Mocane Gas Plant - Executive Summary

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Coastal  Field Services Company (CFS), Operators for  the  Mocane 
Gas  Processing Plant, is committed to operating in a manner that 
is safe for CFS workers, the public and the environment.  As part 
of  this commitment, CFS has established a system to help  ensure 
safe  operation of the processes at this facility.  One component 
of  this system is a Risk Management Plan (RMP) that helps manage 
the  risks at CFS and that complies with the requirements of  the 
Environmental Protection Agency's (EPA's) regulation 40 CFR  part 
68,  Accidental Release Prevention Requirements: Risk  Management 
Programs (the RMP rule). 
One  of  the  requirements of the RMP rule is to  submit  a  risk 
management  plan (RMPlan) describing the risk management  program 
at  CFS.   This  document  is  intended  to  satisfy  the  RMPlan 
requirement  of  the RMP rule and to provide the  public  with  a 
description of the risk management program at CFS. 
The RMP program at CFS consists of three (3) elements: 
1)   A hazard assessment to help understand: 
              The potential offsite consequences of hypothetical 
              accidental releases and; 
         l    accidents that have occurred during the last five (5) years 
              associated with the use of substances regulated by the RMP rule 
              (regulated substances). 
2)   A prevention program to help maintain and safely operate the 
    processes  containing more than a threshold  quantity  of  a 
    regulated substance (covered processes). 
3)   An  emergency response program to help respond to accidental 
    releases of regulated substances from covered processes. 
Information further describing these elements is provided in this 
Although the RMP program at CFS helps provide assurance that  the 
facility is m 
aintained and operated in a safe manner, it is  only 
one  component of the safety program at CFS.  In fact, CFS has  a 
comprehensive safety program in place establishing many levels of 
safeguards against release of a hazardous substance and  injuries 
and damage to its employees, the public and the environment. 
 Issue Date: 
CFS  limits  the  use of hazardous substances.   Before  using  a 
hazardous  substance, less hazardous alternatives are considered. 
When a hazardous substance is used at CFS, consideration is given 
to  the  potential  for  this substance to adversely  affect  CFS 
workers,  the public, and the environment and CFS takes steps  to 
prevent any such effects. 
CFS  prevents releases of the hazardous substances  used  at  the 
facility.   When  a  hazardous substance  is  used  at  CFS,  the 
equipment is carefully designed, built and operated to reduce the 
likelihood  of  an accidental release.  Industry  and  government 
standards are closely adhered to 
in the design, construction, and 
operation of the equipment. 
CFS  limits damage from a release, if such a release occurs.  CFS 
trains workers to respond to an emergency response, reducing  the 
consequences of a release if it occurs.  In addition,  CFS  works 
with  the  local  fire  department and with the  local  emergency 
planning  committee  (LEPC) to limit injuries  and  environmental 
damage if a release does occur. 
The  safety program at CFS consists of a number of elements, only 
some  of  which  are required by the RMP rule.   This  RMPlan  is 
primarily intended to describe those parts of the safety  program 
at CFS that are required by the RMP rule. 
Accidental Release Prevention and Emergency Response Policies 
CFS  is committed to the safety of workers and the public and the 
preservation  of  the  environment,  through  the  prevention  of 
accidental  releases  of  hazardous  substances.  CFS  implements 
reasonable controls to prevent foreseeable relea 
ses of  hazardous 
substances.    These  controls  include  training  programs   for 
personnel;  programs  to  help  ensure  safety  in  the   design, 
installation, operation, and maintenance of processes at CFS; and 
programs to evaluate the hazards at CFS. 
In  the event of an accidental release, CFS controls and contains 
the  release in a manner that will be safe for workers  and  will 
help  prevent  injury  to  the public or  the  environment.   CFS 
coordinates  response efforts with the local  emergency  response 
personnel.  Response activities have also been discussed with the 
 Issue Date: 
Regulated Substances and CFS 
The Mocane Gas Processing Plant is a plant primarily involved  in 
the  recovery of liquid hydrocarbons from a gas stream.  As  part 
of   this  process,  CFS  handles  several  regulated,  flammable 
substances  in  sufficient quantities to be covered  by  the  RMP 
rule.  There are no such quantities of regulated toxic substances 
handled at the Pla 
nt. The following RMP-regulated flammables  are 
found at the Plant: 
         Ethane              Pentane             Propane 
         Condensate               Butane 
Offsite Consequence Analysis 
CFS  performed  an offsite consequence analysis to  estimate  the 
potential  for  an  accidental release of a  regulated  substance 
which  could  affect the public or the environment.  The  offsite 
consequence  analysis  consists  of  evaluating  both  worst-case 
release  scenarios and alternative release scenarios.   CFS  does 
not  expect a worst-case to ever occur.  The alternative  release 
scenarios  were  selected  to help the local  emergency  planning 
committee  improve  the community emergency  response  plan.   An 
alternative release scenario represents a release that: 1)  might 
occur  at a facility such as CFS, and/or, 2) would result in  the 
greatest potential offsite consequences if the release occurred. 
The main objective of performing the offsite consequence analysis 
is to de 
termine the distance at which certain effects might occur 
to  the  public  because  of an accidental  release  (called  the 
endpoint  distance).  Minimal effects could occur at the endpoint 
distance.   At  distances  less than the endpoint  distance,  the 
effects  would be greater; at distances greater than the endpoint 
distance, the effect would be less. 
The  RMP  rule includes specific requirements for the  worst-case 
and  alternative release scenarios that must be reported by  CFS. 
These requirements are: 
         One worst-case and one alternative release scenario for 
         the   class  of  flammable  substances  in  Program   3 
The  following  information summarizes  the  offsite  consequence 
analysis performed by CFS. 
 Issue Date: 
Program 3 Processes 
    Flammable Substances: 
The  worst-case  release  scenario for  flammable  substances  is 
failure of the 30,000 gallon product surge tank, resulting  in  a 
vapor  cloud  explosion.  No 
administrative controls  or  passive 
mitigation  were  considered  for  this  release  scenario.   The 
maximum  distance  to  the 1-psi overpressure  endpoint  is  0.39 
miles.   Several  offsite  receptors  are  located  within   this 
distance,   including  Colorado  Interstate  Gas  Company,   KOCH 
Pipeline Company, and Williams Field Services Company. 
The  alternative release scenario for flammable substances  is  a 
rupture  of  a  truck transport hose between the  truck  and  the 
product loading pumps. 
This scenario assumes that flammable substances (ethane, propane, 
i-butane,    n-butane,   i-pentane,   n-pentane,   and    heavier 
hydrocarbons) are released from a ruptured truck loading hose for 
30  minutes  before workers detect the release  and  isolate  the 
ruptured  section.  The substances form a vapor cloud,  resulting 
in  a  vapor  cloud  explosion.   The  maximum  distance  to  the 
overpressure  endpoint is 0.29 miles.  Offsite  receptors,  which 
could  be  affected  by  
the alternate release  scenario,  include 
Colorado  Interstate  Gas  Company, KOCH  Pipeline  Company,  and 
Williams Field Services Company. 
Accidental Release Prevention Program 
CFS uses a prevention program to help prevent accidental releases 
of  hazardous substances.  Beginning in 1994, CFS formalized this 
prevention  program for processing of natural gas to comply  with 
the  14  elements  of  the OSHA process safety  management  (PSM) 
prevention  program.  In 1996, the EPA RMP rule  established  two 
levels of prevention program requirements.  The level relevant to 
the Mocane Plant is: 
    Program 3: Essentially the same as OSHA PSM, except that the 
    program  also  focuses  on protecting  the  public  and  the 
The  following  sections briefly describe the elements  of  CFS's 
prevention  program  that  address the EPA  RMP  rule  prevention 
program requirements. 
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Program 3 Prevention Program 
The CFS Program 3 prevention program, which applies to the Plant, 
consists of the 
following 12 elements: 
         Employee Participation 
         Process Safety Information 
         Process Hazard Analyses 
         Operating Procedures 
         Pre-Startup Safety Review 
         Mechanical Integrity 
         Hot Work Permits 
         Management of Change 
         Incident Investigation 
         Compliance Audits 
Process Safety Information 
CFS  maintains a variety of technical documents that are used  to 
help ensure safe operation of the CFS processes.  These documents 
1)   Physical properties of hazardous substances handled, 
2)   Operating parameters of the equipment, and 
3)   Design basis and configuration of the equipment. 
CFS ensures that this process safety information is available  to 
all CFS e 
mployees, the LEPC and the fire department. 
Material  safety  data  sheets  (MSDS's)  document  the  physical 
properties  of  hazardous substances handled  at  CFS,  including 
regulated   substances  in  covered  processes.  The  information 
available for each hazardous substance typically includes: 
1)   Toxicity information and permissible exposure limits, 
2)   Physical  data  (e.g., boiling point, melting  point,  flash 
3)   Reactivity and corrosivity data, 
4)   Thermal and chemical stability data, and 
5)   Hazards of mixing substances in the process. 
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MSDS's  for  hazardous substances handled  in  each  process  are 
available  in the Plant's MSDS book so the personnel  have  ready 
reference to this information.  In addition, MSDS's are  provided 
to  the LEPC and the fire department for use in helping formulate 
gency response plans. 
The engineering design documents include the operating parameters 
and  the design basis and configuration of the equipment in  each 
covered process.  The available information includes: 
1)   Operating parameters 
2)   Block flow or simplified process flow diagrams 
3)   Process chemistry 
4)   Maximum intended inventories 
5)   Safe   upper  and  lower  limits  for  parameters  such   as 
    temperature, pressure or flow 
6)   Consequences of deviations from established operating limits 
7)   Design basis and configuration of equipment 
8)   Piping  and  instrument  diagrams,  including  materials  of 
9)   Electrical classification 
10)  Safety systems 
11)  Applicable design codes and standards, and 
12)  Design basis for relief and ventilation systems. 
When  important  information was not available  from  the  design 
documents, it was developed through special projects or,  in  the 
case  of operating parameters, during process hazard analyses  of 
e  process.  Many of the operating parameters are  included  in 
the  operating procedures to help with the safe operation of  the 
process. These documents are used: 1) to train employees;  2)  to 
perform  process  hazards analyses, and 3) to help  maintain  the 
Process Hazard Analysis 
The CFS 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. 
 Issue Date: 
The  Mocane  Gas Processing 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 Process Hazard Analysis (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 pla 
nt periodically updates and  revalidates 
the   hazard  analysis  results.   These  periodic  reviews   are 
conducted at least every five 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 Mocane Gas Processing Plant maintains written procedures that 
address various modes of process operations, such as: 
    Unit Start-up 
    Normal Operations 
    Temporary Operations 
    Emergency Shutdown 
    Normal shutdown 
    Initial start-up of a new process 
 Issue Date: 
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  cert 
ified as current and accurate.  The procedures  are 
kept  current  and  accurate by revising  them  as  necessary  to 
reflect changes through the 
management of change process. 
In  addition, the Mocane Gas Processing Plant maintains Operating 
Procedures, which provide guidance on how to respond to upper  or 
lower  limit  exceedances  for specific  processes  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. 
To  complement the written procedures for process operations, the 
Mocane  Gas  Processing  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 
red with a qualified 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.   All  of  this training is  documented  for  each 
operator,  including the means used to verify that  the  operator 
understood  the  training.  Documentation is  maintained  at  the 
Plant, which certifies on-the-job experience for each operator. 
The  Mocane  Gas Processing 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 plant has procedures  in  place  to 
ensure that contractors: 
    Perform their work in a safe manner, 
    Have the appropriate knowledge and skills, 
    Are aware of the hazards in their workplace, 
    Understand what  
they should do in the event of an emergency, 
    Understand and follow site safety rules, and 
    Inform  gas plant personnel of any hazards they find  during 
    their work. 
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This is accomplished by providing contractors with: 
    A process overview, 
    Information about safety and health hazards, 
    Emergency response plan requirements, and 
    Safe work practices prior to their beginning work. 
In  addition, the 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 (PSSR) 
CFS  conducts a (Pre-Startup Safety Reviews) PSSR for  any  major 
facility  modifications  that require a  change  in  the  process 
safety  i 
nformation.   The  purpose  of  the  Pre-Startup  Safety 
Reviews  (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  ensure  that 
construction is in accordance with the design specifications  and 
that  all  supporting systems are operationally ready.  The  PSSR 
review  team uses checklists or startup procedures to verify  all 
aspects of readiness. 
A PSSR involves field verification of the construction and serves 
as  a  quality assurance function by requiring verification  that 
accident    prevention   program   requirements   are    properly 
Mechanical Integrity 
The  Mocane  Gas Processing Plant has well-established Mechanical 
Integrity  (MI)  practices and procedures  to  maintain  pressure 
vessels, piping systems, relief and vent systems, controls, pumps 
and   compressors  and  emergency  shutdown  s 
ystems  in  a  safe 
operating condition.  The basis aspects of this program include: 
    Conducting training, 
    Developing written procedures, 
    Performing inspections and tests, 
    Correcting identified deficiencies, and 
    Applying quality assurance measures. 
 Issue Date: 
In combination, these activities form a system that maintains the 
mechanical integrity of the process. 
Maintenance personnel receive training on: 
    An overview of the process, 
    Safety and health hazards, 
    Applicable maintenance procedures, 
    Emergency response plans, and 
    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 thicknes 
s 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 MI program is  quality  assurance. 
The  Mocane  Gas Processing 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  Mocane  Gas  Processing Plant has  long-standing  safe  work 
practices  in  place  to help ensure worker and  process  safety. 
Examples of these include: 
    Control of the entry/presence/exit of support personnel, 
    A  lockout/tagout  procedure to ensure isolation  of  energy 
    sources for equipment undergoing  
    A  procedure for safe removal of hazardous substances before 
    process piping or equipment is opened, 
    A permit and procedure to control spark-producing activities 
    (i.e., hot work), and, 
    A  permit and procedure to ensure that, adequate precautions 
    are in place before entry into a confined space. 
Issue Date: 
These  procedures (and others), along with training  of  affected 
personnel,  form  a  system to help ensure  that  operations  and 
maintenance activities are performed safely. 
CFS maintains a Safe Work Practices Manual as a guidance document 
to  promote  employee safety, comply with applicable safety  laws 
and  regulations,  eliminate  injuries,  and  prevent  accidental 
Management of Change 
The  Mocane  Gas Processing 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 op 
erating conditions), procedures, 
and  other  facility changes be properly reviewed and  authorized 
before being implemented.  Changes are reviewed to: 
    Ensure that adequate controls are in place to manage any new 
    hazards, and 
    Verify  that existing controls have not been compromised  by 
    the change. 
Affected  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 
Incident Investigation 
CFS  promptly  investigates  all incidents  that  result  in,  or 
reasonably  could  have resulted in, a fire/explosion,  flammable 
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   investi 
gation   team  documents  its   findings,   develops 
recommendations to prevent 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  findings. 
Incident  investigation reports are retained  for  a  least  five 
years  so  that  the  reports can be reviewed during  future  PHA 
 Issue Date: 
Compliance Audits 
To   help   ensure  that  the  accident  prevention  program   is 
functioning   properly,   the   Mocane   Gas   Processing   Plant 
periodically   conducts  an  audit  to  determine   whether   the 
procedures  and  practices required by  the  accident  prevention 
program are being implem 
Compliance  audits are conducted at least every three (3)  years. 
Both Operations and Corporate staff personnel may 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 
The  processes  at the Mocane Gas Processing 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. 
Universal Prevention Activities 
The  accident prevention program is applied to the entire  Mocane 
Gas  Processing  Plant.  Collectively, these  prevention  program 
activities  help prevent potential 
accident scenarios that  could 
be caused by equipment failures and human errors. 
Specialized Safety Features 
CFS has safety features on many units to help: 
    Contain/control a release, 
    Quickly detect a release, and 
    Reduce the consequences of (mitigate) a release. 
The  following types of safety features are used in  the  covered 
l    Release detection:  Hydrocarbon detectors with alarms. 
l    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 pressure and temperature).  Curbing or diking to contain 
    liquid releases.  Backup power equipment (e.g., 24-volt backup 
    power supply for process control system).  Atmospheric relief 
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    Release   mitigation:  Fire  suppression  and  extinguishing 
    systems.   Fire  water  monitors and hydrants  for  specific 
    process   units.   Trained  emergency  response   personnel. 
    Personal   protective   equipment  (e.g.,   fire   retardant 
    protective clothing). 
Five Year Accident History 
The  Mocane  Gas  Processing Plant has  an  excellent  record  of 
accident prevention over the past five years.  There have been no 
accidents  or  incidents  in the past five  years,  resulting  in 
offsite effects. 
Emergency Response Program Information 
The  Mocane  Gas  Processing 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 

ubstance  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 (SPCC Plan 
Procedures),  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 CFS facilities.  The emergency response program changes are 
administered  through  the  Plant Supervisory  approval  process, 
which  includes  
informing and/or training affected  personnel  in 
the changes. 
The  overall  emergency  response  program  for  the  Mocane  Gas 
Processing  Plant  is  coordinated with the  Beaver  County  LEPC 
located in Beaver, Oklahoma.  This coordination includes periodic 
meetings   of  the  committee,  which  includes  local  emergency 
response  officials,  local government  officials,  and  industry 
The  Mocane  Gas  Processing Plant has communications  capability 
with   appropriate   LEPC   officials  and   emergency   response 
organizations  (e.g., Beaver Fire Department).  This  provides  a 
means  of  notifying the public of an incident, if necessary,  as 
well as facilitating quick response to an incident. 
 Issue Date:    Revision Date:     Revision         Page 14 
  03/16/99                        Number: 0 
Planned Changes to Improve Safety 
CFS is committed to operating the Mocane Gas Processing Plant  in 
a  safe mann 
er for workers, the public, and the environment.  CFS 
personnel utilize auditing processes to ensure the Plant complies 
with safe operations of its processes. 
In  the  event  improvements in safety can  be  realized  through 
auditing  efforts, actions are planned and instituted to  respond 
to  safety  enhancements of operating practices. Improvements  to 
safety are a continual process at the Plant.
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