ndeq neshap training subpart zzzz - engines
DESCRIPTION
NDEQ NESHAP Training Subpart ZZZZ - Engines. Melissa Ellis February 24, 2011. Overview. Objectives Industry Overview Rule Background Applicability Requirements Tips Tools & Resources. Acronyms. HP = horsepower CI = compression ignition SI = spark ignition 4S = four stroke - PowerPoint PPT PresentationTRANSCRIPT
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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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Spark Ignition Engines
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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Spark Ignition Engines
Lean Burn Excess air in combustion chamber O2 rich exhaust Not rich burn
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Spark Ignition
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Spark Ignition Engines
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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
500 hours or annually
Non-emergency < 300 HP
1,000 hours or annually
1,000 hours or annually
500 hours or annually
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Work Practice Standards
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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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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Non-emergency > 300 HP
Initial notification 8/31/10
Performance test60 days prior to test
Compliance StatusWithin 60 days after test
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Non-emergency > 300 HP
ReportsSemiannual
Malfunctions & deviationsEven if noneDue 30 days after calendar half or
according to Title V scheduleAnnual if limited use
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Non-emergency > 300 HP
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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Work Practice Standards
Engine Type & Requirement
Oil Change& Filter replaced
Inspect Spark Plugs
Inspect Hoses & Belts
Emergency & Black Start
500 hours or annually
1,000 hours or annually
500 hours or annually
Non-emergency Landfill/Digester
1,440 hours or annually
1,440 hours or annually
1,440 hours or annually
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Work Practice Standards
Engine Type & Requirement
Oil Change& Filter replaced
Inspect Spark Plugs
Inspect Hoses & Belts
Non-Emergency 2SLB
4,320 hours or annually
4,320 hours or annually
4,320 hours or annually
Non-emergency 4SLB & 4SRB < 500 HP
1,440 hours or annually
1,440 hours or annually
1,440 hours or annually
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Work Practice Standards
Engine Type & Requirement
Oil Change& Filter replaced
Inspect Spark Plugs
Inspect Hoses & Belts
Non-Emergency 4SLB & 4SRB > 500 HP operate < 24 hrs/yr
500 hours or annually
1,000 hours or annually
500 hours or annually
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Work Practice Standards
RecordsMalfunctionsMaintenanceEmergency – hours of operation
No reports or notifications required
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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
Initial notification 2/16/11
Performance Test60 days prior to test
Compliance StatusWithin 60 days of test
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4SLB & 4SRB > 500 HP operates > 24 hr/yr
ReportsSemiannual
Malfunctions & deviationsEven if noneDue 30 days after calendar half or
according to Title V scheduleAnnual if limited use
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4SLB & 4SRB > 500 HP operates > 24 hr/yr
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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Work Practice Standards
Engine Type & Requirement
Oil Change& Filter replaced
Inspect Air Cleaner
Inspect Hoses & Belts
Emergency & Black Start < 500 HP
500 hours or annually
1,000 hours or annually
500 hours or annually
Non-emergency < 100 HP
1,000 hours or annually
1,000 hours or annually
500 hours or annually
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Work Practice Standards
Records Malfunctions Maintenance Emergency – hours of operation
No reports or notifications required
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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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Non-emergency > 100 HP
Initial notification 8/31/10
Performance test60 days prior to test
Compliance StatusWithin 60 days after test
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Non-emergency > 100 HP
ReportsSemiannual
Malfunctions & deviationsEven if noneDue 30 days after calendar half or
according to Title V scheduleAnnual if limited use
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Non-emergency > 100 HP
RecordsNotifications & reportsMalfunctionsTest dataCPMS or CEMS data (> 500
HP)
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All Existing CI @ Major
Startup requirementsMinimize idle time to < 30 min.
Compliance date 5/3/13
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Existing SI @ Major < 500 HP
8/20/10 rules Work practice
Emergency (hour meter installed) & Black Start < 500 HP
Non-emergency < 100 HP
Numerical standards Non-emergency > 100 < 500 HP
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Work Practice Standards
Engine Type & Requirement
Oil Change& Filter replaced
Inspect Spark Plugs
Inspect Hoses & Belts
Emergency & Black Start < 500 HP
500 hours or annually
1,000 hours or annually
500 hours or annually
Non-emergency < 100 HP (not 2SLB)
1,440 hours or annually
1,440 hours or annually
1,440 hours or annually
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Work Practice Standards
Engine Type & Requirement
Oil Change& Filter replaced
Inspect Spark Plugs
Inspect Hoses & Belts
Non-emergency 2SLB < 100 HP
4,320 hours or annually
4,320 hours or annually
4,320 hours or annually
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Work Practice Standards
RecordsMalfunctionsMaintenanceEmergency – hours of operation
No reports or notifications required
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Existing SI @ Major >100 < 500 HP
CO or Formaldehyde Limit
May need controls Initial testing
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Existing SI @ Major >100 < 500 HP
Initial notification 2/16/11
Performance Test60 days prior to test
Compliance StatusWithin 60 days of test
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Existing SI @ Major >100 < 500 HP
ReportsSemiannual
Malfunctions & deviationsEven if noneDue 30 days after calendar half or
according to Title V scheduleAnnual if limited use
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Existing SI @ Major >100 < 500 HP
RecordsNotifications & reportsMalfunctionsTest data
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All Existing SI @ Major < 500 HP All have startup requirements
Minimize idle time to < 30 min.
Compliance date 10/19/13
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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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New SI 4SLB @ Major > 250 < 500 HP
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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New SI 4SLB @ Major > 250 < 500 HP
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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New SI 4SLB @ Major > 250 < 500 HP
ReportsSemiannual
Malfunctions & deviationsEven if noneDue 30 days after calendar half or
according to Title V scheduleAnnual if limited use
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New SI 4SLB @ Major > 250 < 500 HP
Records Notifications & reports Malfunctions Test data CPMS & CEMS data
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New SI 4SLB @ Major > 250 < 500 HP
All have startup requirementsMinimize idle time to < 30 min.
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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Major sources > 500 HP
Numerical standards for formaldehyde or CO
Initial testing
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Major sources > 500 HP
Periodic testing Semiannual if no CEMS & reducing CO Semiannual if reducing formaldehyde Can reduce to annual
Continuous monitoring CPMS CEMS
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Major sources > 500 HP
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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Major sources > 500 HP
ReportsSemiannual
Malfunctions & deviationsEven if noneDue 30 days after calendar half or
according to Title V scheduleAnnual if limited use
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Major sources > 500 HP
RecordsNotifications & reportsMalfunctionsTest dataCPMS & CEMS data
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Major sources > 500 HP
All have startup requirementsMinimize idle time to < 30 min.
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
Performance Test60 days prior to test
Compliance StatusWithin 60 days after test
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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!!