Wattenberg Gas Plant - Executive Summary

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ACCIDENTAL RELEASE PREVENTION AND RESPONSE POLICIES 
 
The Wattenberg 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, gas plant trained personnel will respond to control and contain the release.   
 
DESCRIPTION OF THE STATIONARY SOURCE AND REGULATED SUBSTANCES 
 
The Wattenberg Gas Plant, located in Aurora, Colorado, operates a variety of processes to produce petroleum products (e.g., natural gas, propane, NGL mix) from natural gas.  The Wattenberg Gas Plant has several regulated flammables, such as ethane and propane.  Additionally, the Wattenberg Gas Plant processes hydrogen sulfide, which is also a regulated substance.   
 
OF 
FSITE CONSEQUENCE ANALYSIS RESULTS 
 
The worst-case scenario (WCS) associated with the release of flammable substances in Program Level 3 processes at the gas plant, is a vapor cloud explosion (VCE) involving the full inventory of the largest storage tank containing a NGL mix.  The maximum distance to the 1-psi endpoint for the WCS is 0.77 mile.  Although we have numerous controls to prevent such releases and to manage their consequences, no credit for passive mitigation measures was taken into account in evaluating this WCS.   
 
The alternative release scenario (ARS) for flammable substances at the gas plant is a VCE resulting from the release of NGL from a product line (39,000 lbs released in 15 minutes).  The release is expected to be isolated by the operators within 15 minutes (active mitigation).  The maximum distance to the 1-psi endpoint for this event is 0.19 mile.  This event was selected as being a practical scenario for use on emergency planning and response.   
 
Although the W 
attenberg Gas Plant processes hydrogen sulfide, the plant does not process or store toxic regulated substances exceeding the threshold amounts. 
 
GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM 
 
The following is a summary of the accident prevention program in place at the plant.  Because processes at the gas plant that are regulated by the Environmental Protection Agencys (EPAs) risk management program (RMP) regulation are also subject to the Occupational Safety and Health Administrations (OSHAs) process safety management (PSM) standard, this summary addresses each of the OSHA PSM elements and describes the management system in place to implement the accident prevention program.   
 
Employee Participation 
 
The Wattenberg 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 chemical information to participating as a member of a proces 
s 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 accident prevention program are documented in an employee participation plan that is maintained at the gas plant and addresses each accident prevention program element.  In addition, the gas plant has a number of initiatives under way that address process safety and employee safety issues.  These initiates include forming teams to promote both process and personal safety.  The teams typically have members from various areas of the plant, including operations, maintenance, engineering, and plant management.   
 
Process Safety Information 
 
The Wattenberg 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 hazards, limits for key process parameters and specific chemical inventories, and  
equipment design basis/configuration information.  Specific departments within the gas plant are assigned responsibility for maintaining up-to-date process safety information.  A table summarizing the reference documents and their location is readily available as part of the written employee participation plan to help employees locate any necessary process safety information.   
 
Chemical-specific information, including exposure hazards and emergency response/exposure treatment considerations, is provided in material safety data sheets (MSDSs).  This information is supplemented by documents that specifically address known corrosion concerns and any known hazards associated with the inadvertent mixing of chemicals.  For specific process areas, the gas plant has documented safety-related limits for specific process parameters (e.g., temperature, level, composition) in key process parameter documents.  The gas plant ensures that the process is maintained within these limits using process c 
ontrols 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 Wattenberg 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 pla 
ce to manage these hazards.   
 
The Wattenberg Gas Plant primarily uses the hazard and operability (HAZOP) analysis technique 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 that highest risk receive immediate attention.  All approved mitigation o 
ptions 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 Wattenberg 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 st 
artup 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 Wattenberg Gas Plant maintains key process parameter documents that provide 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 Wattenberg Gas Plant has implemented a comprehensive training program for all employees involved in operating a process.  New employee 
s 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 Wattenberg Gas Plant uses contractors to supplement its workforce 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 event of an emergency, (5) understand 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) emergency response plan requirements, and (4) safe work practices prior to their beginning work.  In addition, the Wattenberg 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 Wattenberg Gas Plant conducts a PSSR for any new facilit 
y 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 Wattenberg 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 pro 
gram 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.   
 
Maintenance personnel receive training on (1) an overview of the process, (2) safety and health hazards, (3) applicable maintenance procedures, (4) emergency response plans, and (5) applicable safe work practices to help ensure that they can perform their jobs in a safe manner.  Job plans/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 equipm 
ent 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 Wattenberg 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 Wattenberg 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 s 
park-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 Wattenberg 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 to (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 inco 
rporate these changes.  In addition, operating and maintenance personnel are provided any necessary training on the change.   
 
Incident Investigation 
 
The Wattenberg Gas Plant promptly investigates all incidents that resulted in, or reasonably could have resulted in, a fire/explosion, 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 teams 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 fin 
dings.  Incident investigation reports are retained for at least 5 years so that the reports can be reviewed during PHAs and PHA revalidations.   
 
Compliance Audits 
 
To help ensure that the accident prevention program is functioning properly, the Wattenberg 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 teams 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 Wattenberg Gas Plant have hazards that must be managed to ensure continued safe operation.  The fol 
lowing is a description of existing safety features applicable to prevention of accidental releases of regulated substances in the facility.   
 
Universal Prevention Activities 
 
The accident prevention program summarized previously is applied to all RMP-covered processes at the Wattenberg Gas Plant.  Collectively, these prevention program activities help prevent potential accident scenarios that could be caused by equipment failures and human errors.   
 
Specialized Safety Features 
 
The Wattenberg 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 
 
1.  Hydrocarbon detectors with alarms, beacons, and signal inputs to control room. 
 
2.  Hydrogen sulfide detectors with alarms, beacons, and signal inputs to control room. 
 
Release Containment/Control 
 
1.  Process relief valves that d 
ischarge to a flare to capture and incinerate episodic releases.   
 
2.  Valves to permit isolation of the process (manual and automated). 
 
3.  Automated shutdown systems for specific process parameters (e.g., high temperature, hydrocarbon and hydrogen sulfide releases, fires (linked to fire-eyes), Plant ESD). 
 
4.  Curbing or diking to contain liquid releases. 
 
5.  Redundant equipment and instrumentation (e.g., uninterruptible power supply for process control system, backup firewater pump).   
 
6.  Atmospheric relief devices. 
 
7.  Manual-operated ESD stations. 
 
Release Mitigation 
 
1.  Fire suppression and extinguishing systems (water, carbon dioxide). 
 
2.  Deluge system for specific equipment (gas sweetening process unit). 
 
3.  Trained emergency response personnel. 
 
4.  Personal protective equipment (e.g., chemical protective clothing, self-contained breathing apparatus). 
 
FIVE-YEAR ACCIDENT HISTORY 
 
The Wattenberg Gas Plant has an excellent record of accident prevention over the past 5  
years.  In the event of an accidental release, we investigate the incident very carefully to determine ways to prevent similar incidents from recurring.   
 
EMERGENCY RESPONSE PROGRAM INFORMATION 
 
The Wattenberg 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 provides action plans 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 plan addresses 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.   
 
The plant has procedures that address maintenance, inspection, and testing of emergency response equipment.  These are mainta 
ined in a commercial computer database system (Maximo) that automatically creates work orders for routine inspections.  Users can also create special work orders for maintenance needs that arise in the normal conduct of plant operations.  Plant procedures also include 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.  Such updates are based on modifications made to gas plant processes or other Wattenberg Gas Plant facilities.  The emergency response program changes are administered through the Management of Change (MOC) element of Process Safety Management (PSM), which includes informing and/or training affected personnel in the changes.   
 
The overall emergency response program for the Wattenberg Gas Plant is coordinated with the Adams County Local Emergency Planning Committee (LEPC).  The Wattenbe 
rg Gas Plant has around-the-clock communications 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 this coordination, the Wattenberg Gas Plant conducts periodic emergency drills that may involve the LEPC and emergency response organizations.   
 
All employees and contractors who work at the plant are required to complete a plant process safety overview once a year.  All such personnel must take and pass a written exam to ensure that they understand the basic plant processes and know the all emergency and evacuation procedures for drills and actual contingencies.   
 
In addition to maintaining a comprehensive emergency response program, the Wattenberg Gas Plant implements many preventative measures to minimize the incidence of equipment and process failure.  It conducts monthly Spill Preve 
ntion Control and Countermeasures inspections to check the integrity of spill containment structures.  Monthly plant safety walkthroughs, job audits, formal internal Health, Safety, and Environmental audits and formal internal PSM audits are also conducted.  Fugitive emissions testing is conducted quarterly to find process leaks in valves, pumps, flanges, and other connections in the system.  Finally, the plant has a rigorous piping and vessel inspection program to monitor the status of metals that are contacted by plant processes. 
 
 
PLANNED CHANGES TO IMPROVE SAFETY 
 
The Wattenberg Gas Plant routinely resolves findings from Process Hazard Assessments (PHAs), some of which result in modifications to the process.  There are no changes planned at this time.  
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