DRAFT OKLAHOMA DEPARTMENT OF ENVIRONMENTAL QUALITY AIR QUALITY DIVISION MEMORANDUM April 16, 2012 TO: THROUGH: THROUGH: THROUGH: FROM: SUBJECT: Phillip Fielder, Permits and Engineering Group Manager Kendal Stegmann, Senior Environmental Manager, Compliance and Enforcement Phillip Martin, P.E., Existing Source Permits Section Manager Peer Review John Howell, P.E., Existing Source Permits Section Evaluation of Operating Permit Application No. 2009-463-TVR Whiting Oil and Gas Corporation Hough Morrow A Unit (HMAU) NE ¼ of Section 13-T5N-R13ECM Texas County, Oklahoma Latitude 36.904 N Longitude 101.604 W Driving Directions: From the intersection of Hwy 3 and NS077 (Goodwell Rd) northwest of Guymon, Oklahoma: 10.0 miles north; east 2.2 miles south 0.2 miles into facility. SECTION I. INTRODUCTION Whiting Petroleum Corporation (Whiting) has submitted an application for renewal of the title V operating permit for the Hough Morrow A Unit (HMAU). This facility is an existing emulsion breaking/injection well operation with an associated secondary Enhanced Oil Recovery (EOR) operation (SIC 1311). The facility is located in an attainment area. The facility is a PSD major source, currently operating under Permit No. 2004-175-TV, issued June 24, 2005. The facility has removed two internal combustion engines at the facility and reduced its facility-wide emissions below major source thresholds. Whiting has requested that the final permit be issued as a synthetic minor source operating permit for the facility. This permit modification includes the following: Whiting has installed electric driven compressors in place of the previously permitted units (ENG-1 and ENG-2). Whiting requests that the engines be removed from the permit. Whiting has reduced potential flaring event emissions. Whiting has requested that the annual limit be reduced to 800 MMSCF. Include blowdown emissions in the emissions inventory.
PERMIT MEMORANDUM 2009-463-TVR DRAFT 2 Update storage tank list and emissions. Whiting requests combined emission limits for the storage tanks at the facility. The emergency generator is listed as a permitted emission source. Include loadout emissions. Update process piping fugitive emissions. Facility and permit status will change to synthetic minor source. The facility-wide permitted emissions upon issuance of this permit are less than major source thresholds of 100 TPY for criteria pollutants, 25 TPY total hazardous air pollutants (HAPs), and 10 TPY individual HAP emissions, and the facility will qualify as a synthetic minor source. SECTION II. PROCESS DESCRIPTION The EOR Program involves alternating injections of CO 2 and produced water into the oil-bearing formations to enhance oil recovery operations. As a result, CO 2 is the primary component (approx. 90%) of gas being produced from the wells. Recovered liquid and natural gas from the surrounding waterflood production wells are piped under pressure (15 psi) to a free-water knock out (FWKO) tank. The crude oil/emulsion layer is forwarded to a heater treater. From the heater treater, the separated crude and any remaining emulsion is forwarded to three stock tanks. From the stock tanks, the crude is introduced into an oil-sales pipeline and any remaining emulsion is recirculated into the heater treater. Produced water from the FWKO goes through a series of water transfer tanks, raw water tank, and the new 5,000-bbl settling tank. The 5,000-bbl settling tank will be constantly skimming oil to be transferred to the oil skim tank and transferred to either the sales oil tanks or trucked offsite as needed. Water from the settling tank is then routed to the water suction tanks for subsequent injection. Natural gas from the FWKO tank, heater treater, 5,000-bbl settling tank, and hydrocarbon liquid tanks are recovered by a vapor recovery unit (VRU) and then directed to a gas-sales pipeline to the nearby Dry Trail gas processing plant. Process water from the FWKO tank and heater treater are forwarded to a raw water tank. In the raw water tank, the process water is blended with salt water from other operations and is either blended with fresh water trucked on-site in suction tanks for subsequent well injection (associated with the EOR operation) or is forwarded to a transfer tank for subsequent disposal well injection. The raw water is collected in a skim tank and is sent to the heater treater. The pumps used to pipe the fresh water to multiple injection wells are powered by two electric motors. The pump to advance salt water to the disposal well injection is driven by a 25-hp electric transfer pump. The flare is used to combust excess gas, which typically contains a high percentage of CO 2. A pressurized vessel contiguous to the flare captures liquids in the gas stream prior to flaring. Other on-site tanks store salt water (four tanks) from production wells that may or may not be associated with the EOR operation. Other on-site operations may include cold degreasing, torch cutting and welding/soldering for maintenance purposes, bioremediation and soil aeration activities, and surface coating activities for maintenance purposes.
PERMIT MEMORANDUM 2009-463-TVR DRAFT 3 SECTION III. PREVIOUSLY PERMITTED EQUIPMENT EU ID# Point ID# EUG 1 Internal Combustion Engines Construction/ EU Name/Model Serial No. Modification Date 19050 1978 engine with a catalytic converter* 19051 1978/1997 E-ENG1 ENG-1 650-hp White/Superior, 8G-825 E-ENG2 ENG-2 800-hp White/Superior, 8G-825 engine with a catalytic converter *ENG-1 is attached to a water pump which restricts the RPM of the engine. The engine is derated to 650 hp @ 730 rpm. EUG 2 Storage Tanks EU ID# Point ID# Contents Capacity Construction Barrels Gallons Date E-TNK1A TNK-1A Crude Oil 773 32,465 March 2000 E-TNK2A TNK-2A Crude Oil 773 32,465 March 2000 E-TNK3A TNK-3A Crude Oil 773 32,465 March 2000 EUG 3 Heater EU ID# Point ID# Equipment Capacity Construction MMBtu/hr Date E-HT1 HT-1 Heater Treater 3.0 2000 EUG 4 Flare EU ID# Point ID# Equipment Capacity Construction MMSCFD Date E-FL1 FL-1 Process Flare 20.0 2004 EUG 5 Fugitive VOC Emission Sources EU Point Equipment Number E-FUG P-FUG Valves - Inlet Gas 80 Pressure Relief Valves 12 Flange/Connectors - Inlet Gas 190 Compressor Seals 12 Open Ended Lines 1 Pump Seals 2
PERMIT MEMORANDUM 2009-463-TVR DRAFT 4 SECTION IV. PERMITTED EQUIPMENT [THIS PERMIT] EUG 2 Storage Tanks EU ID# Point ID# Contents Capacity Construction Barrels Gallons Date E-TNK1A TNK-1A Crude Oil 773 32,465 March 2000 E-TNK2A TNK-2A Crude Oil 773 32,465 March 2000 E-TNK3A TNK-3A Crude Oil 773 32,465 March 2000 E-TW1 TW1* Raw Water 1,000 42,000 March 2000 E-TW2 TW2* Suction Water 1,000 42,000 March 2000 E-TW3 TW3* Suction Water 1,000 42,000 March 2000 E-TW4 TW4* Transfer Water 750 31,500 March 2000 E-TW5 TW5** Overflow Water 400 16,800 2011 E-TW6 TW6** Raw Water Settling 5,000 210,000 2011 E-T4 E-T4* Produced Water [Crude Oil Skim Tank] 210 8,820 March 2000 *Previously regarded as an Insignificant Activity ** New tank EUG 3 Heater EU ID# Point ID# Equipment Capacity Construction MMBtu/hr Date E-HT1 HT-1* Heater Treater 3.0 2000 *Previously regarded as an Insignificant Activity EUG 4 Flare EU ID# Point ID# Equipment Capacity Construction MMSCFD Date E-FL1 FL-1 Process Flare 20.0 2004 EUG 5 Fugitive VOC Emission Sources EU Point Equipment Number E-FUG P-FUG* Valves - Inlet Gas 80 Pressure Relief Valves 12 Flange/Connectors - Inlet Gas 190 Compressor Seals 12 Open Ended Lines 1 Pump Seals 2 *Previously regarded as an Insignificant Activity EUG 6 Compressor Blowdowns EU ID# Point ID# Equipment Construction Date E-B1 B-1* Electric Compressors Replaced 2009 *Previously regarded as an Insignificant Activity
PERMIT MEMORANDUM 2009-463-TVR DRAFT 5 EUG 6 Truck Loadout EU ID# Point ID# Equipment Construction Date E-L1 L-1* Condensate Loadout 2000 *Previously regarded as an Insignificant Activity EUG 7 Generator Engine EU id# Point ID# EU Name/Model Installation Date E-GEN GEN 300-hp Chevrolet 350 emergency generator engine (Natural gas fueled) 2000 SECTION V. EMISSIONS Compressor engines were replaced with electric motors. There are no regulated emissions from electric motors. Tank working and breathing losses were calculated using the EPA TANKS 4.09 program, with a throughput of 91,980,000 gallons per year. Vapor recovery efficiency of 98% was also assumed for tank emission calculations. Loadout emissions are calculated using methods of AP-42 (1/95), Section 5.2 and 500,000 gallons per year throughput. Fugitive emissions of VOCs were calculated using the USEPA document, Protocol for Equipment Leak Estimates (EPA-453/r95-017) and estimated equipment component counts. Tank flash emissions were calculated using the Aspen HYSIS process simulation with 98% collection efficiency from the vapor recovery system. Emissions from the heater treater are based on AP-42 (7/98) Tables 1.4-1 & 2. NO X and CO emissions from the flare were calculated using emission factors from AP-42 Table 13.5-1. VOC emissions were derived for the flare using a gas analysis, gas throughput, mass balance equations, and 98% destruction efficiency. SO 2 emissions were derived for the flare using a gas analysis, gas throughput, and mass balance equations. Flare gas throughput is limited to 800 MMSCF/year. Blowdown emissions were calculated using a mass balance equation. Whiting uses 8,000 SCF of gas expelled per blowdown event as a conservative estimate. The gas contains 18.08% VOC by mass from an extended gas analysis with contingency added. Annual VOC emissions from blowdown events are calculated by multiplying the total volume of blowdowns, dividing by the volume of gas per pound-mole, multiplying by pound mass of gas per pound-mole, multiplying by percent VOC in the gas, and converting pounds to tons. Annual Blowdown Emissions Calculation [384,000(SCF/yr)/380(SCF/lb-mol)]*20.48(lb/lb-mol)*18.08% VOC /2,000(lb/ton) = 1.87 TPY VOC
PERMIT MEMORANDUM 2009-463-TVR DRAFT 6 Previous Facility-Wide Emissions EU NOx CO VOC SO 2 lb/hr TPY lb/hr TPY lb/hr TPY lb/hr TPY E-ENG1 4.30 18.83 4.30 18.83 0.29 1.27 0.13 0.57 E-ENG2 5.29 23.17 5.29 23.17 0.35 1.53 0.16 0.70 TNK-1A -- -- -- -- 4.16 18.26 -- -- TNK-2A -- -- -- -- 0.01 0.05 -- -- TNK-3A -- -- -- -- 0.01 0.05 -- -- E-FUG -- -- -- -- -- 3.15 -- -- HT-1 0.29 1.29 0.25 1.08 0.02 0.07 0.08 0.34 FL-1 10.79 28.92 92.52 248.00 81.07 217.31 21.48 57.59 Total 20.67 72.21 102.36 291.08 85.91 241.69 21.85 59.20 Facility-Wide Emissions [This Permit] EU ID# Source NO X CO VOC SO 2 lb/hr TPY lb/hr TPY lb/hr TPY TPY 1 lb/hr TPY TNK1A Condensate, 773 bbl 7.45 32.63 TNK2A Condensate, 773 bbl 0.11 0.48 TNK3A Condensate, 773 bbl 0.11 0.48 T4 Skim Tank, 210 bbl 0.13 0.59 TW1 Raw Water, 1,000 bbl 0.24 1.06 TW2 Suction Water, 1,000 bbl 0.24 1.06 43.12 1 TW3 Suction Water, 1,000 bbl 0.24 1.06 TW4 Transfer Water, 750 bbl TW5 Overflow Water 400 bbl 0.11 0.49 TW6 Raw Water Settling 5,000 bbl 1.20 5.27 LOAD Truck Loading 0.51 0.51 HT1 Heater treater 0.30 1.31 0.25 1.10 0.02 0.07 0.07 <0.01 0.01 FL1 2 Process/Emergency 11.64 5.66 63.31 30.79 85.47 41.23 41.23 22.66 Flare BLOW Compressor Blowdowns 1.87 1.87 FUG Piping Fugitives 2.41 11.18 11.18 GEN 3 300-hp Chevrolet 9.79 2.45 8.93 2.23 0.28 0.07 0.07 Generator TOTAL 12.73 9.42 72.49 34.12 98.01 98.05 98.05 <0.01 22.67 1 VOC emissions in tons per year with tank emissions combined including working, breathing and flash. 2 Based on 800 MMSCF/year throughput and 98% destruction efficiency. 3 Based on 500 hours per year operation. Difference in Facility-Wide Emissions NO X CO VOC TPY TPY TPY Previous Emissions 72.21 291.08 241.69 Current Emissions 9.42 34.12 98.05 Emissions Change -62.79-256.96-143.64
PERMIT MEMORANDUM 2009-463-TVR DRAFT 7 The internal combustion engine will have emissions of hazardous air pollutants (HAPs), the most significant being formaldehyde. Potential formaldehyde emissions calculations for the Chevrolet 350 engine is based on the uncontrolled 4-stroke lean-burn engine factor of 0.0528 lb/mmbtu from AP-42 (7/00), Section 3.2, with a heat input of 2.40 MMBtu/hr. Total formaldehyde emissions are below major source levels. Engine Formaldehyde Emissions Formaldehyde Source lb/hr TPY 300-hp Chevrolet 350 Emergency Generator Engine 0.13 0.03 Total HAP emissions are below major source levels. Greenhouse Gases The applicant has presented estimates of PTE for greenhouse gases (CO 2 -equivalent) at this site, demonstrating that the facility is not a PSD-major source for this pollutant. SECTION VI. OKLAHOMA AIR POLLUTION CONTROL RULES OAC 252:100-1 (General Provisions) [Applicable] Subchapter 1 includes definitions but there are no regulatory requirements. OAC 252:100-2 (Incorporation by Reference) [Applicable] This subchapter incorporates by reference applicable provisions of Title 40 of the Code of Federal Regulations listed in OAC 252:100, Appendix Q. These requirements are addressed in the Federal Regulations section. OAC 252:100-3 (Air Quality Standards and Increments) [Applicable] Subchapter 3 enumerates the primary and secondary ambient air quality standards and the significant deterioration increments. At this time, all of Oklahoma is in attainment of these standards. OAC 252:100-5 (Registration, Emissions Inventory, and Annual Operating Fees) [Applicable] Subchapter 5 requires sources of air contaminants to register with Air Quality, file emission inventories annually, and pay annual operating fees based upon total annual emissions of regulated pollutants. Emission inventories were submitted and fees paid for previous years as required. OAC 252:100-7 (Permits for Minor Facilities) [Applicable] Subchapter 7 sets forth the permit application fees and the basic substantive requirements of permits for minor facilities. Since criteria pollutant emissions are less than 100 TPY for each pollutant, and emissions of Hazardous Air Pollutants (HAP) will not exceed 10 TPY for any individual HAP or 25 TPY for any aggregate of HAP, the facility is defined as a minor source. As such, BACT is not required.
PERMIT MEMORANDUM 2009-463-TVR DRAFT 8 OAC 252:100-9 (Excess Emission Reporting Requirements) [Applicable] Except as provided in OAC 252:100-9-7(a)(1), the owner or operator of a source of excess emissions shall notify the Director as soon as possible but no later than 4:30 p.m. the following working day of the first occurrence of excess emissions in each excess emission event. No later than thirty (30) calendar days after the start of any excess emission event, the owner or operator of an air contaminant source from which excess emissions have occurred shall submit a report for each excess emission event describing the extent of the event and the actions taken by the owner or operator of the facility in response to this event. Request for affirmative defense, as described in OAC 252:100-9-8, shall be included in the excess emission event report. Additional reporting may be required in the case of ongoing emission events and in the case of excess emissions reporting required by 40 CFR Parts 60, 61, or 63. OAC 252:100-13 (Open Burning) [Applicable] Open burning of refuse and other combustible material is prohibited except as authorized in the specific examples and under the conditions listed in this subchapter. OAC 252:100-19 (Particulate Matter (PM)) [Applicable] Section 19-4 regulates emissions of PM from new and existing fuel-burning equipment, with emission limits based on maximum design heat input rating. Appendix C specifies a PM emission limitation of 0.60 lbs/mmbtu for all equipment at this facility with a heat input rating of 10 Million BTU per hour (MMBTUH) or less. Fuel-burning equipment is defined in OAC 252:100-19 as any internal combustion engine or gas turbine, or other combustion device used to convert the combustion of fuel into usable energy. AP-42 (7/98) Table 1.4-2 lists natural gas total PM emissions to be 7.6 lbs/million scf or about 0.0076 lbs/mmbtu, which is in compliance. AP- 42 (7/00), Sec. 3.2 lists the total PM emissions from uncontrolled 4-stroke rich-burn natural gasfired engines to be 0.0095 lbs/mmbtu. This permit requires the use of natural gas for the emergency generator and the heater treater to ensure compliance with Subchapter 19. OAC 252:100-25 (Visible Emissions and Particulates) [Applicable] This subchapter states that no person shall allow the discharge of any fumes, aerosol, mist, gas, smoke, vapor, particulate matter, or any combination thereof exhibiting greater than 20% opacity except for short term occurrences, which consist of not more than one six-minute (6) period in any consecutive 60 minutes, not to exceed three such periods in any consecutive 24-hour period. In no case shall the average of any six-minute (6) period exceed 60% opacity. OAC 252:100-29 (Fugitive Dust) [Applicable] No person shall cause or permit the discharge of any visible fugitive dust emissions beyond the property line on which the emissions originate in such a manner as to damage or to interfere with the use of adjacent properties, or cause air quality standards to be exceeded, or interfere with the maintenance of air quality standards. Under normal operating conditions, this facility will not cause a problem in this area, therefore it is not necessary to require specific precautions to be taken. OAC 252:100-31 (Sulfur Compounds) [Applicable] Part 5 limits sulfur dioxide emissions from new petroleum or natural gas process equipment (constructed after July 1, 1972). For gaseous fuels the limit is 0.2 lb/mmbtu heat input averaged
PERMIT MEMORANDUM 2009-463-TVR DRAFT 9 over 3 hours. This is equivalent to approximately 0.2 weight percent sulfur in the fuel gas, which is equivalent to 2,000 ppmw sulfur. Thus, a limitation of 343 ppmv sulfur in a field gas supply will be in compliance. The permit requires the use of pipeline-grade natural gas or field gas with a maximum sulfur content of 343 ppmv. Part 5 also limits hydrogen sulfide emissions from new petroleum or natural gas process equipment (constructed after July 1, 1972). Removal of hydrogen sulfide in the exhaust stream, or oxidation to sulfur dioxide, is required unless hydrogen sulfide emissions would be less than 0.3 lb/hr for a two-hour average. Hydrogen sulfide emissions shall be reduced by a minimum of 95% of the hydrogen sulfide in the exhaust gas. Direct oxidation of hydrogen sulfide is allowed for units whose emissions would be less than 100 lb/hr of sulfur dioxide for a two-hour average. All emissions from the heater treater are vented to the plant flare for conversion of hydrogen sulfide to sulfur dioxide at an efficiency of 98%. The permit will require the flare to be equipped with an alarm to signal non-combustion of the exhaust gases. The permit will also require the facility to measure and record annually the H 2 S concentration of the gas combusted in the flare. OAC 252:100-33 (Nitrogen Oxides) [Not Applicable] This subchapter limits new gas-fired fuel-burning equipment with rated heat input greater than or equal to 50 MMBTUH to emissions of 0.2 lb of NO X per MMBTU. There are no equipment items that exceed the 50 MMBTUH threshold. OAC 252:100-35 (Carbon Monoxide) [Not Applicable] This facility has none of the affected sources: gray iron cupola, blast furnace, basic oxygen furnace, petroleum catalytic cracking unit or petroleum catalytic reforming unit. OAC 252:100-37 (Volatile Organic Compounds) [Applicable] Part 3 requires storage tanks constructed after December 28, 1974, with a capacity of 400 gallons or more and storing a VOC with a vapor pressure greater than 1.5 psia to be equipped with a permanent submerged fill pipe or with an organic vapor recovery system. The three crude oil tanks are equipped with a vapor recovery system. Part 3 requires loading facilities with a throughput equal to or less than 40,000 gallons per day to be equipped with a system for submerged filling of tank trucks or trailers if the capacity of the vehicle is greater than 200 gallons. This facility does not have the physical equipment (loading arm and pump) to conduct this type of loading. Therefore, this requirement is not applicable. Part 5 limits the VOC content of coating of parts and products. This facility does not normally conduct coating or painting operations except for routine maintenance of the facility and equipment which is exempt and considered a Trivial Activity. Part 7 requires fuel-burning and refuse-burning equipment to be operated to minimize emissions of VOC. The equipment at this location is subject to this requirement. Temperature and available air must be sufficient to provide essentially complete combustion. Part 7 requires all effluent water separator openings, which receive water containing more than 200 gallons per day of any VOC, to be sealed or the separator to be equipped with an external floating roof or a fixed roof with an internal floating roof or a vapor recovery system. The freewater knockout unit is a sealed vessel that is equipped with a vapor recovery system.
PERMIT MEMORANDUM 2009-463-TVR DRAFT 10 OAC 252:100-42 (Toxic Air Contaminants (TAC)) [Applicable] This subchapter regulates toxic air contaminants (TAC) that are emitted into the ambient air in areas of concern (AOC). Any work practice, material substitution, or control equipment required by the Department prior to June 11, 2004, to control a TAC, shall be retained, unless a modification is approved by the Director. Since no AOC has been designated there are no specific requirements for this facility at this time. OAC 252:100-43 (Testing, Monitoring, and Recordkeeping) [Applicable] This subchapter provides general requirements for testing, monitoring and recordkeeping and applies to any testing, monitoring or recordkeeping activity conducted at any stationary source. To determine compliance with emissions limitations or standards, the Air Quality Director may require the owner or operator of any source in the state of Oklahoma to install, maintain and operate monitoring equipment or to conduct tests, including stack tests, of the air contaminant source. All required testing must be conducted by methods approved by the Air Quality Director and under the direction of qualified personnel. A notice-of-intent to test and a testing protocol shall be submitted to Air Quality at least 30 days prior to any EPA Reference Method stack tests. Emissions and other data required to demonstrate compliance with any federal or state emission limit or standard, or any requirement set forth in a valid permit shall be recorded, maintained, and submitted as required by this subchapter, an applicable rule, or permit requirement. Data from any required testing or monitoring not conducted in accordance with the provisions of this subchapter shall be considered invalid. Nothing shall preclude the use, including the exclusive use, of any credible evidence or information relevant to whether a source would have been in compliance with applicable requirements if the appropriate performance or compliance test or procedure had been performed. SECTION VII. FEDERAL REGULATIONS PSD, 40 CFR Part 52 [Not Applicable] PSD does not apply. Final total emissions are less than the threshold of 250 TPY of any single regulated pollutant and the facility is not one of the listed stationary sources with an emission threshold of 100 TPY. NSPS, 40 CFR Part 60 [Not Applicable] Subpart Kb, VOL Storage Vessels. This subpart regulates hydrocarbon storage tanks with a capacity larger than 19,812-gal (75 m 3 ) and built after July 23, 1984. The three crude oil storage tanks are used prior to custody transfer as defined by the subpart, thus they are exempt. Subpart GG, Stationary Gas Turbines. There are none at this facility. Subpart VV, Equipment Leaks of VOC in the Synthetic Organic Chemical Manufacturing Industry. The equipment is not in a SOCMI plant. Subpart KKK, Equipment Leaks of VOC from Onshore Natural Gas Processing Plants. The facility does not engage in natural gas processing. Subpart LLL, Onshore Natural Gas Processing: SO 2 Emissions. This subpart affects sweetening units and sweetening units followed by a sulfur recover unit which commence construction or modification after January 20, 1984. This is no sweetening unit at this facility.
PERMIT MEMORANDUM 2009-463-TVR DRAFT 11 Subpart IIII, Standards of Performance for Stationary Compression Ignition Internal Combustion Engines, affects stationary compression ignition (CI) internal combustion engines (ICE) based on power and displacement ratings, depending on date of construction, beginning with those manufactured after April 1, 2006. For the purposes of this subpart, the date that construction commences is the date the engine is ordered by the owner or operator. There are no CI engines at this facility Subpart JJJJ, Stationary Spark Ignition (SI) Internal Combustion Engines (ICE). This subpart was published in the Federal Register on January 18, 2008. It promulgates emission standards for new SI engines ordered after June 12, 2006, that are manufactured after certain dates, and for all SI engines modified or reconstructed after June 12, 2006, regardless of size. The specific emission standards (either in g/hp-hr or as a concentration limit) vary based on engine class, engine power rating, lean-burn or rich-burn, fuel type, duty (emergency or non-emergency), and manufacture date. Engine manufacturers are required to certify certain engines to meet the emission standards and may voluntarily certify other engines. An initial notification is required only for owners and operators of engines greater than 500 HP that are non-certified and are subject to emission standards. The emergency generator engine at this facility was manufactured prior to the applicability date and is not subject to Subpart JJJJ. NESHAP, 40 CFR Part 61 [Not Applicable] There are no emissions of any of the regulated pollutants: arsenic, asbestos, benzene, beryllium, coke oven emissions, mercury, radionuclides, or vinyl chloride except for trace amounts of benzene. Subpart J, Equipment Leaks of Benzene, concerns only process streams that contain more than 10% benzene by weight. Analysis of Oklahoma natural gas indicates a maximum benzene content of less than 1%. NESHAP, 40 CFR Part 63 [ZZZZ Applicable] Subpart HH, Oil and Natural Gas Production Facilities. This subpart applies to affected emission points that are located at facilities that are major and area sources of HAP, and either process, upgrade, or store hydrocarbon liquids prior to custody transfer or that process, upgrade, or store natural gas prior to entering the natural gas transmission and storage source category. This facility is not a major source of HAPs and does not have a glycol dehydration unit. Subpart ZZZZ, Reciprocating Internal Combustion Engines (RICE). This subpart affects RICE with a site-rating greater than 500 brake horsepower that are located at a major source and new and reconstructed engines (after June 12, 2006) with a site rating less than or equal to 500 HP located at major sources, and located at area sources. Owners and operators of new or reconstructed engines at area sources and of new or reconstructed engines with a site rating equal to or less than 500 HP located at a major source (except new or reconstructed 4-stroke lean-burn engines with a site rating greater than or equal to 250 HP and less than or equal to 500 HP located at a major source) must meet the requirements of Subpart ZZZZ by complying with either 40 CFR Part 60 Subpart IIII (for CI engines) or 40 CFR Part 60 Subpart JJJJ (for SI engines). Based on emission calculations, this facility is a minor source of HAP. The engine was manufactured prior to July 1, 2007 and has not been modified or reconstructed and is considered an existing engine.
PERMIT MEMORANDUM 2009-463-TVR DRAFT 12 On August 20, 2010, EPA finalized additional requirements for stationary SI RICE located at area sources. A summary of these requirements for the emergency generator engine located at this facility are shown below. Engine Category Normal Operation @ 15% O 2 Existing Emergency SI & Black Start CI Change oil and filter every 500 hours of operation or annually, whichever one comes first; Inspect spark plugs every 1,000 hours of operation or annually, whichever one comes first; and Inspect all hoses and belts every 500 hours of operation or annually, whichever one comes first and replace as necessary. Initial notification is not required for an existing stationary emergency RICE. The facility must comply with this subpart by the initial compliance date of October 19, 2013. Chemical Accident Prevention Provisions, 40 CFR Part 68 [Not Applicable] This facility will not process or store more than the threshold quantity of any regulated substance (Section 112r of the Clean Air Act 1990 Amendments). More information on this federal program is available on the web page: www.epa.gov/ceppo. SECTION VIII. COMPLIANCE Tier Classification and Public Review This application has been determined to be a Tier II based on the request for changing a Title V operating permit to a synthetic minor source operating permit. The application also fulfills the operator s obligation to submit a title V renewal application. The permittee has submitted an affidavit that they are not seeking a permit for land use or for any operation upon land owned by others without their knowledge. The affidavit certifies that the applicant possesses a current lease or easement given by the landowner for the purpose or purposes stated in the application. The applicant published the Notice of Filing a Tier II Application in The Guymon Daily Herald, a daily newspaper, in the city of Guymon, Texas County, on January 12, 2010. The notice stated that the application was available for public review at the Guymon Public Library and at the Oklahoma City DEQ Air Quality Division main office. The applicant will publish the Notice of Draft Permit in a newspaper in Texas County. The notice will state that the draft permit is available for public review for a period of 30 days within the county and at the Air Quality Division main office and on the Air Quality section of the DEQ web page at http://www.deq.state.ok.us. This facility is located within 50 miles of the Oklahoma-Kansas and the Oklahoma-Texas borders. Kansas and Texas will be notified of this draft permit. EPA Review The proposed permit will be forwarded to EPA for a 45-day review period after public review.
PERMIT MEMORANDUM 2009-463-TVR DRAFT 13 Inspection A full compliance evaluation was conducted at Whiting Oil and Gas Corporation Hough Morrow A Unit (HMAU) on May 17, 2011. The evaluation was announced since the Facility is not manned during business hours. Melanie Foster, Environmental Programs Manager, and Jennie Brixey, Environmental Programs Specialist, conducted the evaluation for the Air Quality Division of the Oklahoma Department of Environmental Quality. Nina Palmer, EH&S Coordinator; Gary Wright, current Operations Supervisor; Kerry Shoemake, incoming Operations Supervisor; and Roger Valliquette, Production Foreman represented the Facility. Operating records are kept at the Postle Field Office. Based on the information provided or obtained during this evaluation, no compliance issues were discovered. Testing The 300-hp Chevrolet 350 emergency generator engine at this facility is an existing source and not required to conduct emission testing at this time. Fees Paid Significant modification to a Title V operating permit fee of $1,000. SUMMARY The applicant has demonstrated the ability to comply with the applicable Air Quality rules and regulations. Ambient air quality standards are not threatened at this site. There is no other active Air Quality compliance or enforcement action concerning this facility that would affect the issuance of this permit. Issuance of the operating permit is recommended, contingent on public and EPA review.
PERMIT TO OPERATE AIR POLLUTION CONTROL FACILITY SPECIFIC CONDITIONS DRAFT Whiting Oil and Gas Corporation Permit No. 2009-463-TVR Hough Morrow A Unit (HMAU) The permittee is authorized to operate in conformity with the specifications submitted to Air Quality on December 17, 2009, and supplemental material. The Evaluation Memorandum dated April 16, 2012, explains the derivation of applicable permit requirements and estimates of emissions; however, it does not contain operating limitations or permit requirements. Continuing operations under this permit constitutes acceptance of, and consent to, the conditions contained herein. 1. Points of emissions and emissions limitations for each point: Facility-Wide Emissions EU ID# Source NO X CO VOC SO 2 lb/hr TPY lb/hr TPY lb/hr TPY lb/hr TPY TNK1A Condensate, 773 bbl TNK2A Condensate, 773 bbl TNK3A Condensate, 773 bbl T4 Skim Tank, 210 bbl TW1 Raw Water, 1,000 bbl TW2 Suction Water, 1,000 bbl TW3 Suction Water, 43.12 1 1,000 bbl TW4 Transfer Water, 750 bbl TW5 Overflow Water 400 bbl TW6 Settling, 5000 bbl FLASH Tank Flashing LOAD Truck Loading 0.51 HT1 Heater treater 0.30 1.31 0.25 1.10 0.02 0.07 <0.01 0.01 FL1 2 Process/Emergency Flare 11.64 5.66 63.31 30.79 85.47 41.23 22.66 BLOW Compressor Blowdowns 1.87 GEN 3 300-hp Chevrolet Generator 9.79 2.45 8.93 2.23 0.28 0.07 1 Combined emission limit for tanks includes working, breathing and flash emissions. 2 Based on 800 MMSCF/year throughput. 3 Based on 500 hours per year operation. 2. The gaseous fuel-burning equipment shall be fired with pipeline grade natural gas or other gaseous fuel with a sulfur content less than 343 ppmv. Compliance can be shown by the following methods: for pipeline grade natural gas, a current gas company bill; for other gaseous fuel, a current lab analysis, stain-tube analysis, gas contract, tariff sheet, or other approved methods. Compliance shall be demonstrated at least once annually.
SPECIFIC CONDITIONS 2009-463-TVR DRAFT 2 3. The permittee shall be authorized to operate this facility continuously (24 hours per day, every day of the year). 4. The generator engine at the facility shall have a permanent identification plate attached, which shows the make, model number, and serial number. 5. At least once per calendar quarter, the permittee shall conduct tests of NO X and CO emissions in exhaust gases from each engine/turbine when operating under representative conditions for that period. Testing is required for any engine/turbine that runs for more than 220 hours during that calendar quarter. A quarterly test may be conducted no sooner than 20 calendar days after the most recent test. Testing shall be conducted using a portable analyzer in accordance with a protocol meeting the requirements of the latest AQD Portable Analyzer Guidance document, or an equivalent method approved by Air Quality. When four consecutive quarterly tests show the engine/turbine to be in compliance with the emissions limitations shown in the permit, then the testing frequency may be reduced to semi-annual testing. A semi-annual test may be conducted no sooner than 60 calendar days nor later than 180 calendar days after the most recent test. Likewise, when the following two consecutive semi-annual tests show compliance, the testing frequency may be reduced to annual testing. An annual test may be conducted no sooner than 120 calendar days nor later than 365 calendar days after the most recent test. Upon any showing of non-compliance with emissions limitations or testing that indicates that emissions are within 10% of the emission limitations, the testing frequency shall revert to quarterly. Reduced testing frequency does not apply to engines with catalytic converters or oxidation catalysts. 6. The permittee shall keep operation and maintenance (O&M) records for those engines which do not conduct quarterly testing. Such records shall at a minimum include the dates of operation, and maintenance, type of work performed, and the increase, if any, in emissions as a result. 7. The emergency generator is limited to 500 hours per year operation (12 month rolling total). When the emergency generator engine exceeds 500 hours per year operation the permittee shall comply with the provisions of OAC 252:100-9 for excess emissions. Requirements of OAC 252:100-9 include immediate notification and written notification of Air Quality and demonstrations that the excess emissions meet the criteria specified in OAC 252:100-9. 8. Replacement (including temporary periods of 6 months or less for maintenance purposes), of the internal combustion engines/turbines with emissions specified in this permit with engines/turbines of lesser or equal emissions of each pollutant (in lbs/hr and TPY) are authorized under the following conditions. a. The permittee shall notify AQD in writing within 10 days of start-up of the replacement engine(s)/turbine(s). Said notice shall identify the old engine /turbine and shall include the new engine/turbine make and model, serial number, horsepower rating, fuel usage, stack flow (ACFM), stack temperature ( F), stack height (feet), stack diameter (inches), and pollutant emission rates (g/hp-hr, lb/hr, and TPY) at maximum horsepower for the altitude/location.
SPECIFIC CONDITIONS 2009-463-TVR DRAFT 3 b. Quarterly emissions tests for the replacement engine(s)/turbine(s) shall be conducted to confirm continued compliance with NO X and CO emissions limitations. A copy of the first quarter testing shall be provided to AQD within 60 days of start-up of each replacement or additional engine/turbine. The test report shall include the engine/turbine fuel usage, stack flow (ACFM), stack temperature ( o F), stack height (feet), stack diameter (inches), and pollutant emissions rates (g/hp-hr, lbs/hr, and TPY) at maximum rated horsepower for the altitude/location. c. Replacement equipment and emissions are limited to equipment and emissions that are not subject to NSPS, NESHAP, or PSD. 9. The permittee shall monitor and document compressor blowdown emissions. For compressor blowdown events, the permittee shall estimate the volume of gas released and compute the tons of VOCs emitted per month and maintain 12-month rolling totals showing tons of VOCs emitted due to compressor blowdowns. 10. The crude oil throughput of the facility shall not exceed 91,980,000 gallons in any 12-month period. 11. Volume of crude oil loaded and unloaded by truck shall not exceed 500,000 gallons in any 12-month period. 12. The free-water knock out tank, 5,000 bbl settling tank, heater treater, and each oil tank (TNK1A, TNK2A, and TNK3A) shall be operated with a vapor recovery system with a minimum 98% capture efficiency. 13. The flare shall be installed and operated as follows: a. The flare shall be limited to a maximum of 800 MMSCF of gas flared per any 12-month period. This limit is for flare events and does not include pilot gas. b. The flare shall be equipped with a gas flow monitoring device. c. The flare shall be equipped with a continuous pilot light. d. The amount of gas flared (MMSCF) shall be monitored and recorded (daily, monthly, and 12-month rolling total). e. An extended gas analysis shall be performed annually on the gas entering the flare. f. The flare shall be designed for smokeless operation and be operated using good combustion practices. g. The flare shall be equipped with an alarm to signal non-combustion of the exhaust gases. h. The H 2 S concentration of the gas combusted in the flare shall be measured and recorded annually. 14. The owner/operator shall comply with all applicable requirements of the NESHAP: Reciprocating Internal Combustion Engines, Subpart ZZZZ, for each affected facility including but not limited to: What This Subpart Covers b. 63.6580 What is the purpose of subpart ZZZZ? c. 63.6585 Am I subject to this subpart?
SPECIFIC CONDITIONS 2009-463-TVR DRAFT 4 d. 63.6590 What parts of my plant does this subpart cover? e. 63.6595 When do I have to comply with this subpart? Emission and Operating Limitations f. 63.6603 What emission limitations and operating limitations must I meet if I own or operate an existing stationary RICE located at an area source of HAP emissions? General Compliance Requirements g. 63.6605 What are my general requirements for complying with this subpart? Testing and Initial Compliance Requirements h. 63.6625 What are my monitoring, installation, operation, and maintenance requirements? i. 63.6630 How do I demonstrate initial compliance with the emission limitations and operating limitations? Continuous Compliance Requirements j. 63.6640 How do I demonstrate continuous compliance with the emission limitations and operating limitations? Notifications, Reports, and Records k. 63.6650 What reports must I submit and when? l. 63.6655 What records must I keep? m. 63.6660 In what form and how long must I keep my records? Other Requirements and Information n. 63.6665 What parts of the General Provisions apply to me? o. 63.6670 Who implements and enforces this subpart? p. 63.6675 What definitions apply to this subpart? 15. The permittee shall maintain the following records of operations as listed below. These records shall be maintained on-site or at a local field office for at least five years after the date of recording and shall be provided to regulatory personnel upon request. a. Periodic testing for each permitted engine and replacement engines. b. Operating hours for each engine/turbine if less than 220 hours per quarter and not tested. c. For the fuel(s) burned, the appropriate document(s) as described in Specific Condition 2. d. Summary of O&M records for any engine not tested in each 6 month period. e. The amount of gas flared, MMSCF (monthly and 12-month rolling total). f. The H 2 S content of the gas being flared (annually). g. Total oil throughput for the facility (monthly and 12-month rolling total). h. Volume of crude oil loaded and unloaded by truck (monthly and 12-month rolling total). i. Number of hours if the vapor recovery unit is not in service (monthly and 12-month rolling total). j. Compressor blowdown emissions as described in Specific Condition No. 9 (monthly and 12-month rolling total). k. Records required by NESHAP, Subpart ZZZZ. 16. No later than 60 days after the issuance of this minor source operating permit, the permittee shall submit to Air Quality Division of DEQ, with a copy to the US EPA, Region 6, a certification of compliance with the terms and conditions of the Part 70 operating permit for the time period between the most recent certification of compliance and the issuance date of
SPECIFIC CONDITIONS 2009-463-TVR DRAFT 5 the synthetic minor permit. The certification of compliance shall also contain a report of all required monitoring not reported since the last semi-annual monitoring report. 17. This permit supersedes all previous Air Quality permits for this facility, which are now null and void.
PERMIT AIR QUALITY DIVISION STATE OF OKLAHOMA DEPARTMENT OF ENVIRONMENTAL QUALITY 707 N. ROBINSON, SUITE 4100 P.O. BOX 1677 OKLAHOMA CITY, OKLAHOMA 73101-1677 Permit No. 2009-463-O DRAFT Whiting Oil and Gas Corporation, having complied with the requirements of the law, is hereby granted permission to operate the Hough Morrow A Unit facility located in Section 13, Township 5N, Range 13ECM, in Texas County, Oklahoma, subject to standard conditions dated April 8, 2010, and specific conditions, both attached. DRAFT Director, Air Quality Division Date DRAFT DEQ Form #100-885 Revised 10/20/06
MINOR SOURCE PERMIT TO OPERATE / CONSTRUCT AIR POLLUTION CONTROL FACILITY STANDARD CONDITIONS (April 8, 2010) A. The issuing Authority for the permit is the Air Quality Division (AQD) of the Oklahoma Department of Environmental Quality (DEQ) in accordance with and under the authority of the Oklahoma Clean Air Act. The permit does not relieve the holder of the obligation to comply with other applicable federal, state, or local statutes, regulations, rules, or ordinances. This specifically includes compliance with the rules of the other Divisions of DEQ: Land Protection Division and Water Quality Division. B. A duly issued construction permit or authorization to construct or modify will terminate and become null and void (unless extended as provided in OAC 252:100-7-15(g)) if the construction is not commenced within 18 months after the date the permit or authorization was issued, or if work is suspended for more than 18 months after it is commenced. [OAC 252:100-7-15(f)] C. The recipient of a construction permit shall apply for a permit to operate (or modified operating permit) within 60 days following the first day of operation. [OAC 252:100-7-18(a)] D. Unless specified otherwise, the term of an operating permit shall be unlimited. E. Notification to the Air Quality Division of DEQ of the sale or transfer of ownership of this facility is required and shall be made in writing by the transferor within 10 days after such date. A new permit is not required. [OAC 252:100-7-2(f)] F. The following limitations apply to the facility unless covered in the Specific Conditions: 1. No person shall cause or permit the discharge of emissions such that National Ambient Air Quality Standards (NAAQS) are exceeded on land outside the permitted facility. [OAC 252:100-3] 2. All facilities that emit air contaminants are required to file an emission inventory and pay annual operating fees based on the inventory. Instructions and forms are available on the Air Quality section of the DEQ web page. www.deq.state.ok.us [OAC 252:100-5] 3. Deviations that result in emissions exceeding those allowed in this permit shall be reported consistent with the requirements of OAC 252:100-9, Excess Emission Reporting Requirements. [OAC 252:100-9] 4. Open burning of refuse and other combustible material is prohibited except as authorized in the specific examples and under the conditions listed in the Open Burning subchapter. [OAC 252:100-13] 5. No particulate emissions from new fuel-burning equipment with a rated heat input of 10 MMBTUH or less shall exceed 0.6 lbs/mmbtu. [OAC 252:100-19] 6. No discharge of greater than 20% opacity is allowed except for short-term occurrences which consist of not more than one six-minute period in any consecutive 60 minutes, not to exceed three such periods in any consecutive 24 hours. In no case shall the average of any six-minute period exceed 60% opacity. [OAC 252:100-25]
MINOR SOURCE STANDARD CONDITIONS April 8, 2010 2 7. No visible fugitive dust emissions shall be discharged beyond the property line on which the emissions originate in such a manner as to damage or to interfere with the use of adjacent properties, or cause air quality standards to be exceeded, or interfere with the maintenance of air quality standards. [OAC 252:100-29] 8. No sulfur oxide emissions from new gas-fired fuel-burning equipment shall exceed 0.2 lbs/mmbtu. No existing source shall exceed the listed ambient air standards for sulfur dioxide. [OAC 252:100-31] 9. Volatile Organic Compound (VOC) storage tanks built after December 28, 1974, and with a capacity of 400 gallons or more storing a liquid with a vapor pressure of 1.5 psia or greater under actual conditions shall be equipped with a permanent submerged fill pipe or with an organic material vapor-recovery system. [OAC 252:100-37-15(b)] 10. All fuel-burning equipment shall at all times be properly operated and maintained in a manner that will minimize emissions of VOCs. [OAC 252:100-37-36] G. Any owner or operator subject to provisions of NSPS shall provide written notification as follows: [40 CFR 60.7 (a)] 1. A notification of the date construction (or reconstruction as defined under 60.15) of an affected facility is commenced postmarked no later than 30 days after such date. This requirement shall not apply in the case of mass-produced facilities which are purchased in completed form. 2. A notification of any physical or operational change to an existing facility which may increase the emission rate of any air pollutant to which a standard applies, unless that change is specifically exempted under an applicable subpart or in 60.14(e). This notice shall be postmarked 60 days or as soon as practicable before the change is commenced and shall include information describing the precise nature of the change, present and proposed emission control systems, productive capacity of the facility before and after the change, and the expected completion date of the change. The Administrator may request additional relevant information subsequent to this notice. 3. A notification of the actual date of initial start-up of an affected facility postmarked within 15 days after such date. 4. If a continuous emission monitoring system is included in the construction, a notification of the date upon which the test demonstrating the system performance will commence, along with a pretest plan, postmarked no less than 30 days prior to such a date. H. Any owner or operator subject to provisions of NSPS shall maintain records of the occurrence and duration of any start-up, shutdown, or malfunction in the operation of an affected facility or any malfunction of the air pollution control equipment. [40 CFR 60.7 (b)] I. Any owner or operator subject to the provisions of NSPS shall maintain a file of all measurements and other information required by this subpart recorded in a permanent file suitable for inspection. This file shall be retained for at least five years following the date of such measurements, maintenance, and records. [40 CFR 60.7 (f)] J. Any owner or operator subject to the provisions of NSPS shall conduct performance test(s) and furnish to AQD a written report of the results of such test(s). Test(s) shall be conducted within 60 days after achieving the maximum production rate at which the facility will be operated, but not later than 180 days after initial start-up. [40 CFR 60.8]
Texas Commission on Environmental Quality Operating Permits Divisions (MC 163) P. O. Box 13087 Austin, Texas 78711-3087 Subject: Significant Modification to a Title V Operating Permit Application No. 2009-463- TVR Facility: Whiting Petroleum Corporation Hough Morrow A Unit (HMAU) Location: Section 13, Township 5N, Range 13E CM Texas County, Oklahoma Permit Writer: John Howell Dear Sir / Madame: The subject facility has requested a significant modification to a Title V operating permit under 40 CFR Part 70. Air Quality Division has completed the initial review of the application and prepared a draft permit for public review. Since this facility is within 50 miles of the Oklahoma- Texas border, a copy of the proposed permit will be provided to you upon request. Information on all permit actions and a copy of this draft permit are available for review by the public in the Air Quality Section of DEQ Web Page: http://www.deq.state.ok.us. Thank you for your cooperation. If you have any questions, please refer to the permit number above and contact me or contact the permit writer at (405) 702-4100. Sincerely, Phillip Fielder, P.E. Permits and Engineering Group Manager AIR QUALITY DIVISION