Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport Risk Management Plan Revised OCA and Hazard Review Ammonia Tank Farm Relocation Oak Creek Power Plant (OCPP) 1.0 Scope ChemReport Incorporated, an environmental and safety engineering firm, was retained by We Energies to update the existing Risk Management Plan (RMP) for the Oak Creek Power Plant (OCPP) in response to the permanent relocation of the ammonia storage tank farm subsequent to a bluff failure that occurred on October 31, 2011. The OCCP facility is located at 11060 South Chicago Road in Oak Creek, Wisconsin (See Appendix A for a map of the location). The original RMP was developed for the use and storage of aqueous ammonia used in the facility’s Selective Catalytic Reduction (SCR) system to control NOx emissions and all other elements of the original RMP remain applicable. However, due to the permanent relocation of the ammonia storage tank farm, the following elements of the RMP have been revised: Offsite Consequence Analysis (OCA) Process Hazard Analysis (PHA) 2.0 Background The OCPP facility is regulated under the RMP regulations as a Program Level 2 Facility. The SCR system consists of two reaction chambers installed with Boilers 5 and 6 ducted to one SCR chamber and Boilers 7 and 8 ducted to the second SCR chamber. The SCR Project, as originally constructed in 2010 and 2011, utilized two 20,000 gallon above-ground storage tanks for the planned storage of aqueous ammonia at a concentration of approximately 29 percent. The initial RMP was developed and finalized on July 20, 2011. Approximately three (3) months later, on October 31, 2011, a ravine on the OCPP site, which had been filled with fly ash in the 1960s, collapsed sending a mixture of fly ash and soil down the bluff. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 1 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport The bluff failure undermined the foundation of the storage pad for the ammonia storage tanks, rendering the ammonia tank farm unusable. At the time of the bluff failure, the ammonia storage tanks were empty and there was no threat of an ammonia release. As the tank farm was unusable after the bluff failure, a temporary ammonia storage system was designed using a staged tanker truck for ammonia storage until the tank farm could be permanently relocated. In preparation for the use of the temporary tanker truck storage system, the OCA and PHA were updated and revised on December 13, 2011. While the temporary ammonia tank truck system was being used, construction began on the permanent ammonia storage tank farm which was completed in August of 2012. As the relocation of the ammonia storage tank farm constitutes a major process change, the RMP is being updated with the following revised OCA and PHA. 3.0 System Design and RMP Elements ChemReport met with We Energies on July 9, 2012 to discuss any physical or operational changes from the original design of the ammonia storage tank farm and conducted a visual tour of the newly reconstructed system. According to Jim Petersen of We Energies, all aspects of the original tank farm design, specifications and operating parameters used for the original 2010–2011 tank farm were reused for the permanent storage tank farm, including all safety systems and DCS operating parameters. The only change associated with the newly relocated permanent installation is the amount of ammonia contained in the piping run to the SCR system since the new tank farm has been located further away. (See Appendix B for the new tank farm location.) Due to the additional volume of ammonia and changed location of the tank farm, an updated Offsite Consequence Analysis (OCA) was performed by ChemReport. The original Process Hazard Analysis (PHA) did not need to be fully revised as the permanent ammonia storage tank farm has been constructed according to the original tank farm specifications, using the same equipment and operational procedures. The original distribution system was only changed to provide more piping to reach the more remote location of the tank farm. The SCR system components (e.g. injection lances, DCS logic, etc.) remain the same. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 2 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport We Energies did however conduct the necessary evaluation(s) of the geological conditions associated with the permanent tank farm area to ensure that it was not prone to future failure and also evaluated the integrity of the reused ammonia storage tanks and associated system components. This documentation is on file at We Energies and is separate from the RMP documentation. The PHA was updated for the construction of the final ammonia storage tank farm installation as described in Section 15.0 of this document. 4.0 Threshold Determination The OCPP SCR system uses aqueous ammonia (ammonia) in the SCR system at an approximate concentration of 29%. Two 20,000 gallon, diked, above-ground storage tanks are used to store the ammonia on-site. The ammonia is distributed to the SCR system through piping consisting of various diameters (1-1/2”, 1”, and 3/4”) equaling a volume of approximately 650 gallons when the piping system is full. Each 20,000 gallon storage tank is controlled by the facility’s Distributive Control System (DCS) and operational procedures limiting tank filling to no more than 95% of the tank’s capacity, resulting in a maximum tank volume of 19,000 gallons per tank. At an approximate weight of 7.66 pounds per gallon, the maximum amount of ammonia in either tank is 145,540 pounds. The total amount of aqueous ammonia that can be contained within the entire relocated ammonia storage tank farm is calculated as follows: Table 1 Ammonia Threshold Determination Tanks: 145,540 lbs/tank x 2 tanks = 291,080 lbs Piping: 650 gals x 7.66 lbs/gal = 4,979 lbs Total Maximum Ammonia in SCR System = 296,059 lbs [ This Section Intentionally Left Blank ] OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 3 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 5.0 ChemReport RMP Program Levels The OCPP facility remains classified as a Program Level 2 facility. The complexity of the RMP is based on one of three possible Program Levels as follows: 1 Processes with no public receptors within the distance to a toxic endpoint concentration from a modeled worst-case release scenario are eligible for Program Level 1 provided that no significant accidents involving a regulated substance have occurred within the last five years. Program Level 1 facilities must comply with limited hazard assessment requirements and minimal prevention and emergency response requirements. 2 Processes that are not eligible for Program Level 1 or are not subject to Program Level 3 are placed into Program Level 2. Program Level 2 facilities must comply with more streamlined prevention program requirements, as well as additional hazard assessment, management, and emergency response requirements. 3 Any process that is not eligible for Program Level 1 and is subject to OSHA's Process Safety Management (PSM) Standard under 29 CFR 1910.119 is subject to Program Level 3 requirements. Program Level 3 facilities must comply with both the OSHA PSM standard and the U.S. EPA RMP rule. Program Level 3 facilities must develop a comprehensive chemical release prevention program and comply with additional requirements concerning process hazard assessments, management techniques, and emergency response requirements. The worst-case release modeling analysis results (discussed in Section 9.0 of this report) for aqueous ammonia show that the distance to a toxic endpoint concentration under a rural land classification is 1.5 miles. This distance exceeds the plant's property boundaries and impacts off-site public receptors. Consequently, the OCPP facility is ineligible for Program Level 1. Additionally, the OCPP facility is not subject to OSHA’s Process Safety Management (PSM) requirements under 29 CFR 1910.119. The threshold for PSM regulation for aqueous ammonia is 15,000 pounds of aqueous ammonia meeting or exceeding 44% in concentration. The aqueous ammonia used at OCPP is only 29% in concentration. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 4 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport The original review of chemical substances in inventory at OCPP in June of 2011 showed no other substances were present in amounts that would subject the OCPP facility to the PSM requirements and no new substances have been introduced at the facility since that time according to We Energies personnel. As the OCPP facility is ineligible for a Program Level 1 designation due to the distance to a toxic endpoint concentration and is not subject to OSHA's Process Safety Management (PSM) Standard, the OCPP facility remains classified as a Program Level 2 Facility under the RMP rule. ChemReport has conducted this update of the OCA and PHA in accordance with the Program Level 2 requirements of the RMP rule. The SCR system is comprised of two main components or sub-processes. The first component is the storage of aqueous ammonia and its delivery system to the SCR operating system. The second component is the SCR operating system itself. Both components are considered to be a single process under the RMP Rule and as such, all aspects of this plan take into account the operation of the entire process. 6.0 Facility and Process Description The OCPP facility is located directly adjacent to Lake Michigan, straddling both Milwaukee and Racine Counties. The location and plant layout of the OCPP facility are contained in Appendix A. The original two 20,000 gallon aqueous ammonia storage tanks are mounted on top of concrete saddles located within a concrete containment dike. The original dike measured approximately 2,000 square feet (40’ x 50’) with a depth of 2.75 feet equating to a total volume of 5,500 cubic feet. After subtracting the volume of the concrete saddles (545 cubic feet), the total amount of containment available was 4,955 cubic feet or 37,063 gallons (4,955 x 7.48) of liquid material. The relocated ammonia storage tank farm has been constructed by adding an additional three (3) feet of length to the original dike dimensions resulting in an additional 500 cubic feet of containment or 3,740 gallons for a total containment volume of 40,803 gallons. The truck unloading pad does not have curbed containment. However, the pad is sloped toward the middle where an open sewer grate would direct any discharge directly to the tank farm containment dike via an underground 6-inch drain. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 5 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport The latitude and longitude for the OCPP facility (centered on the ammonia storage tank farm) were identified using Marplot Version 4.2.2 geospatial mapping software developed jointly by the EPA and the National Oceanic and Atmospheric Administration (NOAA) which place the coordinates at latitude 42o 50' 30” North and longitude -87o 49’ 46" West. The location of the ammonia storage area is shown in Appendix B. According to the North American Industrial Classification System (NAICS), the OCPP facility continues to fall within major industrial grouping "22" with an assigned NAICS Code of 221112. 7.0 Land Use Classification ChemReport previously evaluated the predominant land use surrounding the facility for the purpose of determining whether urban or rural dispersion coefficients should be used when modeling various release scenarios in June of 2011. A review of this analysis by ChemReport showed it to remain current. The Auer (Auer, 1978) Land Use Classification Scheme was used for this purpose according to the criteria detailed in Table 2 below. [ This Section Intentionally Left Blank ] OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 6 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport Table 2 Identification and Classification of Land Use Types Type Use and Structures Vegetation Heavy Industrial: Major chemical, steel and I1 fabrication industries; generally 3-5 story buildings, flat roofs Grass and tree growth extremely rare; < 5% vegetation Light-Moderate Industrial: Rail yards, truck I2 depots, warehouses, industrial parks, minor Very limited grass, trees almost totally fabrications; generally 1-3 story buildings, flat absent; < 5% vegetation roofs C1 Commercial: Office and apartment buildings, hotels; >10 story heights, flat roofs Common Residential: Single family dwellings R1 with normal easements; generally one story, pitched roof structures; frequent driveways Limited grass and trees; < 15% vegetation Abundant grass lawns and light-moderately wooded; > 70% vegetation Compact Residential: Single, some multiple, R2 family dwellings with close spacing; generally Limited lawn sizes and shade trees; <2 story, pitched roof structures; garages (via < 30% vegetation alley), no driveways Compact R3 Residential: Old multi-family dwellings with close (<2 m) lateral separation; Limited lawn sizes, old established shade generally 2 story, flat roof structures; garages trees; < 35% vegetation (via alley) and ash pits, no driveways R4 Estate Residential: Expansive family dwellings Abundant grass lawns and lightly wooded; on multiple-acre tracts > 80% vegetation Metropolitan Natural: Major municipal, state, A1 or federal parks, golf courses, cemeteries, campuses; occasional single story structures A2 Agricultural Rural A3 Undeveloped: Uncultivated; wasteland A4 Undeveloped Rural A5 Water Surfaces: Rivers, lakes Nearly total grass and lightly wooded > 95% vegetation Local crops (e.g., corn, soybean); > 95% vegetation Mostly wild grasses and weeds, lightly wooded; > 90% vegetation Heavily wooded; > 95% vegetation OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 7 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport A three (3) kilometer radius centered at the OCPP facility was superimposed on the aerial photograph used to determine the facility’s latitude and longitude. This figure was then used to evaluate all land uses within the circle exhibiting the characteristics of I1, I2, C1, R2 and R3 classifications per the Auer criteria. These classifications were then shaded to indicate an urban setting. As illustrated in Appendix C, the urban land use within the three kilometer radius of the facility is less than 25%, well below the 50% threshold used to determine the predominant land use for dispersion modeling. Consequently, the predominant land use setting for the OCPP facility was determined to be “rural” for dispersion modeling purposes which remains current through August of 2012. Prior reconnaissance of the area was performed by ChemReport in June of 2011 to confirm interpretations made on the site imagery. New surveillance was conducted in July of 2012 to assess any significant new developments that may have occurred in the vicinity of the facility. While a few residential structures were noted to be under construction, they were determined to not be significant enough to shift the land use classification above the 50% threshold. 8.0 Climatological Parameters ChemReport evaluated local climatological conditions for the last 36 months to be used as data inputs for the release modeling scenarios. Data for this evaluation was obtained from the National Oceanic and Atmospheric Administration’s (NOAA) weather station located at the Mitchell International Airport in Milwaukee, Wisconsin. NOAA annual summary data was available for 2010 and 2011. To complete the data set needed for the most recent 36 months, NOAA monthly data was used for August through December of 2009, and January through July of 2012. Meteorological data for the last 36 months is summarized in Table 3 below. [ This Section Intentionally Left Blank ] OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 8 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport Table 3 NOAA Climatological Data 3-Year Annual Averages and Maximums % Relative Humidity Temp oF Max Temp oF AVG Wind (mph) AVG Aug 2009 68.0 90.0 68.8 8.6 Sep 2009 73.0 85.0 63.9 6.2 Oct 2009 72.0 69.0 48.3 9.7 Nov 2009 71.0 71.0 44.9 8.3 Dec 2009 73.0 51.0 26.4 10.2 2010 68 / 816.0* 92.0 50.3 / 603.6* 9.0 / 108.0* 2011 70 / 840.0* 98.0 48.6 / 583.2* 9.4 / 112.8* Jan 2012 69.0 55.0 28.4 9.9 Feb 2012 70.0 53.0 31.2 9.4 Mar 2012 67.0 84.0 48.8 10.4 Apr 2012 65.0 74.0 46.3 10.3 May 2012 62.0 90.0 61.0 9.2 Jun 2012 57.0 96.0 81.3 9.5 Jul 2012 65.0 103.0 87.3 8.3 Date Data Summary For Dispersion Modeling (Bold Font) Average 68.6 - 50.7 9.2 Maximum 73.0 103.0 - 10.4 Minimum 57.0 - - 6.2 Data Source(s): * Annual average multiplied by 12 to obtain weighted datum Annual Local Climatological Data – NOAA, National Climatic Data Center Monthly Data – National Weather Service, Monthly Data Summary General Mitchell International Airport (MKE) Milwaukee, WI – WBAN: 14839 OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 9 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport Atmospheric stability classifications of “F” and “D” were used for the worst-case and alternative-case modeling scenarios, respectively. U.S. EPA requires that worst-case modeling scenarios use an atmospheric stability classification of “F” which represents the most stable atmospheric conditions and provides for the most conservative distance to a toxic endpoint concentration. ChemReport used the RMP standard defaults of “F” and “D” because site-specific atmospheric stabilities could not be accurately determined. Atmospheric stabilities are based on minimum wind speed and cloud cover as indicated in Table 4 taken from the User’s Manual for the Aerial Locations of Hazardous Atmospheres (ALOHA) dispersion modeling software program used by ChemReport to determine the distances to toxic endpoint concentrations for the OCPP facility. Table 4 ALOHA Atmospheric Stability Chart Surface Wind Speed DAY TIME NIGHT TIME Incoming Solar Radiation Cloud Cover Strong Moderate Slight > 5/10 < 5/10 Miles per hour Meters per second <4 <2 A A-B B E F 4 to 7 2 to 3 A-B B C E F 7 to 11 3 to 5 B B-C C D E 11 to 13 5 to 6 C C-D D D D > 13 >6 C D D D D Facility cloud cover for the 36 month time frame needed for modeling was not available to determine a specific atmospheric stability rating. As a result, the default value of “F” was used for the worst-case release scenario and default value of “D” was used for the alternative-case scenario. In addition to using atmospheric stability ratings for dispersion modeling in ALOHA, the software program requires additional inputs for cloud cover. The “F” stability classification used for the ALOHA worst-case modeling analysis assumed a conservative worst-case cloud cover value of zero (no cloud cover). The “D” stability classification used for the alternativecase analysis assumed an average cloud cover value of 50%. The meteorological parameters used for all modeling are summarized in Table 5 below. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 10 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport Table 5 ALOHA Meteorological Modeling Parameters Conditions Worst-Case Alternative-Case Wind Speed 1.5 meters/second 3.0 meters/second Assumed Wind Direction From West From West EPA Stability Rating F D Cloud Cover 0 50% Temperature/Humidity 103F + 69% RH 50.7F + 69% RH Liquid Temperature 103F 50.7F ALOHA allows for additional meteorological data to be input into the model for inversions. An inversion is an atmospheric condition in which an unstable layer of air near the ground lies beneath a very stable layer of air above. The height of the abrupt change of atmospheric stability is called the inversion height. An inversion can trap pollutant gases below the inversion height. This may cause ground-level concentrations of a pollutant to reach higher levels than would otherwise be expected. The type of inversion of concern for dispersion modeling is a low-level inversion that could trap a pollutant cloud near the ground. Low ground fog is a good indicator of the presence of this type of inversion. However, inversions are unpredictable and should only be input into the ALOHA model for real-time modeling during an actual chemical release. As a result, all ALOHA modeling was performed without assuming that an inversion existed. ChemReport used the prevailing westerly wind direction as a default variable only. For RMP purposes, ALOHA is used to calculate the radius to a toxic endpoint of 0.14 mg/l (200 ppm) of ammonia. The calculated distance is independent of the wind direction that is input into the ALOHA modeling program. ChemReport verified that the wind direction used in the ALOHA model is immaterial by running the model using several different wind direction inputs with all of them resulting in the same distance to the toxic endpoint. The assumption under the RMP program is that during a release, the wind may be blowing from any direction. This is particularly true during the summer months when diurnal wind variation is common along Lake Michigan as air that is cooler and more dense above the OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 11 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport water blows inland from the east off the lake during the day, replacing air over the land that is warmer and therefore, rising. Cooling at night tends to cause the wind to shift back to the prevailing direction (west). As a consequence, the RMP standard requires that a radius be used to define a circle that encompasses the entire area surrounding the source that may exceed 200 ppm during a release. The actual area within that circle that would be affected during a release would be dependent on the wind direction at that time. 9.0 Worst-Case Release Scenario Worst-case release dispersion modeling was performed on the greatest volume that could be released from the largest storage vessel and associated SCR system piping. For worst-case release modeling purposes, ChemReport used the maximum volume of ammonia contained in a single 20,000 gallon storage tank which was aggregated with the 650 gallons of ammonia contained in the ammonia piping system, as shown in Table 6 below: Table 6 Worst-Case Release Scenario Aqueous Ammonia Volume Gallons Pounds Storage Tank: 20,000 gallons @ 95% Full x 7.66 lbs/gal = 19,000 145,540 Piping: 650 gals x 7.66 lbs/gal = 650 4,979 = 19,650 150,519 Total Maximum Aqueous Ammonia Release Under the RMP rule, only the contents of a single and largest vessel and associated piping within the regulated process containing aqueous ammonia must be modeled. The worst-case release scenario assumed that the entire contents of the storage tank aggregated with the entire contents of all associated piping were released into the secondary containment area. 9.1 Worst-Case Release Scenario Modeling ALOHA Version 5.4.3 (March 2012), the most current version available as of August 2012 was used to perform the modeling of a worst-case release scenario. Although there are many different release scenarios that can be evaluated in ALOHA, the two primary methods applicable to the OCPP system are the “direct release” and “puddle release” models. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 12 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport With the direct release model, ALOHA uses the chemical properties of pure ammonia vapors when calculating the distance to a toxic endpoint concentration from the release source. In order to do this, ALOHA requires that the evaporation rate (in lbs/min) of a puddle formed by the release into a dike to be manually calculated and entered into the program. Although the National Oceanic and Atmospheric Administration (NOAA) has developed a puddle evaporation rate calculator for aqueous ammonia which can be used in ALOHA, it yields overly conservative distances to a toxic endpoint concentration because it treats the evaporating vapors as anhydrous ammonia. In actuality, the evaporative properties of aqueous ammonia solution are vastly different from those of anhydrous ammonia. While the use of the direct release method is suitable for RMP planning purposes, further analysis of ALOHA’s capabilities show that the “puddle release” method is more appropriate for aqueous solutions of ammonia when the puddle has a large surface area such as with the OCPP secondary containment system of 2,120 square feet calculated as indicated in Table 7 below: Table 7 Worst-Case Release Scenario Containment Volume Surface Area (ft2) Containment Dimensions Tank Farm Containment 53’L x 40’W x 2.75’H = 2,120 According to NOAA, ALOHA mathematically treats the “Direct Release Model” as a point source and states that ALOHA’s results are less accurate when a puddle is very large and recommends that the user consider a different modeling method in ALOHA. With the puddle release model, the user enters the concentration of the ammonia solution, the total area of the puddle, and the puddle’s volume. ALOHA then calculates the evaporation rate of the puddle as an ammonia solution, eliminating the need for the user to manually calculate it with NOAA’s evaporation rate calculator. After taking into account all atmospheric and other source data inputs from the user, the program calculates the distance to a toxic endpoint concentration. The ALOHA puddle method has been used by the U.S. Department of Energy for dispersion modeling of aqueous ammonia solutions and was selected by ChemReport as the most appropriate method for OCPP. The parameters entered into ALOHA are detailed in Table 8 below. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 13 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport Table 8 Worst-Case Release Scenario Modeling Parameters ALOHA Modeling Method: Puddle Release of 29% Aqueous Ammonia Release Scenario: Diked Release of Storage Tank and Associated Piping Release Duration: ALOHA Default Limited To Duration of 1 Hour Toxic Endpoint: 0.14 mg/L (200 ppm) Passive Mitigation Measures: Dike (2,120 ft2 area) Active Mitigation Measures: Not Allowed Quantity Released: 19,650 gallons (150,519 lbs) Height of Release: Ground Level Dense or Neutrally Buoyant Gas: Neutrally Buoyant Gas Wind Speed/Stability: 1.5 Meters per Second (3.4 MPH) EPA Stability Rating: F Cloud Cover: None (For “F” Stability) Ambient Temperature/Humidity: 103 oF and 69 % Humidity Surface Roughness: Rural Topography Temperature of Substance: 103 oF According to the ALOHA puddle model, a worst-case scenario involving the release of the entire contents of a single aqueous ammonia storage tank and its related piping would result in a distance of 1.5 miles to the defined toxic endpoint concentration of 0.14 mg/l (200 ppm) with a rural land use classification. The ALOHA modeling results are indicated below. [ This Section Intentionally Left Blank ] OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 14 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport WORST-CASE SCENARIO SITE DATA: Location: MILWAUKEE, WISCONSIN Building Air Exchanges Per Hour: 0.54 (unsheltered single storied) Time: August 8, 2012 0925 hours CDT (using computer's clock) CHEMICAL DATA: Chemical Name: AQUEOUS AMMONIA Solution Strength: 29% (by weight) Ambient Boiling Point: 81.0° F Partial Pressure at Ambient Temperature: greater than 1 atm Ambient Saturation Concentration: 1,000,000 ppm or 100.0% Hazardous Component: AMMONIA Molecular Weight: 17.03 g/mol AEGL-1 (60 min): 30 ppm AEGL-2 (60 min): 160 ppm AEGL-3 (60 min): 1100 ppm IDLH: 300 ppm LEL: 150000 ppm UEL: 280000 ppm ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Wind: 1.5 meters/second from W at 3 meters Ground Roughness: open country Cloud Cover: 0 tenths Air Temperature: 103° F Stability Class: F (user override) No Inversion Height Relative Humidity: 69% SOURCE STRENGTH: Evaporating Puddle (Note: chemical is flammable) Puddle Area: 2120 square feet Puddle Volume: 19650 gallons Ground Type: Concrete Ground Temperature: 103° F Initial Puddle Temperature: 81° F Release Duration: ALOHA limited the duration to 1 hour Max Average Sustained Release Rate: 316 pounds/min (averaged over a minute or more) Total Amount Hazardous Component Released: 5,960 pounds THREAT ZONE: Model Run: Gaussian RESULTS 5.6 miles 3.5 miles 1.8 miles 1.5 miles 1.2 miles 0.7 miles --- (25 ppm = ERPG-1) --- (50 ppm = OSHA TWA PEL) --- (150 ppm = ERPG-2) --- (200 ppm = RMP 0.14 mg/l End Point) --- (300 ppm = IDLH) --- (750 ppm = ERPG-3) OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 15 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 10.0 ChemReport Alternative-Case Release Scenario Alternative-case release scenarios are designed to represent a more realistic scenario of a potential release that may occur during the operation of the SCR system. Although a probability analysis of the alternative release scenario does not have to be conducted, a release scenario that is more probable to occur should be selected. ALOHA Version 5.4.3 (March 2012), the most current version available as of August 2012 was used to perform the modeling of an alternative-case release scenario using the “puddle model” as discussed in Section 9.0 on this report. For alternative-case release scenarios, facilities are allowed to consider active mitigation systems, such as interlocks, shutdown systems, pressure relieving devices, emergency isolation systems, and fire water and deluge systems, as well as passive mitigation systems. The permanent ammonia storage and delivery system has the following mitigation systems installed: Passive Mitigation Diked containment of Ammonia Delivery Pad Active Mitigation Emergency shutdown systems located at ammonia pump skid designed to stop the flow of ammonia from the pumps in the event of a release Excess flow valve on the delivery trailer designed to stop flow from the trailer if excess flow is detected Manned loading operations with associated safety equipment so that rapid on-site response and containment can be accomplished Ammonia sensors and alarms located at ammonia pump skid In order to determine which alternative-case release scenario to utilize for the modeling, several scenarios were considered by ChemReport and the PHA Team who believed that the highest potential for a release to occur continues to be during loading activities. The selection of this scenario is consistent with the original OCPP alternative-case release scenario evaluated in June of 2011 and is also consistent with alternative-case release scenarios that have been evaluated at other We Energies facilities that utilize aqueous ammonia. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 16 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport For the OCPP alternative-case release scenario, it was assumed that the unloading hose from the delivery tanker truck to the storage tank either ruptured or somehow became detached from its connections. We Energies provided the information associated with aqueous ammonia delivery by Tanner Industries, the OCPP ammonia supplier in Table 9 below. Table 9 Ammonia Tanker Truck Parameters Parameter Tanner Industries Release Duration 5 minutes (estimated) Amount Released 660 gallons (5,056 lbs) Truck Capacity 6,500 gallons Delivery Rate 132 gpm Size And Length of Delivery Hose 2” Diameter – 3 lengths @ 20 feet each Size And Length of Vapor Return Hose ¾” – 50 feet Excess Flow Valve on Delivery Line Equipped with emergency remote control Vapor Return Via Compressor Yes Type of Quick Disconnect (Liquid Line) Male Evertite Type of Quick Disconnect (Vapor Line) Chicago Fitting Length of The Truck 57’ long x 12’ high x 10’ wide Height of Hose Connections (Liquid Line) 18 – 36 inches Height of Hose Connections (Vapor Line) 60 inches The alternative-case release scenario assumed that a hose became detached during unloading operations from the delivery trailer and that the release would last for no more than five (5) minutes. ChemReport believes the five-minute value is conservative as the truck operator has the means to stop such a release much sooner, either with remotely controlled valves or through the use of the tanker’s excess flow valve. Additionally, the unloading operations are monitored by plant personnel, who are capable to bring such a release under control within five minutes. The actual time it would take to bring such a release under control is estimated to be less than two (2) minutes. Containment for the delivery truck unloading area is provided through a sloped unloading pad that drains into the storage tank containment structure. For the alternative-case release OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 17 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport scenario modeling, it was assumed that the truck would release 132 gallons per minute for a period of 5 minutes into storage tank containment structure for a total release of 660 gallons (660 gal x 7.66 lb/gal = 5,056 pounds). 10.1 Alternative-Case Release Scenario Modeling ALOHA’s puddle release model was again used as previously discussed in Section 9.0 of this report, to determine the distance to a toxic endpoint concentration for the alternativecase release scenario. The parameters entered into ALOHA are presented in Table 10 below. Table 10 Alternative-Case Release Scenario Modeling Parameters ALOHA Modeling Method: Puddle Release of 29% Aqueous Ammonia Release Scenario: Detached Transfer Hose From Truck Release Duration: ALOHA Default Limited To Duration of 1 Hour Toxic Endpoint: 0.14 mg/L (200 ppm) Administrative Controls: Manned Operation Passive Mitigation Measures: Dike (2,120 ft2 area) Active Mitigation Measures: Excess Flow Valve / Alarm System / Operator Shut-Off Quantity Released: 660 Gallons (132 gpm x 5 minutes) Height of Release: Ground Level Dense or Neutrally Buoyant Gas: Neutrally Buoyant Gas Wind Speed/Stability: 3.0 Meters per Second (6.7 MPH) EPA Stability Rating: D Cloud Cover: 50% Ambient Temperature/Humidity: 50.7 oF Relative Humidity: 69% Surface Roughness: Rural Topography Temperature of Substance: 50.7 oF According to the ALOHA model, the alternative-case release scenario involving a five-minute release from a ruptured or detached tank truck delivery hose would result in a distance of 0.22 miles to the defined toxic endpoint concentration of 0.14 mg/l (200 ppm) within a rural land use classification. The ALOHA modeling results are indicated below. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 18 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport ALTERNATIVE-CASE SCENARIO SITE DATA: Location: MILWAUKEE, WISCONSIN Building Air Exchanges Per Hour: 0.70 (unsheltered single storied) Time: August 8, 2012 0937 hours CDT (using computer's clock) CHEMICAL DATA: Chemical Name: AQUEOUS AMMONIA Solution Strength: 29% (by weight) Ambient Boiling Point: 81.0° F Partial Pressure at Ambient Temperature: 0.47 atm Ambient Saturation Concentration: 477,064 ppm or 47.7% Hazardous Component: AMMONIA Molecular Weight: 17.03 g/mol AEGL-1 (60 min): 30 ppm AEGL-2 (60 min): 160 ppm AEGL-3 (60 min): 1100 ppm IDLH: 300 ppm LEL: 150000 ppm UEL: 280000 ppm ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Wind: 3 meters/second from W at 3 meters Ground Roughness: open country Cloud Cover: 5 tenths Air Temperature: 50.7° F Stability Class: D (user override) No Inversion Height Relative Humidity: 69% SOURCE STRENGTH: Evaporating Puddle (Note: chemical is flammable) Puddle Area: 2120 square feet Puddle Volume: 660 gallons Ground Type: Concrete Ground Temperature: 50.7° F Initial Puddle Temperature: Ground temperature Release Duration: ALOHA limited the duration to 1 hour Max Average Sustained Release Rate: 90.7 pounds/min (averaged over a minute or more) Total Amount Hazardous Component Released: 1,106 pounds THREAT ZONE: Model Run: Gaussian RESULTS 0.62 miles 0.45 miles 0.26 miles 0.22 miles 0.18 miles 0.11 miles --- (25 ppm = ERPG-1) --- (50 ppm = OSHA TWA PEL) --- (150 ppm = ERPG-2) --- (200 ppm = RMP 0.14 mg/l End Point) --- (300 ppm = IDLH) --- (750 ppm = ERPG-3) OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 19 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 11.0 ChemReport Summary and Discussion of Modeling Technique Table 11 below summarizes the distances calculated by the ALOHA dispersion modeling program to the predefined toxic endpoint concentration of 0.14 mg/l (200 ppm) for aqueous ammonia for both the worst-case and alternative-case aqueous ammonia release scenarios. Table 11 OCPP Facility ALOHA Modeling Summary Distance To Toxic Endpoint Concentration of 0.14 mg/l (200 ppm) Scenario June 2011 August 2012 Original Tank Farm Relocated Tank Farm Worst-Case (Rural) 1.5 miles 1.5 miles Alternative-Case (Rural) 0.21 miles 0.22 miles U.S. EPA allows regulated entities to utilize a variety of different modeling techniques to estimate the distance to a toxic endpoint concentration for both the worst-case and alternative-case release scenarios. The agency recognizes that modeling results can vary considerably from model to model. U.S. EPA recommends that more precise chemical release modeling techniques be considered for use when performing the offsite consequence analysis (OCA) if the regulated entity has the expertise and data needed to use them, although such techniques are not required to be used under the RMP rule. Site-specific meteorological conditions have a large impact when estimating the distance to a toxic endpoint concentration during a release event. Conditions such as wind speed, temperature, humidity, cloud cover, etc. will greatly influence the extent of a chemical’s ability to migrate away from the release source. The preferred modeling technique that takes these factors into consideration, along with chemical-specific (density, vapor pressure, etc.) and release-specific (diked containment) factors is ALOHA. ALOHA is the primary modeling technique used by emergency responders when estimating impact zones during an actual chemical release emergency as ALOHA is designed to simulate an actual release under conditions observed at a specific site during a release event. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 20 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 12.0 ChemReport Affected Populations – Worst-Case Release Marplot Version 4.2.2 (current as of August 2012) mapping software was used to estimate the population impacts within the 1.5 mile distance to the toxic endpoint concentration of 0.14 mg/L (200 ppm) of ammonia. A circle encompassing a 1.5 mile radius from the center of the relocated ammonia storage tanks was superimposed on the Marplot map to estimate populations that could be affected by a worst-case release (See Appendix D). Affected populations are based on data obtained from the U.S. Census Bureau and linked to the mapping software program. Population data contained in the mapping system is based on calendar year 2010 census data which represents the most current population estimates available from the U.S. Census Bureau. The "Census Blocks" method of calculation was used to estimate populations affected by the worst-case release scenario which is the only option available in Marplot 4.2.2 to estimate populations affected. As the census data does not contain information on populations using Lake Michigan for recreational purposes (boaters and fishermen), ChemReport developed a conservative estimate by assuming that 100 boats could potentially be within a 1.5 mile radius of the OCPP facility with an average of five (5) persons per boat. Additionally, it was assumed that there would be up to 25 people on the OCPP on-site fishing pier during the time of the release. A summary of all affected populations is provided in Table 12 below. Table 12 Affected Populations ALOHA Worst-Case Release Scenario Worst-Case Release Scenario June 2011 August 2012 Original Tank Farm Relocated Tank Farm Distance To Endpoint of 0.14 mg/l 1.5 miles 1.5 miles Population Affected (2010 Census) 638 638 Population Affected (Lake Michigan Boaters) 500 500 Population Affected (Fishing Pier) 25 25 1,163 1,163 Total Population Affected [ This Section Intentionally Left Blank ] OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 21 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 12.1 ChemReport Public Receptors – Worst-Case Release Marplot Version 4.2.2 (current as of August 2012) mapping software and public information systems maintained by the United States Geological Survey, Racine and Milwaukee County Schools, Wisconsin Historical Society, Wisconsin Register of Historical Places, National Park Service Historical Landmark Survey, Racine and Milwaukee County Parks Systems, Wisconsin Department of Corrections and aerial photographs provided by the Southeastern Wisconsin Regional Planning Commission were used to identify the affected receptors within the distance to the toxic endpoint. Affected receptors are identified in Table 13 below: Table 13 Affected Receptors ALOHA Worst-Case Release Scenario Public Receptors Schools: Residences: Hospitals: Prisons / Correctional Facilities: Recreational Areas: Deerfield Elementary School Scanlon School Lamberton School 254 Housing Units (638 occupants) None None Other Recreational Area Cliffside Park On-Site Fishing Pier Major Commercial Office Industrial Facilities: None Other Public Receptors: Recreational Users of Lake Michigan and Shoreline Environmental Receptors National Parks, Forests, Monuments: Designated Sanctuaries, Preserves, Refuges: Federal Wildness Areas: Other Environmental Receptors: None None None Lake Michigan and Shoreline [ This Section Intentionally Left Blank ] OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 22 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 13.0 ChemReport Affected Populations – Alternative-Case Release Marplot Version 4.2.2 (current as of August 2012) mapping software was also used to estimate the population impacts within the 0.22 mile distance to the toxic endpoint concentration of 0.14 mg/L (200 ppm) of ammonia. A circle encompassing a 0.22 mile radius from the center of the ammonia delivery trucks was superimposed on the Marplot map to estimate populations that could be affected by an alternative-case release (See Appendix E). Affected populations are based on data obtained from the U.S. Census Bureau and linked to the mapping software program. Population data contained in the mapping system is based on calendar year 2010 census data which represents the most current population estimates available from the U.S. Census Bureau. The "Census Blocks" method of calculation was used to estimate populations affected by the alternative-case release scenario which is the only option available in Marplot 4.2.2 to estimate populations affected. As the census data does not contain information on populations using Lake Michigan for recreational purposes (boaters and fishermen), ChemReport developed a conservative estimate by assuming that 10 boats could potentially be within a 0.22 mile radius of the OCPP facility with an average of five (5) persons per boat. No individuals were accounted for on the OCPP on-site fishing pier during the time of the release as the pier is outside of the 0.22 mile radius. A summary of all affected populations is presented in Table 14 below. Table 14 Affected Populations ALOHA Alternative-Case Release Scenario Alternative-Case Release Scenario June 2011 Original Tank Farm August 2012 Relocated Tank Farm Distance To Endpoint of 0.14 mg/l 0.21 miles 0.22 miles Population Affected (2010 Census) 0 0 Population Affected (Lake Michigan Boaters) 50 50 Population Affected (Fishing Pier) 0 0 Total Population Affected 50 50 OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 23 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 13.1 ChemReport Public Receptors – Alternative-Case Release Marplot Version 4.2.2 (current as of August 2012) mapping software and public information systems maintained by the United States Geological Survey, Racine and Milwaukee County Schools, Wisconsin Historical Society, Wisconsin Register of Historical Places, National Park Service Historical Landmark Survey, Racine and Milwaukee County Parks Systems, Wisconsin Department of Corrections and aerial photographs provided by the Southeastern Wisconsin Regional Planning Commission were used to identify the affected receptors within the distance to the toxic endpoint. Affected receptors are identified In Table 15 below: Table 15 Affected Receptors ALOHA Alternative-Case Release Scenario Public Receptors Schools: Residences: Hospitals: Prisons / Correctional Facilities: Recreational Areas: Major Commercial Office Industrial Facilities: Other Public Receptors: Environmental Receptors National Parks, Forests, Monuments: Designated Sanctuaries, Preserves, Refuges: Federal Wildness Areas: Other Environmental Receptors: None None None None None None Recreational Users of Lake Michigan and Shoreline None None None Lake Michigan and Shoreline [ This Section Intentionally Left Blank ] OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 24 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport 14.0 RMP Registration Under 40 CFR Part 68.36(b), the RMP is required to be updated within six (6) months after completion of a revised or updated OCA if the updated OCA shows a two-fold increase or decrease (doubled or halved) in the distance to a toxic endpoint. Table 16 below provides a comparison and summary of the current OCA results versus previous modeling. The distance to a toxic endpoint did not change by a two-fold increase or decrease. Consequently, updating of the original RMP is not required based on the re-calculated distance to a toxic endpoint. Table 16 OCA Results Comparison of Modeling Data Worst-Case Scenario June 2011 December 2011* August 2012 Alternative-Case Scenario Population Toxic Distance Population Toxic Distance 1,163 1.5 miles 50 0.21 miles 528 0.91 miles 50 0.14 miles 1,163 1.5 miles 50 0.22 miles * During use of temporary drop tanker for ammonia storage However, under 40 CFR Part 68.190(b)(5), the RMP is required to be updated within six (6) months of a change that requires a revised PHA or hazard review. As the relocated ammonia storage tank farm required a revised hazard review, (conducted on July 9, 2012), an updated RMP must be submitted to U.S. EPA within six (6) months of the hazard review date. [ This Section Intentionally Left Blank ] OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 25 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 15.0 ChemReport Updated Hazard Review A detailed Process Hazard Analysis (PHA) was originally performed November 17 and 18, 2010 using a combination of "What If" scenarios and a process safety checklist (See ChemReport June 2011 RMP Plan) for the original SCR system. The original PHA and safety checklist developed in 2010 continues to remain valid for the components of the SCR system that were unaffected by the October 31, 2011 bluff failure. The PHA also continues to remain valid for the ammonia storage tank farm since the relocated tank farm was designed to original specifications reviewed during the 2010 PHA and uses the same original equipment that was installed prior to the bluff failure. A limited Hazard Review was conducted on July 9, 2012 with Jim Petersen and Dan Adams of We Energies, and Michael Boozer and Sean Cranley of ChemReport. At that meeting, Mr. Petersen explained that the newly constructed ammonia storage tank farm utilized the original equipment that was installed prior to the October 2011 bluff failure and that all procedures and process logic and controls remain valid at the permanent tank farm. The following aspects of the permanent tank farm were discussed and reviewed: 1. As the same tanks that were installed prior to the bluff failure were being re-used, there was no increase in the amount of ammonia stored onsite except that due to the location of the new tank farm, additional piping to the SCR injection system had to be installed. According to We Energies, this additional piping resulted in an additional 221 gallons of ammonia in the piping system. ChemReport accounted for this additional volume in its Worst-Case release scenario. 2. Due to the location of the new tank farm, it was necessary to run a section of the piping from the tank farm to the injection system underneath a local haul road. This section of piping (approximately 25 feet) is installed inside of an underground concrete trench that runs underneath the road. Should the pipe ever leak, the released material would be contained and would drain back into the ammonia storage tank farm dike. Additionally, it was necessary to run a section of the piping inside one of the onsite buildings. However, no valves or drains were installed in the piping run inside of the building so the potential for an indoor ammonia release was determined to be virtually non-existent and should one occur, the facility’s emergency response plan was adequate to address the release. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 26 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport 3. The tank farm’s dike has a sump installed in the corner to be used to pump out any released ammonia into a transport vehicle. Prior to the bluff failure, the old dike’s sump had the potential to overflow into an adjacent pond. The pond was removed after the bluff failure and no longer exists. 4. There exists a series of liquid above-ground storage tanks directly across from the ammonia storage tank farm. However, these tanks contain process water, boiler water and other inert liquid mixtures that would not adversely impact the ammonia tank farm should a release occur. 5. The Washington Group conducted an exhaustive review of a previously performed Geotechnical Engineering Report (prepared in 2007 by Wagner Komurka Geotechnical Group) and determined that the location of the new ammonia storage tank farm would not subject it to any future unexpected geological events such as the one that occurred in October of 2011. 6. The Washington Group would ensure, through appropriate documentation, that the relocated tanks are still suitable for service and that they were not subjected to nonvisual stresses during the bluff collapse that could precipitate or cause a future release of ammonia from either tank. 7. Prior to filling the tanks with ammonia, We Energies will utilize the safety and hazard review checklist developed for the original installation to ensure that all appropriate hazard mitigation controls have been addressed. A copy of the checklist is contained in Appendix F. Subsequent to the July 9, 2012 meeting, We Energies provided ChemReport with additional information indicating that the permanent tank farm dike was extended three (3) feet in length adding an additional 500 cubic feet of containment to the system. ChemReport accounted for this additional containment volume in its Worst-Case and Alternative Case release scenarios modeling analyses. [ This Section Intentionally Left Blank ] OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 27 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 16.0 ChemReport Prevention Program Elements The following additional prevention program elements apply to the SCR aqueous ammonia system as described in Table 17 below. Table 17 Program Level 2 RMP Required Program Elements Citation § 68.48 § 68.50 § 68.52 § 68.54 § 68.56 § 68.58 § 68.60 Section Title Safety Information Hazard Review Operating Procedures Training Maintenance Compliance Audits Incident Investigation The prevention program requirements for RMP Program Level 2 facilities from 40 CFR Part 68 are presented in the sub-sections that follow. All of the previously developed prevention program elements remain valid as the construction and use of the new ammonia storage tank farm uses the same original equipment and procedures that were in place prior to the October 2011 bluff failure. 16.1 Management System The OCPP facility has developed a management system to oversee the risk management program to ensure that all of the risk management program elements are integrated and implemented on an ongoing basis. All affected individuals at OCPP have been trained to understand their respective lines of responsibility and communication. The management system originally developed by OCPP has not changed. As a result, the original management system structure provided in the June 2011 RMP program remains valid and unchanged. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 28 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 16.2 ChemReport Safety Information The original safety information on the SCR system was developed jointly by Washington Group, Riley Power, We Energies and OCPP personnel. The process safety information for the ammonia storage tank farm and SCR system originally developed by OCPP has not changed as the permanent ammonia storage tank farm uses the same original equipment installed prior to the October 2011 bluff failure. 16.3 The Operating Procedures original operating procedures for the entire SCR system and ammonia storage/unloading processes were developed jointly by Washington Group, Riley Power, We Energies and OCPP personnel. These procedures are separate from this document and are not appended to this report. The procedures covered the following operations: Normal operations Emergency shutdown Emergency operations Normal shutdown Start-up following a normal or emergency shutdown or a major change Consequences of deviating Steps to avoid, correct deviations Equipment inspections Maintenance All of the above procedures remain valid as the new ammonia storage tank farm uses the same original equipment installed prior to the October 2011 bluff failure. [ This Section Intentionally Left Blank ] OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 29 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 16.4 ChemReport Training OCPP has trained all SCR system employees in the operating and maintenance procedures described above, and maintains documentation of all training activities. All training programs previously developed remain valid as the new ammonia storage tank farm uses the same original equipment installed prior to the October 2011 bluff failure and the same operating procedures. 16.5 Maintenance Maintenance procedures were previously developed by We Energies using a combination of manufacturers’ or vendors’ recommendations as well as generally acceptable, good engineering practices. Documentation of all preventative maintenance, inspection and testing procedures are maintained at the facility. Maintenance employees have been trained in these procedures. Additionally, a daily operator walk-down checklist has been developed by We Energies so that all major system components are inspected on a daily basis. All maintenance procedures remain valid as the new ammonia storage tank farm uses the same original equipment installed prior to the October 2011 bluff failure. 16.6 Compliance Assessments We Energies corporate environmental staff conduct the requisite compliance assessments of each regulated We Energies facility at least once every three (3) years. 16.7 Incident Investigation We Energies has in place a well-defined Incident Investigation procedure to ensure the prompt investigation of all incidents. The Incident Investigation procedure remains valid as the construction of the new ammonia storage tank did not change how incidents are investigated. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 30 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 17.0 ChemReport Community Emergency Response Plan The Emergency Planning and Community Right-to-Know Act (EPCRA), was designed to prevent or mitigate accidental releases of certain chemical substances. Section 302 of EPCRA requires facilities possessing more than a specified threshold of a listed Extremely Hazardous Substance (EHS) to participate in community wide emergency planning activities that are directed by the local offices of emergency management. Prior to 2001, aqueous ammonia solutions of greater than 20% were listed as an Extremely Hazardous Substance under Section 302 with a threshold planning quantity of 500 pounds. However, in 2001 U.S. EPA specifically exempted aqueous ammonia solutions (regardless of concentration) from Section 302 planning requirements. Consequently, the OCPP facility is not subject to Section 302 emergency planning as a result of its use of aqueous ammonia. OCPP has coordinated its existing emergency response program with the Milwaukee County and Racine County Offices of Emergency Management, Local Fire Departments, and other applicable agencies. Although aqueous ammonia is not regulated under Section 302, its use at the OCPP facility may be factored into the site-specific community emergency response plan(s) developed by Milwaukee and Racine Counties and the facility will notify each agency, including the Oak Creek Fire Department of the planned filling and use of the permanent ammonia storage tanks prior to startup. 18.0 Facility Emergency Response Plan The OCPP facility will implement its own Emergency Response Plan (ERP) that takes into account facility-specific response actions which will be implemented in the event of an emergency (e.g. chemical spill, weather, fire). The chemical response provisions of the ERP provide basic response actions to be taken such as emergency exit routes, evacuation areas, notification procedures, spill kit and Personal Protective Equipment (PPE) locations, etc. Additional response activities are contained in OCPP’s Spill Prevention, Control and Countermeasure (SPCC). The ERP is maintained as a separate document to this RMP Plan. The Emergency Response Plan remains valid as the construction and use of the new ammonia storage tank will not change emergency response procedures. OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 31 of 32 Oak Creek Power Plant OCA Update and Hazard Review Ammonia Tank Farm Relocation Final 09/24/2012 ChemReport Questions concerning the contents of this revised OCA and Hazard Review should be addressed to Mr. Dan Adams, Senior Environmental Consultant for We Energies at (414) 221-4674. CHEMREPORT, INCORPORATED _______________________________ Michael G. Boozer/CHMM Certified Hazardous Materials Manager Project Manager 187769-1 OCPP OCA Update & Hazard Review – Ammonia Tank Farm Relocation Page 32 of 32