Download - NDEQ NESHAP Training Subpart ZZZZ - Engines

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NDEQ NESHAP Training Subpart ZZZZ - Engines

Melissa EllisFebruary 24, 2011

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Overview Objectives Industry Overview Rule Background Applicability Requirements Tips Tools & Resources

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Acronyms

HP = horsepower CI = compression ignition SI = spark ignition 4S = four stroke 2S = two stroke LB = lean burn RB = rich burn

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Objectives

Become familiar with industry

Understand rule requirements

Be aware of tools & resources to

help do your job more effectively

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Industry Overview

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Industry Overview

Stationary Internal Combustion Engines

1. Point of use for 12 months OR 3-12 months for seasonal

2. Not used to propel motor vehicle

3. Not a non-road engine

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Industry Overview

Engines manufactured the same, used differently

Electrical generators & powering emission units

Compression Ignition Spark Ignition

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Compression Ignition Engines Diesel or dual fuel Heat from compression auto-ignites

fuel & air mixture Two-stroke & four-stroke Diesel trucks

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Compression Ignition

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Spark Ignition Engines

Gasoline or natural gas Spark plug ignites fuel/air mixture Motor vehicle Two-stroke or Four-stroke Lean burn or rich burn

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Rich Burn Excess fuel in combustion chamber

during combustion Mfg. recommends operating air/fuel

ratio divided by stoichiometric at full load = < 1.1

Existing with no mfg. recommendations if O2 in exhaust at full load < 2%

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Lean Burn Excess air in combustion chamber O2 rich exhaust Not rich burn

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Spark Ignition

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Nebraska Sources

LOTS? 96+ facilities have notified

Multiple engines on-site Many more that don’t need to notify

Mostly municipal power plants & asphalt/concrete

Most compression ignition

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Rule Background

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Rule Background

NESHAP Subpart ZZZZ 40 CFR Part 63 – 63.6580 Title 129, Chapter 28 001.88 (not

current rules)

Initial final rule = 6/15/04 (effective 8/16/04)

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Rule Background 4 significant rule actions

Original: June 15, 2004 Revision: January 18, 2008 (effective 3/18/08) Revision: March 3, 2010 (effective 5/3/10) Revision: August 20, 2010 (effective 10/19/10)

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Applicability

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Applicability

Stationary sources Major & area sources of HAP New & existing sources

Need to know: Manufacture date, installation date, startup date,

fuel, engine type, horsepower, displacement, black start, emergency or non-emergency

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Applicability

Not subject Not engines tested @ test cell/stand RICE for national security

Request exemption 40 CFR Part 1068, Subpart C

Existing emergency residential, commercial, or institutional at area source

Some existing > 500 HP at major source

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Applicability

Residential, commercial, institutional Homes & apartments Office, hotel, stores, restaurants, banks,

etc. Hospitals, schools, police station, fire, etc.

Farming – not exempt Most smaller engines

See Air Toxics Notebook for list

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Emergency Engines

Emergency & required testing & maintenance

Not peak shaving for your facility or the grid

Does not have interruptible service contract with power utility

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Emergency Engines

Can be used up to 15 hours/yr as part of demand response

Can supply emergency power as part of financial agreement

100 hours/yr – testing & maintenance 50 hours/yr for non-emergency Includes 15 hours for demand response

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Reconsideration

12/7/10 15 hours for demand response

Emergency conditions could lead to potential blackout (unusually low frequency, equipment overload, capacity or energy deficiency, or unacceptable voltage level)

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Black Start & Limited Use

Black Start Used to start combustion turbines Different terminology than industry

Limited Use Operate < 100 hours/yr

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Requirements

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Source Classification

Area SourceExisting = Before 6/12/06

Change in ownership doesn’t make new

New = On or after 6/12/06

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Source Classification

Major Source Existing

> 500 HP = Before 12/19/02 < 500 HP = Before 6/12/06

New > 500 HP = On or after 12/19/02 < 500 HP = On or after 6/12/06

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Typical Controls

Oxidation Catalyst Spark ignition lean burn & compression

ignition Selective Catalytic Reduction (SCR)

Spark ignition lean burn & compression ignition

Non-selective Catalytic Reduction (NSCR) Spark ignition rich burn

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Catalysts

Causes chemical reactions without being changed or consumed

Steel housing contains a metal or ceramic structure which acts as a catalyst support or substrate.

No moving parts, interior surfaces coated with base or precious catalytic metals

Chemical reaction differs depending on lean, rich, or stoichiometric

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Oxidation Catalyst

Flow through honeycomb coated with platinum metals

Small parallel channels = high catalytic contact area to exhaust

Completes combustion & mixed with free O2 in exhaust

Pollutants oxidized into CO2 & H2O vapor Doesn’t reduce NOx

May need to be combined with SCR

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Diesel Oxidation Catalyst

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Selective Catalytic Reduction Converts NOx with aid of catalyst

into N2 and H2O Anhydrous ammonia, aqueous

ammonia or urea added to exhaust & absorbed onto catalyst CO2 is a reaction product when urea is

used

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Selective Catalytic Reduction (SCR)

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Diesel SCR

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Non-selective Catalytic Reduction (NSCR) Also Three-Way Catalysts

(stoichiometric) Causes CO to react with NOx in

presence of catalyst Creates N2 and H2O vapor

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Area Sources

Compression Ignition (SI)Spark Ignition (SI)

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No Requirements

Existing Emergency residential,

commercial, & institutional at area

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No NESHAP Requirements May Be Subject to NSPS

New area sources

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Existing CI @ Area

Work practice Emergency (hour meter) Black start Non-emergency < 300 HP

Numerical standards Non-emergency > 300 HP

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Work Practice Standards

Engine Type & Requirement

Oil Change& Filter replaced

Inspect Air Cleaner

Inspect Hoses & Belts

Emergency & Black Start

500 hours or annually

1,000 hours or annually


Non-emergency < 300 HP




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RecordsMalfunctionsMaintenanceEmergency – hours of operation

No reports or notifications required

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Non-emergency > 300 HP

CO limits Initial Testing Closed crankcase Sulfur fuel requirements <

30 l/cyl

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Meet all from previous slide and Periodic testing

Every three years or 8,760 hours Limited use = Every five years or 8,760

hours Continuous monitoring

CPMS CEMS

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Initial notification 8/31/10

Performance test60 days prior to test

Compliance StatusWithin 60 days after test

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ReportsSemiannual

Malfunctions & deviationsEven if noneDue 30 days after calendar half or

according to Title V scheduleAnnual if limited use

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RecordsNotifications & reportsMalfunctionsTest dataCPMS & CEMS data (> 500 HP)

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All Existing CI @ Area

Startup requirementsMinimize idle time to < 30

min. Compliance date 5/3/13

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Existing SI @ Area 8/20/10 rules Work practice

Emergency (hour meter installed) Black Start Non-emergency

4SLB & 4SRB > 500 HP operates < 24 hr/yr 4SLB & 4SRB < 500 HP 2SLB Landfill/digester gas

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Inspect Spark Plugs


Emergency & Black Start




Non-emergency Landfill/Digester




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Inspect Spark Plugs


Non-Emergency 2SLB




Non-emergency 4SLB & 4SRB < 500 HP




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Inspect Spark Plugs


Non-Emergency 4SLB & 4SRB > 500 HP operate < 24 hrs/yr




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4SLB & 4SRB > 500 HP operates > 24 hr/yr Numerical standards

CO (4SLB) or Formaldehyde (4SRB) limits May need controls & operational

parameters CPMS or CEMS

Initial & periodic testing Every three years or 8,760 hours Limited use = Every five years or 8,760 hours

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4SLB & 4SRB > 500 HP operates > 24 hr/yr


Performance Test60 days prior to test

Compliance StatusWithin 60 days of test

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ReportsSemiannual



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RecordsNotifications & reportsMalfunctionsTest dataCPMS & CEMS data

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All Existing SI @ Area

All have startup requirementsMinimize idle time to < 30 min.

Compliance date 10/19/13

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Major Sources

Existing CIExisting SI < 500 HP

New SI 4SLBOther > 500 HP

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No Requirements Existing @ major

Limited use & emergency > 500 HP Spark ignition 4SLB & 2SLB > 500 HP Landfill/Digester > 500 HP

New @ major Constructed between 6/12/06 –

1/1/08 spark ignition 4SLB > 250 HP < 500 HP

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No NESHAP Requirements May Be Subject to NSPS

New sources @ major source < 500 HP

Emergency and limited use Non-emergency compression ignition Spark ignition 4SLB < 250 HP Spark ignition 2SLB & 4SRB Landfill/digester

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Limited NESHAP Requirements May Be Subject to NSPS (@ major) Initial notification only

New emergency and limited use > 500 HP Monitoring & recordkeeping

New landfill/digester > 500 HP Hour meter installed

New, emergency manufactured after 1/1/08 spark ignition 4SLB > 250 < 500 HP

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Existing CI @ Major

3/3/10 rules Work practice

Emergency (hour meter) < 500 HP Black start < 500 HP Non-emergency < 100 HP

Numerical standards Non-emergency > 100 HP

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Inspect Air Cleaner


Emergency & Black Start < 500 HP








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Records Malfunctions Maintenance Emergency – hours of operation


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Non-emergency >100 HP

CO limits Initial testing > 300 HP

Closed crankcaseFuel requirements < 30 l/cyl

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Non-emergency > 500 HP Meet all from previous slide and Periodic testing

Every three years or 8,760 hours Limited use = Every five years or

8,760 hours Continuous monitoring

CPMS CEMS

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Performance test60 days prior to test


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ReportsSemiannual



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RecordsNotifications & reportsMalfunctionsTest dataCPMS or CEMS data (> 500

HP)

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All Existing CI @ Major

Startup requirementsMinimize idle time to < 30 min.


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Existing SI @ Major < 500 HP

8/20/10 rules Work practice

Emergency (hour meter installed) & Black Start < 500 HP


Numerical standards Non-emergency > 100 < 500 HP

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Inspect Spark Plugs


Emergency & Black Start < 500 HP




Non-emergency < 100 HP (not 2SLB)




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Inspect Spark Plugs


Non-emergency 2SLB < 100 HP




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Existing SI @ Major >100 < 500 HP

CO or Formaldehyde Limit

May need controls Initial testing

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Compliance StatusWithin 60 days of test

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ReportsSemiannual



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RecordsNotifications & reportsMalfunctionsTest data

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All Existing SI @ Major < 500 HP All have startup requirements

Minimize idle time to < 30 min.


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New SI 4SLB @ Major > 250 < 500 HP

1/18/08 rules Manufactured after 1/1/08 > 250 and < 500 HP Numerical standards

Formaldehyde or CO limit

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Initial testing Periodic testing

Semiannual if no CEMS & reducing CO Semiannual if reducing formaldehyde Can reduce to annual

Continuous monitoring CPMS CEMS

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Initial Notification 7/16/08 120 days after startup (startup after 3/18/08)

Performance Test 60 days prior to test

Compliance Status Within 60 days after test

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ReportsSemiannual



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Records Notifications & reports Malfunctions Test data CPMS & CEMS data

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Compliance 1/18/08 or startup

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Major sources > 500 HP

6/15/04 Rules Existing

SI 4SRB New

SI 4SRB, 4SLB, 2SLBCI

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Numerical standards for formaldehyde or CO

Initial testing

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Periodic testing Semiannual if no CEMS & reducing CO Semiannual if reducing formaldehyde Can reduce to annual

Continuous monitoring CPMS CEMS

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Initial Notification 12/13/04 (existing) 120 days after startup (new - startup after

8/16/04) Performance Test

60 days prior to test Compliance Status

Within 60 days after test

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ReportsSemiannual



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RecordsNotifications & reportsMalfunctionsTest dataCPMS & CEMS data

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Compliance 6/15/07 (existing) and 8/16/04 or startup (new)

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Testing

Option for 2SLB, 4SLB, & CI to use portable CO/O2 Analyzer

Not an option for 4SRB or reducing formaldehyde

May reduce costs of testing Might be able to use previous

test – 2 years from rule

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Requirements Summary

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No NESHAP Requirements

Existing Area – Emergency residential,

commercial, institutional Major

Limited use & emergency > 500 HP SI 4SLB & 2SLB > 500 HP Landfill/digester > 500 HP

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No NESHAP - NSPS

New SourcesAll areaMajor < 500 HP

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Limited NESHAP – Maybe NSPS New, major

> 500 HP Emergency & Limited Use (notify) Landfill/digester (monitoring &

recordkeeping) < 500 HP

Emergency 4SLB > 250 HP mfg. after 1/1/08 (hour meter)

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Work Practice

Existing Area Emergency & Black Start CI & SI Non-emergency

CI < 300 HP SI Landfill/digester SI 2SLB SI 4SLB & 4SRB < 500 HP SI 4SLB & 4SRB > 500 HP < 24 hrs/yr

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Work Practice

Existing Major Emergency & Black Start – CI & SI

< 500 HP Non-emergency CI & SI < 100 HP

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Numerical Standards

Existing Area Non-emergency CI > 300 HP SI > 500 HP > 24 hrs/yr

Existing Major Non-emergency CI > 100 HP SI > 100 HP < 500 HP SI 4SRB > 500 HP

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Numerical Standards

New Major Non-Emergency SI 4SLB > 250 HP < 500 HP mfg.

after 1/1/08 SI 4SRB > 500 HP SI 4SLB > 500 HP SI 2SLB > 500 HP CI > 500 HP

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Compliance Date Summary 10/19/13

Existing SI @ area and major (< 500 HP) 5/3/13

Existing CI @ area and major 1/18/08

New 4SLB > 250 HP < 500 HP @ major 6/15/07

Majors > 500 HP

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Initial Notification Summary (not work practice) Due 2/16/11

Existing SI @ area and major (< 500 HP) Due 8/31/10

Existing CI @ area and major Due 7/16/08

New 4SLB > 250 HP < 500 HP @ major Due 12/13/04

Majors > 500 HP

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Other Notifications



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Reports Summary

Only subject to numerical standards

Semiannual Malfunctions & deviations Even if none Due 30 days after calendar half or

according to Title V schedule Annual if limited use

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Records Summary

Notifications & reports Malfunctions Maintenance (work practice) Hours operated (emergency) Test data (numerical) CPMS & CEMS data (some

numerical) Landfill/digester

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Tips, Tools, & Resources

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Tips

Many small municipalities affected Cost of compliance ~$100,000 Many have agreements with NPPD,

NMPP, etc. Dedicating some to emergency & some

non- Reconsideration of demand response

may help

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Permitting Tips

Engine Identification Nonroad or stationary? Emergency, non-, fuel, HP, LB/RB,

4S/2S etc. Mostly power plants, concrete,

& asphalt plants

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Inspection Tips

May not inspect many area sources Area Source Implementation Strategy

Following work practice – probably not inspecting Some may be permitted

Mostly power plants

Emergency operation Check contracts If operate not following emergency –

automatically non-emergency & must comply

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Tools & Resources

Air Toxics Notebook Citations guidance (just updated) EPA guidance – just updated LOTS of info!

Part of National Workgroup Will share all tools/resources

developed or obtained by that group

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Questions/Comments?

Look for the feedback survey in your email!!

Download - NDEQ NESHAP Training Subpart ZZZZ - Engines

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