......................................................................................... 70 Employee Participation (Section 2760.10) ..................................................................................... 71 Hot Work Permit (Section 2760.11) .................................................................................................. 72 Contractors (Section 2760.12) ......................................................................................................... 72 Chapter 6.5 Program 4 Prevention Program (Article 6.5) ............................................................... 75 Chapter 7. Emergency Response Program (Article 7) .................................................................... 76 3 Emergency Response Applicability (Section 2765.1) .................................................................. 76 Emergency Response Program (Section 2765.2) ......................................................................... 76 Emergency Response Program-Program 4 (Section 2765.3) ...................................................... 78 Chapter 8. Regulated Substances for Accidental Release Prevention (Article 8) ..................... 79 Threshold Determination (Section 2770.2) ..................................................................................... 79 List of Substances (Section 2770.5) ................................................................................................. 82 Chapter 9. Other Requirements (Article 9) ....................................................................................... 83 Recordkeeping (Section 2775.1) .................................................................................................... 83 Audits (Section 2775.2) ....................................................................................................................