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Cotton Valley Gas Plant

Parent Companies:
XTO Energy Inc.
EPA Facility ID:
100000033448
Other ID:
Facility DUNS:
0
Parent Company DUNS:
0

Location:

Address:
1256 Marathon Road
Cotton Valley, LA 71018
County:
WEBSTER
Lat / Long:
32.785, -93.374 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Center of Facility
Horizonal accuracy:
10 m
Horizontal reference datum:
North American Datum of 1927
Source map scale:

Owner/Operator:

Name:
XTO Energy Inc.
Phone:
(817) 885-3782
Address:
810 Houston St.
Fort Worth, TX 76102
Foreign Address:

Person responsible for RMP implementation:

Name:
Terry Dobbins
Title:
SR. PLANT SUPERINTENDENT

Emergency contact:

Name:
Bruce Merritt
Title:
PLANT SUPERINTENDENT
Phone:
(318) 832-4107
24-hour phone:
(318) 464-5781
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(817) 885-3782
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Webster Parish LEPC
Full-Time Equivalent Employees:
20
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
3080-00019-V6
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
May 19, 2009
Inspecting Agency:
DOT
Using Predictive Filing:
No

Processes:

Gas Plant
RMP ID:
1000029511
CBI claimed:
No
Program Level:
3
NAICS:
Natural Gas Liquid Extraction (211112)
Chemical name
CAS#
Quantity (lbs.)
CBI
Butane
106-97-8
59,334
No
Pentane
109-66-0
786,791
No
Ethane
74-84-0
31,216
No
Isobutane [Propane, 2-methyl]
75-28-5
69,628
No
Methane
74-82-8
19,234
No
Propane
74-98-6
47,281
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
April 24, 2015
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000024095

Deregistration:

Date:
Effective Date:
Reason:
Other Reason:

2. Toxics: Worst-case

None

3. Toxics: Alternative release

None

4. Flammables: Worst-case

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Gas Plant)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
Passive mitigation
considered:
  • Spill containment dikes
not considered:
  • Blast walls

5. Flammables: Alternative release

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Gas Plant)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
Passive mitigation
considered:
  • Dikes
not considered:
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

Gas Plant, Natural Gas Liquid Extraction (211112)
Prevention Program ID:
1000025501
Safety Review Date
Aug. 19, 2013, since latest RMP submission
PHA Update Date
Aug. 19, 2013, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Polymerization
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Cooling loss
  • Tornado
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Rupture Disks
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Fire Walls
  • Deluge System
  • Water Curtain
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
Sept. 2, 2014, since latest RMP submission
Training Review Date
Aug. 19, 2013, since latest RMP submission
Maintenance Review Date
Sept. 2, 2014, since latest RMP submission
Maintenance Inspection Date
Sept. 2, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 25, 2015
Management of Change Review Date
March 25, 2015
Pre-startup Review Date
March 25, 2015
Compliance Audit Date
Feb. 21, 2013
Compliance Audit Change Completion Date
Feb. 10, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
June 25, 2010
Hot Work Review Date
June 25, 2010
Contractor Safety Review Date
June 25, 2010, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2015, since latest RMP submission

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
Yes
Facility Own Response Plan:
No
Specific Facility Response Plan:
Yes
Inform. Procedures in Response Plan:
No
Emergency Care in Response Plan:
Yes
Plan Review Date:
Response Training Date:
Nov. 20, 2008
Local Response Agency:
Local Response Agency Phone:
(318) 832-4231
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
No
Subject To - OPA:
No
Subject To - State EPCRA:
No
Subject To - Other:

Executive Summary

ACCIDENTAL RELEASE PREVENTION AND RESPONSE POLICIES

The Cotton Valley Gas Plant (CVGP) has a long-standing commitment to safety as evidenced by over 54 years of no significant releases or failures. Preventative maintenance programs and systems are in place to reduce the potential for undesirable effects. Emergency response plans and procedures are in place to handle problems if they arise. This Risk Management Plan (RMP) identifies potential release scenarios, safeguards and emergency response procedures.

CVGP: DESCRIPTION AND REGULATED SUBSTANCES

The CVGP is located just South of Cotton Valley, LA. The plant processes natural gas and condensate. Six systems process the incoming hydrocarbons; inlet separation and compression, condensate stabilization, amine system, dehydration, cryogenic system, and the fractionating train. Regulated flammable materials in natural gas such as methane, ethane, propane, butane, and pentane are present at the plant. Chemicals are utilized at the gas plant, however the type and quantity at the CVGP are not regulated as toxics under the RMP program.

OFFSITE CONSEQUENCE ANALYSIS RESULTS

An offsite consequence analysis was performed for a worst case and alternative release scenarios for flammable substances, since the CVGP is a PSM-regulated, Program 3 facility.

Worst Case Scenario (WSC)

The WCS for a flammable release was determined to be a vapor cloud exposion of a pentane storage tank. The safegaurds in place to prevent an accidental release from this tank make this release scenario far from probable. Regardless of the safety systems in place, the release scenario has been developed for the worst case "what if" scenario for the CVGP. Under the RMP regulations, a WCS for flammable substances must consider a vapor cloud exposion event. An end point based on a one psi overpressure is required. A vapor cloud explosion involving the pentane tank could possibly affect a 0.56mile radius around the tank. Four houses with a
n estimated population of eight people live within the radius.

Alternative Release Scenario (ARS)

The ARS for a flammable release was determined to be a BLEVE of the pentane storage tank. The safegaurds in place to prevent an accidental release from this tank make this release scenario far from probable. Regardless of the safety systems in place, the release scenario has been developed for the "what if" alternative scenario for the CVGP. An end point based on a one psi overpressure is used. A BLEVE involving the propane tank could possibly affect a 0.60 mile radius around the tank.

FIVE -YEAR ACCIDENT HISTORY

With respect to flammables regulated under RMP, the CVGP has an excellent record of accident prevention over the past five years. No offsite events occurred during this time period. The only onsite event occurred in 1997 and resulted in a contractor injury. All events are investitgated to determine ways to mitigate accident potential. Appropriate steps are taken to maintain safe and environmentally sound operations.

EMERGENCY RESPONSE PROGRAM INFORMATION

An emergency response plan is maintained to protect worker and public safety, as well as the environment. This plan has been designed to address response to all emergencies including the WCS. Response strategies include detailed procedures for notification of employees, management, responders, and the public of an emergency situation. Communication, control of any releases, safety measures, and post incident recovery are included in the plan. Phone numbers for medical facilities are included as well as pertinent MSDS that identify safety and medical information.

The plan has been coordinated with local response organizations such as the Webster Parish LEPC, the Cotton Valley Fire Department, and the Webster Parish Sheriff's Office. The Cotton Valley Fire Department will coordinate fire department response. The sheriff's office will contact residents in the area and control access to the site
.

Personnel are trained on the aspects of the plan at least annually. A schedule for performing emergency response drills as well as coordination of periodic drills with local responders is discussed in the plan. The plan is reviewed and updated at least annually.

PLANNED CHANGES TO IMPROVE SAFETY

No particular changes are planned at this time. However, safety policies and procedures are continually reviewed and updated in order to improve safety.