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Opal Gas Plant

Parent Companies:
Williams Field Services Company LLC
EPA Facility ID:
100000158839
Other ID:
Facility DUNS:
876538356
Parent Company DUNS:
879847010

Location:

Address:
1mile west of Opal on Wy Highway 30
Opal, WY 83124
County:
LINCOLN
Lat / Long:
41.773, -110.340 (Get map)
Method:
Unknown
Description:
Plant Entrance (General)
Horizonal accuracy:
10 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Williams Field Services Company LLC
Phone:
(307) 877-4488
Address:
PO Box 40
Opal, WY 83124
Foreign Address:

Person responsible for RMP implementation:

Name:
Dan Kalan
Title:
Operations Manager

Emergency contact:

Name:
Williams Gas Control
Title:
Williams Gas Control
Phone:
(918) 573-7400
24-hour phone:
(800) 635-7400
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Lincoln County LEPC
Full-Time Equivalent Employees:
37
Covered by OSHA PSM:
Yes
EPCRA section 302:
No
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
3-1-018-2
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Sept. 15, 2016
Inspecting Agency:
OSHA
Using Predictive Filing:
No

Processes:

NGL Liquid Extraction
RMP ID:
1000081658
CBI claimed:
No
Program Level:
3
NAICS:
Natural Gas Liquid Extraction (211112)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
150,000
No
Propane
74-98-6
2,700,000
No
Flammable Mixture
00-11-11
1,900,000
No
Flammable Mixture
00-11-11
3,100,000
No
Flammable Mixture
00-11-11
6,500,000
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:
Madison McGuire
Address:
One Williams Center
Mail Drop 43-5
Tulsa, OK 74172
Foreign Address:

Phone:
(918) 573-0274

Latest RMP Submission:

Date:
Aug. 13, 2017
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000065100

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 NGL Liquid Extraction)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Blast walls
Public OCA Chemical (in NGL Liquid Extraction)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
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 NGL Liquid Extraction)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • 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

Sept. 14, 2016 at 02:02
ID:
1000050499
NAICS:
Natural Gas Liquid Extraction (211112)
Duration:
2 hours and 43 minutes
Chemicals involved:
  • Flammable Mixture
  • Flammable Mixture
Release events:
Gas release
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
7.0 miles/h NNE
Temperature:
46.00 ℉
Atmospheric stability:
D
Precipitation present:
Yes
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
1
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
0
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$1000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Human Error
Contributing factors:
  • Human error
  • Improper procedure
  • Management error
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised maintenance
  • Revised training
  • Revised operating procedures
April 23, 2014 at 14:00
ID:
1000050498
NAICS:
Natural Gas Liquid Extraction (211112)
Duration:
1 hours
Chemicals involved:
  • Methane
Release events:
Gas release
Fire
Weather conditions at time of event
Wind speed:
20.0 miles/h E
Temperature:
40.00 ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
0
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$35000000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
32
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Equipment failure
  • Quantity released was consumed in the fire.
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • TXP-3 Plant is permanently shutdown. Investigation is complete.

7. Prevention: Program level 3

NGL Liquid Extraction, Natural Gas Liquid Extraction (211112)
Prevention Program ID:
1000068733
Safety Review Date
June 27, 2017
PHA Update Date
June 27, 2017
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Deluge System
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 30, 2016
Training Review Date
Dec. 30, 2016
Maintenance Review Date
Dec. 30, 2016
Maintenance Inspection Date
June 19, 2017
Equipment Tested
Yes
Management of Change Most Recent Date
June 27, 2017
Management of Change Review Date
Aug. 1, 2017
Pre-startup Review Date
July 27, 2017
Compliance Audit Date
July 21, 2017
Compliance Audit Change Completion Date
June 30, 2018
Incident Investigation Date
Sept. 14, 2016
Incident Invest. Change Completion Date
June 14, 2017
Participation Plan Review Date
April 27, 2017
Hot Work Review Date
Aug. 1, 2017
Contractor Safety Review Date
Jan. 10, 2017
Contractor Safety Eval. Date
June 23, 2017

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:
May 31, 2017
Local Response Agency:
Local Response Agency Phone:
(800) 442-9001
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
Yes
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

Accidental Release Prevention and Emergency Response Policies



The Opal Gas Plant has implemented all the elements of a Program 3 Risk Management Plan (RMP) and all the elements of OSHA's Process Safety Management (PSM) program. The Opal Gas Plant has also implemented elements of Williams Integrated Management Plan (WIMS), and Williams System Integrity Plan (SIP); both of which contain additional environmental, health, and safety standards.



The Opal Gas Plant's Emergency Response Plan (ERP) is site-specific. It includes required actions by plant employees as well as required notification and coordination with local responders and agencies. The Opal Gas Plant has a signed Memorandum of Understanding (MOU) with the local fire agency for coordination of emergency response. All employees are trained in the execution of the ERP.



Williams CEO, Alan Armstrong, has supported the commitment to safety in saying, "While each [of Williams Core Values & Beliefs] are important, our commitment to Safety and Environmental Stewardship is critical, reminding us that Williams is committed to the health and safety of our work force and to the protection of our neighbors, the environment, and our assets."



The Stationary Source and Regulated Substances



The Opal Conditioning Plant process raw natural gas into methane and natural gas liquids. The raw natural material is received by pipeline. The finished products are delivered to both pipelines and to a truck and rail loading facility.



General Accidental Release Prevention Program



The Opal Gas Plant has implemented all the elements of a Program 3 Risk Management Plan (RMP) and all the elements of OSHA's Process Safety Management (PSM) program. The Opal Gas Plant has also implemented elements of Williams Integrated Management Plan (WIMS), and Williams System Integrity Plan (SIP), both of which contains additional environmental, health, and safety standards to include:



?Process Safety Information: A variety of techn
ical documents that are used to help maintain safe operation of the process.



?Process Hazard Analysis (PHA): A systematic examination of the plant to identify possible hazards and ensure that adequate controls are in place to manage these hazards.



?Operating Procedures: The Opal Gas Plant maintains written procedures that address various modes of process operations, such as (1) initial start-up, (2) normal operations, (3) temporary operations, (4) emergency shutdown, (5) emergency operations, (6) normal shutdown, and (7) start-up after turnaround.



?Contractors: Opal 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 plant has procedures in place to ensure that contractors, (1) perform their work in a safe manner, (2) are aware of any hazards in the workplace, (3) understand what they should do in the event of an emergency, (4) understand and follow site safety rules, and (5) inform plant personnel of any hazards that they find during their work.



?Pre-Startup Safety Reviews (PSSRs): The purpose of the PSSR is to ensure that safety features, procedures, personnel, and equipment are appropriately prepared for startup before placing modified equipment into service.



?Mechanical Integrity: The Opal 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 safe operating condition.



?Safe Work Practices and Procedures: Examples of safe work practices include methods for controlling plant entry, presence and exit of support personnel, lockout/tagout procedures to ensure isolation of energy sources for equipment undergoing maintenance, hot work procedures and permits for work with the potential for generating ignition sources in the presence of flammable or combustible material, and confined
space entry permits and procedures to ensure that adequate precautions are in place before entry is allowed into a permit required confined space.



?Training: The plant has implemented a comprehensive training program for all employees involved in operating a process. The program includes on the job training. Employees are tested to demonstrate competency.



?Management of Change: Changes are reviewed to ensure that adequate controls are in place to manage any new hazards and to verify that existing controls have not been compromised by the change.



?Incident Investigation: The goal of each investigation is to determine that facts concerning an incident or near miss and to develop corrective actions to prevent recurrence of the incident or a similar incident.



?Compliance audits: Audits are conducted on a regular basis to ensure that the facility is in compliance with applicable RMP/PSM/WIMS/SIP procedures and regulations.



Five-Year Accident History



Two reportable releases of a regulated substance have occurred in the last five years. Equipment failure on a Brazed Aluminum Heat Exchanger (BAHX) creating a methane fire outside of the Turbo Expander Process (TXP) #3 building. No injuries occurred but there was damage to the property outside of the building. Equipment was upgraded to improve the reliability of the system and to reduce the likelihood of a reoccurrence.



The second release resulted from an equipment failure on an Emergency Shut Down (ESD) valve resulting in a release of vapors. One fatal injury occurred. The ESD valve was upgraded to improve the reliability of the system and to reduce the likelihood of a reoccurrence.



Emergency Response Program Information



The Opal Gas Plant maintains a written emergency response program to protect employees, contractors, public and the environment from hazards associated with accidental releases of regulated substances. The program consists of procedures for responding to releases of regulated
substances, including the possibility of associated fires or explosions. The procedures address all aspects of emergency response, including evacuation plans, accounting for personnel after an evacuation, and notification of local emergency response agencies and the public if a release occurs. Employees receive training in these procedures annually to perform emergency response duties. The program is updated when necessary based on modifications made to the gas plant processes. Emergency response program changes are administered through the MOC process.



The overall emergency response program for Opal Gas Plant is coordinated with the Lincoln County LEPC. This coordination includes attending periodic meetings, which includes local emergency response officials and industry representatives. The Opal Gas Plant has 24-hour communications capability with the Lincoln County LEPC. The Plant conducts periodic emergency drills that involve the Lincoln County LEPC and emergency response organizations.



Planned Changes to Improve Safety



In response to the most recent accident, the Opal Gas Plant has re-evaluated all elements of process safety. The local leadership team has recommitted to assessment of additional engineering safeguards and continuous improved training of employees and contractors. These additional safeguards will lessen the risk associated with the release of regulated substances.