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Elk Basin Gas Plant

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Facility #1 : Elk Basin Gas Plant


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000029612
Deregistered (Yes/No)No
Facility NameElk Basin Gas Plant
Street Address Line 116 Miles north of Powell Wy.
Street Address Line 2Highway 295
CityPowell
StateWY
Zip Code82435
CountyPark County
113th Congressional DistrictWY00: Wyoming At Large
Owner or Operator NameEncore Energy Partners Operating LL
Parent CompanyEncore Acquisition Company
Latitude44.979139
Longitude-108.840972
Number of RMP Submissions3

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000001293
Submission Typerevised submission for facility
Submission Date06/02/2009
Reason For Submission5-year update (40 CFR 68.190(b)(1))
Process Toxic Amount Total (lbs)0
Process Flammable Amount Total (lbs)320,000
Process Amount Total (lbs)320,000
Number of Potential Offsite Consequence Processes0
Potential Offsite Consequence Toxic Amount Total (lbs)0
Potential Offsite Consequence Flammable Amount Total (lbs)0
Potential Offsite Consequence Amount Total (lbs)0
All Process NAICS211112
Exec Summary Submission Date06/02/2009

Executive Summary facility_Executive_Summary help link help link (Facility #1 : Elk Basin Gas Plant, executive summary: all)

Executive Summary

ACCIDENTAL RELEASE PREVENTION AND RESPONSE POLICIES

The Elk Basin Gas Plant has a long-standing commitment to worker and public safety. This commitment is demonstrated by the resources invested in accident prevention, such as training personnel and considering safety in the design, installation, operation, and maintenance of our processes. Our policy is to implement reasonable controls to prevent foreseeable releases of regulated substances. However, if a release does occur, the Incident Management Plan will be initiated and gas plant trained personnel will respond to control and contain the release.


DESCRIPTION OF THE STATIONARY SOURCE AND REGULATED SUBSTANCES

The Elk Basin Gas Plant, located 16 miles north of Powell, Wyoming, U.S.A., operates a variety of processes to produce petroleum products (e.g., natural gas, propane, butane, and condensate) from natural gas. The Elk Basin Gas Plant has two regulated flammables, butane and propane. In addition, the Elk Basin Gas Plant uses and/or processes the gas from the Elk Basin field that contains hydrogen sulfide (H2S), which is also a regulated substance. The amount of hydrogen sulfide in the entire plant is less than the threshold quantity.


OFFSITE CONSEQUENCE ANALYSIS RESULTS

The worst-case scenario (WCS) associated with toxic substances in Program Level 1 at the gas plant was not calculated due to low amount of Hydrogen Sulfide (1,133 lbs.) contained in the entire gas plant operation.

The alternative release scenario (ARS) is not required for Program Level 1 facilities.

The WCS associated with a release of flammable substances in Program Level 1 processes at the gas plant is a vapor cloud explosion (VCE) involving the full inventory of the largest storage tank containing butane. The maximum inventory in a single tank is 170,966; therefore, the inventory is assumed to release and ignite, resulting in a VCE. The maximum distance to the 1-psi endpoint for this WCS is 0.4 mile. Although we have numero
us controls to prevent such releases and to manage their consequences, no credit for passive mitigation measures was taken into account in evaluating this WCS. Utilizing the AEstimate Population Around Current Map PointerA option in LandView III program estimates the population within the .4 miles radius of exposure for the Worse Case Scenario at two people. However, a tour of the facility will prove that no residents are located within .4 of a mile. Please refer to figure A on the next page for the results for the Worst Case Scenario.


Figure A
Hazard Assessment Results for the Worst-case Scenarios
At the Elk Basin Gas Plant

GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM

The following is a summary of the accident prevention program in place at the plant. The processes at the Elk Basin Gas Plant are regulated by the Environmental Protection Agency's (EPA's) risk management program (RMP) regulation and the Occupational Safety and Health AdministrationAs (OSHA's) process safety management (PSM) standard. The following summary addresses each of the OSHA PSM elements and describes the management system in place to implement the accident prevention program.

Employee Participation

The Elk Basin Gas Plant encourages employees to participate in all facets of process safety management and accident prevention. Examples of employee participation range from updating and compiling technical documents and initiating Management of Change to participating as a member of a process hazard analysis (PHA) team. Employees have access to all information created as part of the gas plant accident prevention program. Specific ways that employees can be involved in the PSM program are documented in an employee participation plan that is maintained at the gas plant.

Process Safety Information

The Elk Basin Gas Plant keeps a variety of technical documents that are used to help maintain safe operation of the processes. These documents address chemical properties and associated h
azards, limits for key process parameters, and equipment design basis/configuration information. Specific departments within the gas plant are assigned responsibility for maintaining up-to-date process safety information.

Chemical-specific information, including exposure hazards and emergency response/ exposure treatment considerations, is provided in material safety data sheets (MSDSs). For specific process areas, the gas plant has documented safety-related limits for specific process parameters (e.g., temperature, level, composition) on the Pipe & Instrument Diagrams (P&ID) along with the Normal Operating Conditions, (NOC). The gas plant ensures that the process is maintained within these limits using process controls and monitoring instruments, highly trained personnel, and protective instrument systems (e.g., automated shutdown systems).

The gas plant also maintains numerous technical documents that provide information about the design and construction of process equipment. This information includes materials of construction, design pressure and temperature ratings, and electrical rating of equipment. This information, in combination with written procedures and trained personnel, provides a basis for establishing inspection and maintenance activities, as well as for evaluating proposed process and facility changes to ensure that safety features in the process are not compromised.


Process Hazard Analysis (PHA)

The Elk Basin Gas Plant has a comprehensive program to help ensure that hazards associated with the various processes are identified and controlled. Within this program, each process is systematically examined to identify hazards and ensure that adequate controls are in place to manage these hazards.

The Elk Basin Gas Plant primarily uses the hazard and operability (HAZOP) analysis technique along with other methods to perform these evaluations. HAZOP analysis is recognized as one of the most systematic and thorough hazard evaluation techniques. The
analyses are conducted using a team of people who have operating and maintenance experience as well as engineering expertise. This team identifies and evaluates hazards of the process as well as accident prevention and mitigation measures, and the team makes suggestions for additional prevention and/or mitigation measures when the team believes such measures are necessary.

The PHA team findings are forwarded to local and corporate management for resolution. Implementation of mitigation options in response to PHA findings is based on a relative risk ranking assigned by the PHA team. This ranking helps ensure that potential accident scenarios assigned the highest risk receive immediate attention. All approved mitigation options in response to PHA team findings are tracked until they are completed. The final resolution of each finding is documented and retained.

To help ensure that the process controls and/or process hazards do not eventually deviate significantly from the original design safety features, the plant periodically updates and revalidates the hazard analysis results. These periodic reviews are conducted at least every 5 years and will be conducted at this frequency until the process is no longer operating. The results and findings from these updates are documented and retained. Once again, the team findings are forwarded to management for consideration, and the final resolution of the findings is documented and retained.

Operating Procedures

The Elk Basin Gas Plant maintains written procedures that address various modes of process operations, such as (1) unit startup, (2) normal operations, (3) temporary operations, (4) emergency shutdown, (5) normal shutdown, and (6) initial startup of a new process. These procedures can be used as a reference by experienced operators and provide a basis for consistent training of new operators. These procedures are periodically reviewed and annually certified as current and accurate. The procedures are kept current
and accurate by revising them as necessary to reflect changes made through the management of change process.

In addition, the Elk Basin Gas Plant maintains a Trouble Shooting Procedure that provides guidance on how to respond to upper or lower limit exceedances for specific process or equipment parameters. This information, along with written operating procedures, is readily available to operators in the process unit and for other personnel to use as necessary to safely perform their job tasks.

Training

To complement the written procedures for process operations, the Elk Basin Gas Plant has implemented a comprehensive training program for all employees involved in operating a process. New employees receive basic training in gas plant operations if they are not already familiar with such operations. After successfully completing this training, a new operator is paired with a senior operator to learn process-specific duties and tasks. After operators demonstrate (e.g., through tests, skills demonstration) having adequate knowledge to perform the duties and tasks in a safe manner on their own, they can work independently. In addition, all operators periodically receive refresher training on the operating procedures to ensure that their skills and knowledge are maintained at an acceptable level. This refresher training is conducted at least every 3 years. All of this training is documented for each operator, including the means used to verify that the operator understood the training.

Contractors

The Elk Basin Gas Plant uses contractors to supplement its work force during periods of increased maintenance or construction activities. Because some contractors work on or near process equipment, the gas plant has procedures in place to ensure that contractors (1) perform their work in a safe manner, (2) have the appropriate knowledge and skills, (3) are aware of the hazards in their workplace, (4) understand what they should do in the event of an emergency, (5) under
stand and follow site safety rules, and (6) inform gas plant personnel of any hazards that they find during their work. This is accomplished by providing contractors with (1) a process overview, (2) information about safety and health hazards, (3) Incident Management Plan requirements, and (4) safe work practices prior to their beginning work. In addition, the Elk Basin Gas Plant evaluates contractor safety programs and performance during the selection of a contractor. Gas plant personnel periodically monitor contractor performance to ensure that contractors are fulfilling their safety obligations.

Pre-startup Safety Reviews (PSSRs)

The Elk Basin Gas Plant conducts a PSSR for any new facility or facility modification that requires a change in the process safety information. The purpose of the PSSR is to ensure that safety features, procedures, personnel, and equipment are appropriately prepared for startup prior to placing the equipment into service. This review provides one additional check to make sure construction is in accordance with the design specifications and that all supporting systems are operationally ready. The PSSR review team uses checklists to verify all aspects of readiness. A PSSR involves field verification of the construction and serves a quality assurance function by requiring verification that accident prevention program requirements are properly implemented.

Mechanical Integrity

The Elk Basin Gas Plant has well-established practices and procedures to maintain pressure vessels, piping systems, relief and vent systems, controls, pumps and compressors, and emergency shutdown systems in a safe operating condition. The basic aspects of this program include: (1) conducting training, (2) developing written procedures, (3) performing inspections and tests, (4) correcting identified deficiencies, and (5) applying quality assurance measures. In combination, these activities form a system that maintains the mechanical integrity of the process.

Maint
enance personnel receive training on (1) an overview of the process, (2) safety and health hazards, (3) applicable maintenance procedures, (4) Incident Management Plans, and (5) applicable safe work practices to help ensure that they can perform their jobs in a safe manner. Written procedures help ensure that work is performed in a consistent manner and provide a basis for training. Inspections and tests are performed to help ensure that equipment functions as intended and to verify that equipment is within acceptable limits (e.g., adequate wall thickness for pressure vessels). If a deficiency is identified, employees will correct the deficiency before placing the equipment back into service (if possible), or a management of change team will review the use of the equipment and determine what actions are necessary to ensure the safe operation of the equipment.

Another integral part of the mechanical integrity program is quality assurance. The Elk Basin Gas Plant incorporates quality assurance measures into equipment purchases and repairs. This helps ensure that new equipment is suitable for its intended use and that proper materials and spare parts are used when repairs are made.

Safe Work Practices

The Elk Basin Gas Plant has long-standing safe work practices in place to help ensure worker and process safety. Examples of these include (1) control of the entry/presence/exit of support personnel, (2) a lockout/tagout procedure to ensure isolation of energy sources for equipment undergoing maintenance, (3) a procedure for safe removal of hazardous substances before process piping or equipment is opened, (4) a permit and procedure to control spark-producing activities (i.e., hot work), and (5) a permit and procedure to ensure that adequate precautions are in place before entry into a confined space. These procedures (and others), along with training of affected personnel, form a system to help ensure that operations and maintenance activities are performed safely.





Management of Change

The Elk Basin Gas Plant has a comprehensive system to manage changes to all covered processes. This system requires that changes to items such as process equipment, chemicals, technology (including process operating conditions), procedures, and other facility changes be properly reviewed and authorized before being implemented. Changes are reviewed to (1) ensure that adequate controls are in place to manage any new hazards and (2) verify that existing controls have not been compromised by the change. Affected chemical hazard information, process operating limits, and equipment information, as well as procedures are updated to incorporate these changes. In addition, operating and maintenance personnel are provided any necessary training on the change.

Incident Investigation

The Elk Basin Gas Plant policy is to promptly investigates all incidents that resulted in, or reasonably could have resulted in, a fire/explosion, toxic gas release, major property damage, environmental loss, or personal injury. The goal of each investigation is to determine the facts and develop corrective actions to prevent a recurrence of the incident or a similar incident. The investigation team documents its findings, develops recommendations to prevent a recurrence, and forwards these results to gas plant management for resolution. Corrective actions taken in response to the investigation teamAs findings and recommendations are tracked until they are complete. The final resolution of each finding or recommendation is documented, and the investigation results are reviewed with all employees (including contractors) who could be affected by the findings. Incident investigation reports are retained for at least 5 years so that the reports can be reviewed during future PHAs and PHA revalidations.

Compliance Audits

To help ensure that the accident prevention program is functioning properly, the Elk Basin Gas Plant periodically conducts an audit to determine whether
the procedures and practices required by the accident prevention program are being implemented. Compliance audits are conducted at least every 3 years. Both hourly and staff personnel participate as audit team members. The audit team develops findings that are forwarded to gas plant management for resolution. Corrective actions taken in response to the audit team's findings are tracked until they are complete. The final resolution of each finding is documented, and the two most recent audit reports are retained.

CHEMICAL-SPECIFIC PREVENTION STEPS

The processes at the Elk Basin Gas Plant have hazards that must be managed to ensure continued safe operation. The following is a description of existing safety features applicable to prevention of accidental releases of regulated substances in the facility.

Specialized Safety Features

The Elk Basin Gas Plant has safety features on many units to help (1) contain/control a release, (2) quickly detect a release, and (3) reduce the consequences of (mitigate) a release. The following types of safety features are used in the covered processes:

Release Detection

* Hydrocarbon detectors with alarms
* H2S detectors with alarms

Release Containment/Control

* Process relief valves that discharge to a flare to capture and incinerate episodic releases

* Valves to permit isolation of the process (manual or automated)

* Automated shutdown systems for specific process parameters (e.g., high temperature)

* Redundant equipment and instrumentation (e.g., uninterruptible power supply for process control system)

* Atmospheric relief devices.
Release Mitigation

* Fire extinguishers located through the plant

* Trained emergency response personnel

* Personal protective equipment (e.g., chemical protective clothing, self-contained breathing apparatus)

FIVE-YEAR ACCIDENT HISTORY

The Elk Basin Gas Plant has an excellent record of accident prevention over the past 5 years. There have been no accidents in the past five years.


2005 2006 2007 2008 2009
Number of RMP Events
with Onsite Effects 0 0 0 0 0

Number of RMP Events
with Offsite Effects 0 0 0 0 0


EMERGENCY RESPONSE PROGRAM INFORMATION

The Elk Basin Gas Plant maintains a written emergency response program, which is in place to protect worker and public safety as well as the environment. The program consists of procedures for responding to a release of a regulated substance, including the possibility of a fire or explosion if a flammable substance is accidentally released. The procedures address all aspects of emergency response, including proper first aid and medical treatment for exposures, evacuation plans and accounting for personnel after an evacuation, notification of local emergency response agencies and the public if a release occurs, and post-incident cleanup and decontamination requirements. In addition, the plant has procedures that address maintenance, inspection, and testing of emergency response equipment, as well as instructions that address the use of emergency response equipment. Employees receive training in these procedures as necessary to perform their specific emergency response duties. The emergency response program is updated when necessary based on modifications made to gas plant processes or other Elk Basin Unit facilities. The emergency response program changes are administered through the MOC process, which includes informing and/or training affected personnel in the changes.

The overall emergency response program for the Elk Basin Gas Plant is coordinated with the Park County, local emergency planning committee (LEPC). This coordination includes periodic meetings of the committee, which includes local emergency response officials, local government officials, and industry representatives. The Elk Basin Unit has around-the-clock co
mmunications capability with appropriate LEPC officials and emergency response organizations (e.g., fire department). This provides a means of notifying the public of an incident, if necessary, as well as facilitating quick response to an incident. In addition to periodic LEPC meetings, the Elk Basin Unit conducts periodic emergency drills that involve emergency response organizations. Annual refresher training is available for the local emergency responders regarding the hazards of regulated substances in the gas plant.


















Encore Energy Partners Operating LLC

Elk Basin Unit

Gas Plant

Executive Summary





Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees26
Owner or Operator NameEncore Energy Partners Operating LL
Owner or Operator Address Line 116 Miles north of Powell Wy.
Owner or Operator Address Line 2Highway 295
Owner or Operator CityPowell
Owner or Operator StateWY
Owner or Operator Zip82435
Parent Dun and Bradstreet Number0
Second Parent Dun and Bradstreet Number0
Number of Full Time Employees26
Number of FTE CBI FlagNo
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VYes
CAA Title V Air Operating Permit ID30-045
Last Safety Inspection ByNever had one
OSHA Star or Merit RankingNo
LEPC NamePark County LEPC

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : Elk Basin Gas Plant, RMP submission #1 : 2009-06-02)
Owner or Operator Phone3077547300
Facility URLwww.encoreacq.com
Facility Dun and Bradstreet Number0
RMP ContactCurt Kyle
RMP Contact TitleSenior Field Foreman
RMP Contact Emailckyle@encoreacq.com
RMP Preparer NameJon Jensen
RMP Preparer Address Line 1PO Box 569
RMP Preparer CityPowell
RMP Preparer StateWY
RMP Preparer Zip82435
RMP Preparer Phone3077547325

Submission - Additional Info facility_Submission_-_Additional_Info help link help link  
RMP Complete FlagYes
Predictive FilingNo
No RMP Accidents Last 5 YearsNo
Complete Check Date06/02/2009
Postmark Date06/02/2009
Anniversary Date06/02/2014
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link (Facility #1 : Elk Basin Gas Plant, RMP submission #1 : 2009-06-02)
Latitude44.979139
Longitude-108.840972
Valid Lat/LongYes
Lat/Long MethodGPS - Unspecified
Lat/Long Location TypeProcess Unit Area Centroid
FRS Latitude44.79
FRS Longitude-108.84
FRS Lat/Long DescriptionPLANT ENTRANCE (GENERAL)
FRS Lat/Long MethodCENSUS-OTHER

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 Scenarios0
Number of Toxic Alternate Case Scenarios0
Number of Flammable Worst-case Scenarios1
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 : Elk Basin Gas Plant, RMP submission #1 : 2009-06-02, process #1 : Elk Basin Gas Plant)
Process DescriptionElk Basin Gas Plant
Program Level1
Confidential Business InformationNo
Toxic Amount Total (lbs)0
Flammable Amount Total (lbs)320,000
Process Amount Total (lbs)320,000
Number of Process Chemicals0
Number of Toxic Worst-Case Scenarios0
Number of Toxic Alternate Scenarios0
Number of Flammable Worst-Case Scenarios1
Number of Flammable Alternate Scenarios0

Process Chemicals facility_Process_Chemicals help link help link  
Process Chemical IDButane
CAS number000106978
Chemical TypeFlammable
Process Chemical Amount (lbs)171,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Elk Basin Gas Plant, RMP submission #1 : 2009-06-02, process #1 : Elk Basin Gas Plant, process chemical #2)
Process Chemical IDPropane
CAS number000074986
Chemical TypeFlammable
Process Chemical Amount (lbs)149,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link  
Process Chemical IDPublic OCA Chemical
CAS number000000000
Process Chemical Amount (lbs)0
Confidential Business InformationNo

Worst-Case Flammable Scenarios facility_Worst-Case_Flammable_Scenarios help link help link  
Model UsedEPA's RMP*Comp(TM)
Passive Mitigation - Blast WallsNo
Passive Mitigation - OtherContainment dikes
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Elk Basin Gas Plant, RMP submission #1 : 2009-06-02, process #1 : Elk Basin Gas Plant, process chemical #4)
Process Chemical IDPublic OCA Chemical
CAS number000000000
Process Chemical Amount (lbs)0
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link  
NAICS Code211112: Natural Gas Liquid Extraction

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 Date04/06/2009
Response Training Date04/23/2009
Local Response AgencyPark County LEPC
Local Response Agency Phone3075278760
Subject To - OSHA EAPYes
Subject To - OSHA HAZWOPERYes
Subject To - CWAYes
Subject To - RCRAYes
Subject To - OPAYes
Subject To - State EPCRAYes


Search Criteria Used
RMP Facility ID100000029612

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