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Hunterstown Combined-Cycle Power Plant

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Facility #1 : Hunterstown Combined-Cycle Pow


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000182795
Deregistered (Yes/No)No
Facility NameHunterstown Combined-Cycle Power Plant
Street Address Line 11731 Hunterstown Road
CityGettysburg
StatePA
Zip Code17325
CountyAdams County
113th Congressional DistrictPA04: Pennsylvania 4
Owner or Operator NameGenOn Wholesale Generation, LP
Parent CompanyGenOn Wholesale Generation, LP
Second Parent CompanyNRG Energy, Inc.
Latitude39.873500
Longitude-077.166750
Number of RMP Submissions3

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000034579
Submission Typerevised submission for facility
Submission Date05/26/2013
Reason For Submission5-year update (40 CFR 68.190(b)(1))
Process Toxic Amount Total (lbs)225,180
Process Flammable Amount Total (lbs)0
Process Amount Total (lbs)225,180
Number of Potential Offsite Consequence Processes1
Potential Offsite Consequence Toxic Amount Total (lbs)225,180
Potential Offsite Consequence Flammable Amount Total (lbs)0
Potential Offsite Consequence Amount Total (lbs)225,180
All Process NAICS22111
Exec Summary Submission Date05/26/2013

Executive Summary facility_Executive_Summary help link help link (Facility #1 : Hunterstown Combined-Cycle Pow, executive summary: all)

Executive Summary
INTRODUCTION



The Hunterstown Power Plant Complex includes an 890 MW nominal rated combined-cycle power plant (HCPP) and an 81 MW (winterload) combustion turbine (CT ) site. The CT Site first went into operation in 1971 and includes three dual fuel (oil/natural gas) fired General Electric PG5331 combustion turbine generator units. The combined cycle power plant began commercial operation in 2003 and has three General Electric PG7251FB combustion-turbine generators (180 MW nominal rating, each); three Alstom triple-pressure heat recovery steam generators (HRSG) each equipped for supplemental firing capability; and one General Electric reheat condensing steam turbine generator (350-MW nominal rating).



The facility is located on about 307 acres in Straban Township, Adams County, Pennsylvania, one mile southwest of Hunterstown. The CT's and HCCPP provide electricity to the PJM network. The site and equipment are owned by GenOn Wholesale Generation, LP, a wholly owned subsidiary of NRG Energy, Inc.





1. ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES AT THE STATIONARY SOURCE



Corporate's policy is to comply with all applicable regulatory requirements, including those for accidental release prevention and emergency response.





2. THE STATIONARY SOURCE AND REGULATED SUBSTANCES HANDLED



a. PRIMARY ACTIVITIES: This facility is a natural gas- and oil-fired electric-power generating station.



b. USE OF REGULATED SUBSTANCES



The aqueous ammonia injection system at HCCP is designed to remove NOx from combustion gas by selective catalytic reduction (SCR). This is accomplished by injecting an approximately 30-percent ammonia solution into the combustion gas before it is passed over a catalyst.



No other toxic or flammable materials will be stored at the facility in quantities above the regulatory threshold.



c. QUANTITIES HANDLED OR STORED



The aqueous ammonia system at HCCPP is comprised of one 30,000-gallon storage tank, pumps, a
nd piping, instrumentation and controls. The storage tank is in a concrete diked area for secondary containment.





3. THE WORST-CASE RELEASE SCENARIO AND THE ALTERNATIVE RELEASE SCENARIO



a. WORST CASE RELEASE SCENARIO



The worst case release scenario (WCS) assumes the entire contents of the 30,000-gallon storage tank are released instantaneously into the secondary containment, and the ammonia evaporates over time. The WCS can include the effects of passive mitigation systems, and for HCCPP this is the use of secondary containment to minimize ammonia liquid spills. The quantity released is calculated as:



30,000 gallons * 7.506 lb/gal = 225,180 lb



Per EPA guidance, because the horizontal surface area of the secondary containment system (1,950 ft2) is less than that of the worst-case liquid pool (no secondary containment, one-centimeter deep pool) the rate at which the material is released is calculated as:



QR = 1.4 x LFA x A



where: QR = Release rate (pounds per minute)

1.4 = Wind speed factor

LFA = Liquid Factor Ambient

A = Diked area (square feet)



1.4 x 0.026 x 1,958 ft2 = 71.3 lb/minute



Therefore the unmitigated WCS release to air duration is calculated by:



225,180 lb / 71.3 lb/minute = 3,158.2 minutes or 52.6 hours



b. ALTERNATIVE RELEASE SCENARIO



This scenario assumes that some of the contents (1,000 gallon) of an ammonia tanker truck are spilled due to hose rupture (no secondary containment). The quantity released in the event is calculated as:



Amount released = transfer rate x release duration

Where:

Transfer rate = 200 pgm (maximum observed transfer rate = 6000 gal/30 minutes)

Release Duration = 5 minutes (estimated maximum respnse time for transfer pump shut-off)

Amount Released = 200 gpm x 5 minutes = 1000 gallons



And:

1,000 gallons / 7.48 gal/ft3 = 134 ft3



1,000 gallons x 7.506 lb/gal = 7,506 lbs



Per EPA guidanc
e, the horizontal surface area of the spill is that of the worst-case liquid pool (no secondary containment, one-centimeter deep pool). The pool area is calculated as:



134 ft3 / 0.033 = 4,061 ft2 (1-cm deep pool)



The quantity released is thus calculated as:



QR = QS x 1.4 x LFA x DF



where: QR = Release rate (pounds per minute)

QS = Quantity released (pounds)

1.4 = Wind speed factor

LFA = Liquid Factor Ambient

DF = Density Factor



QR = 7.506 lbs. x 1.4 x 0.026 x 0.55 = 185 lb/minute



Therefore the ARS release duration is:



7,506 lb / 185 lb/minute = 40.6 minutes



It should be noted that the above conditions are a conservative estimate and not normal operating conditions. The ammonia unloading transfer rate ranges from 67 gpm to 200 gpm, depending on weather conditions and operator preferences. Additionally, standard operating procedures require the delivery operator to be present throughout the delivery. Therefore the actual response time to transfer pump shut off should be nearly instantaneious (30 seconds to 1 minute). In addition, the ammonia tank truck has excess flow valves which would close upon the increase in flow from a hose rupture.



C. DISTANCES TO ENDPOINT



The offsite consequences of this accidental release scenario were evaluated with a screening computer dispersion model (RMP*Comp, online version). Offsite consequence analysis of the worst-case scenario must include the following improbable weather conditions: a wind speed of 1.5 m/s (3.4 mph), "F" atmospheric stability class, a temperature of 77F, and relative humidity of 50%. The maximum calculated distance to the worst case scenario endpoint using the RMP*Comp model is 0.5 miles for the worst case release scenario for aqueous ammonia. The endpoint represents the maximum downwind distance that the catastrophic release (under worst-case or alternative weather conditions) could pose a hazard to the public. There are p
ublic receptors (residences) within the radius of impact for the worst-case scenario, and thus this facility is subject to RMP Program 2.



More typical meteorological parameters were used in analyzing the alternative release scenario, including a mean wind speed of 3 m/s (6.7 mph) and "D" atmospheric stability. The maximum calculated distances to the alternative release scenario endpoint using the RMP*Comp model is 0.3 miles. There are public receptors (residences) in the impact areas for the alternative release scenario.





4. GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS



The aqueous ammonia storage and handling system prevention program includes the following:

- the ammonia storage tank is built to exacting standard

- ammonia tank trucks will only be unloaded during daylight hours on weekdays

- a comprehensive plan covering all componenets of the aqueous ammonia system with respect to operation, meaintenance, inspection, and training is in place at the facility.

- internal compliance audits are conducted regularly

- all incidents related to the aquous ammonia system are investigated promptly.



5. FIVE-YEAR ACCIDENT HISTORY



There have been no accidental spills or other emergencies involving the ammonia storage system in the past five years at this site as defined in 40 CFR Part 68.





6. THE EMERGENCY RESPONSE PROGRAM



In the unlikely event that an accidental release of ammonia would occur, the station has prepared a detailed written emergency response plan. Yearly drills will be held to test the plan under simulated conditions.





7. PLANNED CHANGES TO IMPROVE SAFETY



All station safety programs, including the emergency response program, will be reviewed periodically for improvement opportunities.
Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees30
Owner or Operator NameGenOn Wholesale Generation, LP
Owner or Operator Address Line 11731 Hunterstown Road
Owner or Operator CityGettysburg
Owner or Operator StatePA
Owner or Operator Zip17325
Parent Dun and Bradstreet Number0
Second Parent Dun and Bradstreet Number0
Number of Full Time Employees30
Number of FTE CBI FlagNo
Covered by OSHA PSM StandardNo
Covered by EPCRA Section 302Yes
Covered by CAA Title VYes
CAA Title V Air Operating Permit IDTVOP 01-05029
Last Safety Inspection ByNever had one
OSHA Star or Merit RankingNo
LEPC NameAdams County LEPC

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : Hunterstown Combined-Cycle Pow, RMP submission #1 : 2013-05-26)
Owner or Operator Phone7173383500
Facility URLwww.genon.com
Facility Dun and Bradstreet Number878271998
RMP ContactJesse Bowser
RMP Contact TitleReliability Engineer
RMP Contact Emailjesse.bowser@nrgenergy.com
RMP Preparer NameJulia Parsons, URS Corporation
RMP Preparer Address Line 1Foster Plaza 4, Suite 300
RMP Preparer Address Line 2501 Holiday Drive
RMP Preparer CityPittsburgh
RMP Preparer StatePA
RMP Preparer Zip15220
RMP Preparer Phone4125034597

Submission - Additional Info facility_Submission_-_Additional_Info help link help link  
RMP DescriptionHunterstown 2008 Renewal
RMP Complete FlagYes
Predictive FilingNo
No RMP Accidents Last 5 YearsYes
Complete Check Date05/26/2013
Postmark Date05/26/2013
Anniversary Date05/26/2018
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link (Facility #1 : Hunterstown Combined-Cycle Pow, RMP submission #1 : 2013-05-26)
Latitude39.873500
Longitude-077.166750
Valid Lat/LongYes
Lat/Long MethodInterpolation - Map
Lat/Long Location TypeStorage Tank
FRS Latitude39.87
FRS Longitude-77.16
FRS Lat/Long DescriptionFACILITY CENTROID
FRS Lat/Long MethodINTERPOLATION-MAP

Submission - Counts and Totals facility_Submission_-_Counts_and_Totals help link help link  
Number of RMP Accidents0
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)0
RMP Accident Amount Total (lbs)0
Number of RMP Accidents0
Number of Processes1
Number of Process Chemicals0
Number of Toxic Worst-case Scenarios1
Number of Toxic Alternate Case Scenarios1
Number of Flammable Worst-case Scenarios0
Number of Flammable Alternate Case Scenarios0
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)0
RMP Accident Amount Total (lbs)0
Total RMP Accident Deaths0
Total RMP Accident Injuries0
Total RMP Accident Evacuated/Sheltering In Place0
Total RMP Accident Property Damage$0

Processes facility_Processes help link help link (Facility #1 : Hunterstown Combined-Cycle Pow, RMP submission #1 : 2013-05-26, process #1 : SCR injection of ammonia)
Process DescriptionSCR injection of ammonia
Program Level2
Confidential Business InformationNo
Toxic Amount Total (lbs)225,180
Flammable Amount Total (lbs)0
Process Amount Total (lbs)225,180
Number of Process Chemicals0
Number of Toxic Worst-Case Scenarios1
Number of Toxic Alternate Scenarios1
Number of Flammable Worst-Case Scenarios0
Number of Flammable Alternate Scenarios0

Process Chemicals facility_Process_Chemicals help link help link  
Process Chemical IDAmmonia (conc 20% or greater)
CAS number007664417
Chemical TypeToxic
Process Chemical Amount (lbs)225,180
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Hunterstown Combined-Cycle Pow, RMP submission #1 : 2013-05-26, process #1 : SCR injection of ammonia, process chemical #2)
Process Chemical IDPublic OCA Chemical
CAS number000000000
Process Chemical Amount (lbs)0
Confidential Business InformationNo

Worst-Case Toxic Scenarios facility_Worst-Case_Toxic_Scenarios help link help link  
Percent Weight (Within Mixture)30
Physical StateLiquid
Model UsedEPA's RMP*Comp(TM)
Release Duration (minutes)3,158.2
Wind Speed (meters/sec)1.5
Atmospheric Stability ClassF
TopographyRural
Passive Mitigation - DikesYes
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsYes
Confidential Business InformationNo

Alternate Case Toxic Scenarios facility_Alternate_Case_Toxic_Scenarios help link help link (Facility #1 : Hunterstown Combined-Cycle Pow, RMP submission #1 : 2013-05-26, process #1 : SCR injection of ammonia, process chemical #2, alternate toxic scenario #1)
Percent Weight (Within Mixture)30
Physical StateLiquid
Model UsedEPA's RMP*Comp(TM)
Wind Speed3
Atmospheric Stability ClassD
TopographyRural
Passive Mitigation - DikesNo
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsNo
Active Mitigation - SprinklersNo
Active Mitigation - Deluge SystemsNo
Active Mitigation - Water CurtainNo
Active Mitigation - NeutralizationNo
Active Mitigation - Excess Flow ValvesYes
Active Mitigation - FlaresNo
Active Mitigation - ScrubbersNo
Active Mitigation - Emergency ShutdownNo
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : Hunterstown Combined-Cycle Pow, RMP submission #1 : 2013-05-26, process #1 : SCR injection of ammonia, process NAICS code #1 : 22111)
NAICS Code22111: Electric Power Generation

Prevention Program 2 facility_Prevention_Program_2 help link help link  
Safety Info Review Date05/01/2008
Safety Regs - NFPA 58No
Safety Regs - OSHA (Ammonia)No
Safety Regs - ASTM StandardsNo
Safety Regs - ANSI StandardsYes
Safety Regs - ASME StandardsYes
Safety Regs - NoneNo
PHA Review Date05/21/2008
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireNo
Hazard Identified - ExplosionNo
Hazard Identified - Runaway ReactionNo
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureNo
Hazard Identified - CorrosionNo
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationNo
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossNo
Hazard Identified - EarthquakeNo
Hazard Identified - FloodNo
Hazard Identified - TornadoNo
Hazard Identified - HurricaneNo
Process Controls - VentsNo
Process Controls - Relief ValvesYes
Process Controls - Check ValvesYes
Process Controls - ScrubbersNo
Process Controls - FlaresNo
Process Controls - Manual ShutoffsYes
Process Controls - Auto ShutoffsNo
Process Controls - InterlocksNo
Process Controls - AlarmsYes
Process Controls - Keyed BypassNo
Process Controls - Emergency AirNo
Process Controls - Emergency PowerNo
Process Controls - Backup PumpNo
Process Controls - GroundingYes
Process Controls - Inhibitor AdditionNo
Process Controls - Rupture DisksNo
Process Controls - Excess Flow DevicesNo
Process Controls - Quench SystemNo
Process Controls - Purge SystemNo
Process Controls - NoneNo
Mitigation Systems - SprinklersNo
Mitigation Systems - DikesYes
Mitigation Systems - Fire WallsNo
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsNo
Mitigation Systems - Water CurtainsNo
Mitigation Systems - EnclosureNo
Mitigation Systems - NeutralizationNo
Mitigation Systems - NoneNo
Monitoring Systems - Process AreaNo
Monitoring Systems - PerimeterNo
Monitoring Systems - NoneYes
Changes Since PHA - Reduced InventoryNo
Changes Since PHA - Increased InventoryNo
Changes Since PHA - Process ParametersNo
Changes Since PHA - Process ControlsNo
Changes Since PHA - Process DetectionNo
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneYes
Procedure Review Date05/13/2008
Training Review Date05/01/2012
Type of Training - ClassroomNo
Type of Training - On the JobYes
Type of Training - OtherReview of applicable plans and procedures.
Competency Testing - Written TestsNo
Competency Testing - Oral TestsNo
Competency Testing - DemonstrationNo
Competency Testing - ObservationNo
Competency Testing - OtherSigned acknowledgement that review was completed.
Maintenance Review Date05/28/2008
Maintenance Inspection Date05/23/2008
Equipment TestedAmmonia tank
Compliance Audit Date05/09/2013
Confidential Business InformationNo

Prevention Program 2 Chemicals facility_Prevention_Program_2_Chemicals help link help link (Facility #1 : Hunterstown Combined-Cycle Pow, RMP submission #1 : 2013-05-26, process #1 : SCR injection of ammonia, process NAICS code #1 : 22111, prev. program 2 #1, prev. program 2 chemical: all)
Process Chemical Record ID
1000050799

Prevention Program 2 Text facility_Prevention_Program_2_Text help link help link  
Prevention Program Description
The facility prevention program includes all elements required by regulations: safety information, hazards analysis, operating procedures, training, maintenance, compliance audits, incident investigations, emergency response plan, and management program.

Emergency Response Plan Info facility_Emergency_Response_Plan_Info help link help link  
Facility In Community PlanYes
Facility Own Response PlanYes
Specific Facility Response PlanYes
Inform. Procedures in Response PlanYes
Emergency Care in Response PlanYes
Plan Review Date08/06/2011
Response Training Date05/01/2012
Local Response AgencyAdams County LEPC
Local Response Agency Phone7173348603
Subject To - OSHA EAPYes
Subject To - OSHA HAZWOPERNo
Subject To - CWAYes
Subject To - RCRANo
Subject To - OPAYes
Subject To - State EPCRANo


Search Criteria Used
RMP Facility ID100000182795

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