Workshop B

Managing Engine Compliance … Best

Practices for a RICE/ICE Compliance Plan

Tuesday, March 22, 2016 9:45 a.m. to 11 a.m.

1

Biographical Information

William J. Bruscino, C.M. Manager of Consulting Services

Trinity Consultants 8425 Pulsar Place, Suite 280, Columbus, Ohio 43240

Phone: 614.433.0733 Fax: 614.433.0734 bbruscino@trinityconsultants.com

Mr. Bruscino manages air quality permitting and compliance services for industries such as refining, chemical manufacturing upstream and midstream oil and gas, and general manufacturing. His experience includes Title V and PSD permitting in EPA Regions IV, V, and VI as well as compliance assessments and implementation projects. Mr. Bruscino has recently been directing efforts for numerous energy audits required by the Boiler MACT rule as well as general 3rd party compliance audits throughout the state of Ohio. He has also assisted multiple facilities in establishing Title V and minor source air compliance programs including environmental management information system (EMIS) implementations. Mr. Bruscino currently manages Trinity’s Columbus, Ohio office and is a member of the Air & Waste Management Association. He received a Bachelor’s degree in chemical engineering from the University of Cincinnati.

James W. Sumner, QEP US Region – Air Leader

Global Operations, Environment, Health & Safety General Electric Company

(513) 607-0590 jim.sumner@ge.com Jim Sumner is an air program leader with GE’s Global Operations, Environment, Health & Safety team. In this role, Jim supports GE facilities across the US. He has over 37 years’ experience in the EHS management field including extended environmental and international experience. This includes environmental policy and concepts, permitting, regulatory advocacy, and air, water, and waste management. Prior to joining GE Jim worked for 10 years at the Ohio EPA where he was supervisor for the Air Pollution Control Program within the Southwest District. Jim graduated with honors from Florida Institute of Technology with a Bachelor’s Degree in Environmental Science and is certified as a Qualified Environmental Professional (QEP). Professional memberships include the Air & Waste Management Association and the Water Environment Federation.

MEC Workshop BB – Managing Engine Compliance

Focusing on NSPS IIII, NSPS JJJJ and NESHAP ZZZZ (“RICE MACT”)

Cincinnati, OH – March 22, 2016

Mr. Jim Sumner - GEMr. William Bruscino - Trinity

Engine Background

Engine

˃ Technically, “Engine” = “Motor” = a machine designed to convert energy into useful mechanical motion

˃ Commonly, “Engine” = Heat Engine = an engine that combusts (oxidizes)fuel to create heat energy, which is converted to motion C. 1910 single‐cylinder gasoline engine

EPA’s Categorization of Engines = Key Terms

Reciprocating

Internal Combustion

Displacement

Rich v. Lean Burn˃ Rich burn (RB)

more fuel, less air˃ Lean burn (LB)

less fuel, more air Lower combustion

temperature Up to 50:1 A/F ratios

for spark ignition engines and 500:1 for diesel engines♦ Flame extinction/

stability issues

For Gasoline

EPA Draws a Different Line

˃ Some theoretical LB RICEare considered RB by EPA Any engine where the

recommended A/F ratio divided by the ideal A/F ratio at full load is less than or equal to 1.1

λ = 1.1, which equates to an A/F ratio of ~16:1 and~2% excess O2

λ = 1.1 For Gasoline

Federal Engine Regulations –Brief Overview

Federal RegulationsOur Focus

˃ 40 CFR Part 60 Subpart IIII, Standards of Performance for [New] Stationary CompressionIgnition Internal Combustion Engines (CI ICE NSPS)

˃ 40 CFR Part 60 Subpart JJJJ, Standards of Performance for [New] Stationary SparkIgnition Internal Combustion Engines (SI ICE NSPS)

˃ 40 CFR Part 63 Subpart ZZZZ, National EmissionStandards for Hazardous Air Pollutants for Stationary Reciprocating Internal Combustion Engines (RICE NESHAP)

˃ Also, Subpart A for each Part

Introduction to QUAD-ZILLA

“[this] is the most complicated and confusing regulation in the entire suite of EPA NSPS and NESHAPS regulations, bar none. We seriously believe that a viable defense could be mounted against an EPA enforcement action with the simple but true statement, 'Your honor, we honestly could not discern our obligation under the rule in a timely manner.‘”

- Public comment submitted in response to EPA’s request for public input on improving regulations per Executive Order 13563

Summary of Regulated Engine Pollutants

NSPS JJJJ NSPS IIII RICE MACT

VOC NMHC/HC

Formaldehyde and CO (as surrogates for Total 

HAPs)

NOx NOx

CO CO

PM

Criteria Pollutants HAPs

˃ 40 CFR 89 - New and In-Use Nonroad CI Engines Tiers 1, 2, and 3

˃ 40 CFR 1039 - New and In-Use Nonroad CI Engines Tier 4

˃ 40 CFR 90 – Nonroad SI Engines < 19 kW˃ 40 CFR 1048 – New Nonroad SI Engines > 19 kW˃ 40 CFR 1054 – New Small Nonroad SI Engines˃ 40 CFR 94 - Marine CI Engines

Tier 2˃ 40 CFR 1042 - New and In-use Marine CI Engines

Tiers 3 and 4˃ 40 CFR 91 - Marine SI Engines˃ 40 CFR 1045 – Marine SI Engines˃ For more information, e.g., history, about Tier

standards, http://www.dieselnet.com/standards

Federal Regulations Others

Nonroad and Marine Engines

Nonroad and Marine Engines˃ Not subject to IIII, JJJJ, & ZZZZ˃ Marine ICE…an integral part of a marine vessel˃ Nonroad (or “Non-road”) engine means any ICE

that is in or on a piece of equipment that is… self-propelled (may serve other purposes too); or propelled while performing its function; or portable or transportable

♦ Designed to be moved, e.g., on wheels or skids, etc.♦ And actually is moved routinely♦ Portability is moot if it remains [in service] at a location

(building, structure, facility, or installation)…– for more than 12 months…or…– for seasonal sources, for the entire season

(3 months or more) for at least 2 years

1068.30, 89.2, 90, 91, 94, 1039, 1042, 1045, 1048, 1054

“Mobile” = Onroad + Nonroad + Marine

Temporary Exemption – Two Big Caveats1. Replacing one temporary engine with

another to be used for the same purpose does not restart the 12-month clock

The 12-month clock applies to the location and purpose, not a particular engine

2. An engine to be used temporarily in place of a stationary engine (e.g., while it is being overhauled) is considered a stationary engine

The location and purpose is stationary even if it consists of more than one engine over time

NSPS IIIIStandards of Performance for Stationary [New] CompressionIgnition Internal Combustion Engines

(Original proposal for CI ICE NSPS was in 1979; it was never finalized)

NSPS IIII Applicability

˃ Potentially applies to: All stationary compression-ignition engines

♦ Reciprocating, rotary, other (except turbines)

Of any size (horsepower rating) Emergency & Non-Emergency

˃ If: Constructed (ORDERED) after 7/11/2005 and

manufactured after 4/1/2006 Modified or reconstructed after 7/11/2005

60.4200

Exemptions

˃ Engines at test stands˃ National security exemption (upon

request) Informal indications are that this is meant

for true military purposes˃ Engines manufactured as certified NFPA

fire pump engine before 7/1/06 or modified/reconstructed to meet NFPA certification before 7/11/05

60.4200(b) & (d)

NSPS IIII Emission Standards˃ Pollutants: NMHC/HC, NOX, NMHC+NOX,

CO, PM˃ The rule is modeled after the mobile

(nonroad and marine) standards˃ General engine categories:

Per-cylinder displacement < 10 L 10 L ≥ per-cylinder displacement > 30 L Per-cylinder displacement ≥ 30 L Emergency Fire pump

60.4204 & 4205

NSPS IIII Emission Standards˃ For displacement < 10 L/cylinder

Meet nonroad “Tier” standards♦ Tiers 1, 2, & 3 in 89.112♦ Tier 4 in 1039.102♦ Specific requirements depend on use, model

year, displacement, and power Emergency engines are exempt from the

most stringent (Tier 4) standards Delayed schedule for fire pump engines

60.4204 & 4205

NSPS IIII Emission Standards˃ For 10 L/cylinder ≥ Displacement < 30

L/cylinder “Tier” standards for marine engines

♦ Tier 2 in Part 94; Tiers 3 and 4 in Part 1042

Emergency engines are exempted from most stringent (i.e., Tier 4) standards

˃ For Displacement ≥ 30 L/cylinder Standards for large marine engines

♦ Achievable via the use of SCR & ESP

60.4204 & 4205

Import / Install DeadlinesRegardless of manufacture date, i.e., so for old engines, certain engines imported or installed after the following dates must meet the emission standards for the previous model year

60.4208

Type / Size Import/Install Deadline Model Year Standards

All (excluding fire pump ICE) 12/31/2008 2007

HP < 25 12/31/2009 2008

25 ≥ HP < 75 12/31/2014 2013

75 ≥ HP < 175 12/31/2013 2012

HP ≥ 175 12/31/2012 2011

HP ≥ 750 12/31/2016 2015

804 ≥ HP < 2680and 10 ≥ Disp. (L) < 30

12/31/2018 2017

* These provisions were added to prevent stockpiling of earlier Tier engines.** They do not apply to modified or reconstructed or moved (from one plant site to another) engines

NSPS IIII Compliance Requirements˃ Displacement < 30 L/cylinder

Purchase certified engine and follow manufacturer instructions or

Conduct initial testing (and subsequent testing if > 500 hp) and

Develop and follow a maintenance plan If pre-2007 model year, additional options:

♦ Test of a similar engine or data from engine manufacturer or control vendor indicating compliance

˃ Displacement ≥ 30 L/cylinder Testing and control device monitoring

60.4211

Engine Manufacturer Certifications˃ Engine manufacturers must certify 2007

model year and later engines <30 L/cyl.

60.4201

NSPS IIII Fuel Requirements60.4207

Cetane is a measure of ignitability of diesel fuel

Emergency Engines

See discussion of definition and operational requirements in MACT ZZZZ section

60.4211(f)

Useful References

˃ Flowcharts˃ EPA Websites

NSPS IIII reg, background info, and implementation toolshttp://www.epa.gov/ttn/atw/icengines/

Summary spreadsheet http://www.epa.gov/region1/rice Reg Navigator

http://www.epa.gov/ttn/atw/rice/output/quiz.html

˃ Florida DEP spreadsheets www.dep.state.fl.us/air/emission/engine_pump_tools.htm

NSPS JJJJStandards of Performance for Stationary [New] SparkIgnition Internal Combustion Engines

NSPS JJJJ Applicability˃ Potentially applies to:

All stationary spark-ignition engines♦ Reciprocating, rotary, other (except turbines)

Of any size (horsepower rating) That fires any fuel Emergency & Non-Emergency

˃ Exemptions: Engines at test stands National security exemption (upon request)

60.4230

Owners/operators of ICE modified or reconstructed after 6/12/2006

NSPS JJJJ ApplicabilityConstructed (ORDERED) after 6/12/2006 and 

manufactured after…

60.4230, 4236

Type / Size Manufactured Date

≥ 500 HP except LB 500 ≤ HP < 1350

7/1/2007

LB 500 ≤ HP < 1350 1/1/2008

< 500 hp 7/1/2008

Emergency > 25 hp 1/1/2009

If < 25 hp, no emergency / non‐emergency differentiation

NSPS JJJJ Standards˃ Emission standards for HC/NMHC, NOX, CO,

and VOC (excluding CH2O) Depends on use, fuel, model year, and power

˃ All engines ≤ 25 hp All are certified by the manufacturer to standards

in 90 or 1054

˃ Engines > 25 hp Purchase voluntarily certified engine (standards in

1048 or Table 1) and follow manufacturer’s instructions or

Test and develop/follow a maintenance plan

Any gasoline must meet 80 ppm sulfur limit (40 CFR 80.195)

60.4233, 4235, 4244(f)

Import / Install DeadlinesRegardless of manufacture date, i.e., so for very old engines, any engines imported or installed after the following dates must meet the emission standards of 60.4233

60.4236

Type / Size Manufactured Date

≥ 500 HP except LB 500 ≤ HP < 1350

7/1/2007

LB 500 ≤ HP < 1350 1/1/2008

< 500 hp 7/1/2008

Emergency > 25 hp 1/1/2009

Import/Install Deadline

7/1/2009

7/1/2010

7/1/2010

1/1/2011

* These provisions were added to prevent stockpiling of earlier Tier engines.** They do not apply to modified or reconstructed or moved (from one plant site to another) engines

NSPS JJJJ RequirementsNon-Emergency and Emergency ICE

˃ Purchase a certified engine Follow mfr. Instructions…–or– maintenance plan Upon loss of certification, initial performance

test if ≥100 hp (within 1 year) and subsequent* performance tests if >500 HP

Cannot comply via non-certified options

˃ Non-certified Engines Maintenance plan Initial performance test if ≥25 hp

♦ Within 60/180 days

Subsequent* performance tests and initial notifications if >500 HP

* Every 8,760 hours or 3 years, whichever is first

60.4243

Required for:≤ 25 hp;> 25 hp gasoline;> 25 hp RB LPG

Required for:Modified and reconstructed engines

Emergency Engines

˃ See discussion of definition and operational requirements in MACT ZZZZ section

˃ Certain (depending on power and build date) emergency SI ICE not meeting non-emergency emissions standards must have a nonresettablehour meter: HP ≥ 500 HP “built” on or after 7/1/2010 130 ≤ HP < 500 “built” on or after 1/1/2011 HP < 130 “built” on or after 7/1/2008

“built” = “manufactured” based on reading of preambles

60.4243(d) & 4237

Useful References

˃ Flowcharts˃ EPA Website

NSPS JJJJ reg, background info, and implementation toolshttp://www.epa.gov/ttn/atw/icengines/

Summary spreadsheet Reg Navigator

http://www.epa.gov/ttn/atw/rice/output/quiz.html

˃ Florida DEP spreadsheets www.dep.state.fl.us/air/emission/engine_pump_tools.htm

˃ Texas flowchart 102 pages!

NESHAP ZZZZNational Emissions Standards for Hazardous Air Pollutants for Reciprocating Internal Combustion Engines

a.k.a., the RICE MACT

History of RICE MACT

Big, major engines; Limits based on catalytic controls; monitoring of T and ΔPRelatively few engines regulated at this point

Proposed 12/19/02

History of RICE MACT

Balance of new RICE, nearly all of which comply via NSPS (exception: 4SLB 250 - 500 hp, which complies with the 2004 rule requirements)

Proposed 6/12/06

History of RICE MACT

Balance of existing RICE; mix of management practices and emission limits based on catalytic controls

Proposed 3/5/09

RICE MACT Today˃ Applies to all stationary reciprocating ICE˃ Exemptions:

Engines at test stands National security exemption (upon request) Existing, emergency engines at residential,

commercial, and institutional area sources…♦ that do not operate and are not contractually obligated to

be available for more than 15 hr/yr for emergency demand response or voltage or frequency deviations

♦ that do not supply power as part of a financial arrangement with another entity

What if a headquarters “commercial” office building is co-located with a manufacturing plant?♦ Informally EPA has said that engines providing backup power

to the HQ building are exempt

63.6585

Existing v. New Sources˃ Determination based on “commence construction”

date (start of on-site construction, not ordered)

˃ What if an engine is relocated to a new facility? Relocation and/or a change in ownership of an existing

RICE does not make it new

63.6590(a)

Potential RICE MACT Requirements

˃ Emission limits (CO and CH2O)˃ Continuous & monthly monitoring (T and ΔP)

Monitoring system evaluations˃ Stack testing (emissions or catalyst activity)˃ Reporting and notifications˃ Management/work practices (maintenance)˃ Hour meter˃ Plans (testing, monitoring, maintenance)˃ Recordkeeping

Overview of Requirements for Existing CI Engines

Source Status Use category Rating Emission Limit(s)

Control Device Monitor

Initial Perform. Test

Ongoing Perform. Test

Initial Notif./Comp Reports

Work Practices/Maint. Plan

Hour Meter

Major

Non‐Emergency > 500 HP Non‐Emergency 300 – 500 HP Non‐Emergency 100 – 300 HP Non‐Emergency < 100 HP Emergency ≤ 500 HP Emergency > 500 HP No MACT Requirements

Limited Use > 500 HP No MACT Requirements

Limited Use ≤ 500 HP No Such Category – Limited Use Provisions Only Apply to Existing RICE if > 500 HP

Area

Non‐Emergency > 500 HP Non‐Emergency 300 – 500 HP Non‐Emergency < 300 HP Emergency Any

Note: Sometimes it is better to NOT be an emergency engine(same scenario with SI engines too)

Overview of Requirements for New CI Engines

Source Status Use category Rating Emission Limit(s)

Control Device Monitor

Initial Perform. Test

Ongoing Perform. Test

Initial Notif./Comp Reports

Hour Meter

Major

Non‐Emergency > 500 HP Non‐Emergency ≤ 500 HP Comply with NSPS Only

Emergency > 500 HP IN only Emergency ≤ 500 HP Comply with NSPS Only

Limited Use > 500 HP IN only NAbS

Limited Use ≤ 500 HP Comply with NSPS Only

Area ALL ALL Comply with NSPS Only

Overview of Requirements for Existing SI Engines

Source Status Use category ICE Type Rating Emission 

Limit(s)

Control Device 

Monitor / Engine 

Shutdown

Initial Perform. Test / Cat. Activity Check

Ongoing Perform. Test / Cat. Activity Check

Initial Notif./Comp Reports

Work Practices/Maint. Plan

Hour Meter

Major

Non‐Emergency 4SRB > 500 HP Non‐Emergency 2SLB, 4SLB > 500 HP No MACT Requirements

Non‐Emergency Landfill/Digester Gas > 500 HP No MACT Requirements

Non‐Emergency 2SLB, 4SLB, 4SRB 100 – 500 HP Non‐Emergency Landfill/Digester Gas 100 – 500 HP Non‐Emergency 2SLB, 4SLB, 4SRB < 100 HP Non‐Emergency Landfill/Digester Gas < 100 HP Emergency Any ≤ 500 HP Emergency Any > 500 HP No MACT Requirements

Limited Use Any > 500 HP No MACT Requirements

Limited Use Any ≤ 500 HP No Such Category – Limited Use Provisions Only Apply to Existing RICE if > 500 HP

Area

Non‐Emergency 4SLB, 4SRB > 500 HP Non‐Emergency 4SLB, 4SRB 

if <24 hrs/yr or remote > 500 HP Non‐Emergency 4SLB, 4SRB ≤ 500 HP Non‐Emergency 2SLB Any Non‐Emergency Landfill/Digester Any Emergency Any Any

Overview of Requirements for New SI Engines

Source Status Use category ICE Type Rating Emission Limit(s)

Control Device Monitor

Initial Perform. Test / Cat. Activity Check

Ongoing Perform. Test / Cat. Activity Check

Initial Notif./Comp Reports

Hour Meter

Major

Non‐Emergency 4SRB > 500 HP Non‐Emergency 2SLB > 500 HP Non‐Emergency 4SLB > 500 HP Non‐Emergency 4SLB 

If manf’d ≥ 1/1/08 250 – 500 HP

Non‐Emergency 4SLB If manf’d < 1/1/08 250 – 500 HP No MACT Requirements

Non‐Emergency 4SRB ≤ 500 HP Comply with NSPS Only

Non‐Emergency 2SLB ≤ 500 HP Comply with NSPS Only

Non‐Emergency 4SLB < 250 HP Comply with NSPS Only

Non‐Emergency Landfill/Digester Gas > 500 HP I.N. &Fuel usage

Non‐Emergency Landfill/Digester Gas ≤ 500 HP Comply with NSPS Only

Emergency ALL > 500 HP I.N. only Emergency ALL ≤ 500 HP Comply with NSPS Only

Emergency 4SLB If manf’d ≥ 1/1/08 250 – 500 HP

Limited Use ALL > 500 HP I.N. only NAbS

Limited Use ALL ≤ 500 HP Comply with NSPS Only

Area ALL ALL ALL Comply with NSPS Only

Work Practice Standards

˃ Minimize startup and idling time (30 minutes) Startup means the time from initial start

until applied load and engine and associated equipment (including catalyst) reaches steady state or normal operation

How do you demonstrate compliance? ♦ Log startups, durations?♦ Point to startup procedure?

63.6625 & 6640

˃ Develop and follow maintenance plan Or manufacturer’s emissions-related instructions

˃ Oil & filter changes on specified frequencies Generally, 4320 hrs for 2S; 1440 for 4S; 1000 hrs for

CI, and 500 hrs for emergency RICE Optional oil analysis program

˃ Inspections of spark plugs, belts, and hoses on specified frequencies Generally, 4320 hrs for 2S; 1440 for 4S; 500 hrs for

CI, and 500 or 1000 hrs for emergency RICE˃ Maintenance documentation will be key

Tables 1 – 4, 63.6625(e)

Maintenance As Work Practice

Oil Analysis Program

Parameter Condemning Limits

Total Base Number (TBN) – CI < 30% of new oil

Total Acid Number (TAN) – SI  Increases by more than 3.0 mg of potassium hydroxide per gram from TAN of new oil

Viscosity Changed by more than 20% from the viscosity of new oil

% Water Content by Volume > 0.5 %

˃ Oil analysis must be performed at same frequency specified for oil changes

˃ If condemned, change oil within 2 business days

˃ Must keep records of the analysis˃ You can petition EPA for use of alternative parameters

˃ But these are fairly generous already˃ “Our informal guidance has been that it would also extend the 

time for the filter change” ‐ EPA

63.6625(i) & (j)

˃ Operations logs˃ Records of startups and idling periods˃ Inspections / checklists˃ Maintenance logs˃ Document control

Maintenance Plan

Engines with NO Requirements

˃ Technically, still “affected sources”˃ At major sources, existing RICE > 500 hp:

SI 2SLB SI 4SLB Emergency

♦ If it does not operate and is not contractually obligated to be available for more than 15 hr/yr for emergency demand response or voltage or frequency deviations

Limited use (LU) Landfill or digester gas (LG/DG)

(>10% gross heat input annually)

63.6590(b)(3)

Original floor was ‘no control’. Will be reconsidered…in 8 years

Engines Subject To Limited Requirements

˃ At major sources, new and reconstructed RICE > 500 hp: Emergency

♦ If it does not operate and is not contractually obligated to be available for more than 15 hr/yr for emergency demand response or voltage or frequency deviations

♦ Initial notification only

Limited use♦ Initial notification only

Landfill or digester gas♦ Initial notification and daily fuel monitoring & reporting

63.6590(b)(1) & (2)

A Dilemma for Emergency, Limited Use, Landfill Gas, and Digester Gas Engines With No or Limited Requirements

˃ How do you prove that the engine qualifies as emergency or limited use or that it burns the required amount of LG or DG?

˃ And does the proof have to be enforceable?˃ Some states, e.g., Arkansas, say yes

So you end up being subject to the RICE MACT definition in 63.6640 for emergency or limited use (hours of operation limitations) or the minimum LG/DG usages

EPA recognizes the problem but doesn’t offer much help

Some Important DefinitionsLimited Use RICE˃ Operates 100 hours per year or less

Includes routine testing and maintenance

˃ The limited use exemptions only apply to the following RICE at major sources Existing, > 500 hp

♦ No requirements

New/reconstructed, ≤ 500 hp ♦ Comply with NSPS as applicable

New/reconstructed, > 500 hp ♦ Initial notification only

63.6675, 6590

Some Important DefinitionsEmergency RICE

˃ The RICE is operated to provide electrical power or mechanical work during an emergency situation

˃ Examples: Power generation during normal supply

interruptions Pumping water for fire suppression or flood

control

˃ Operational limitations in 63.6640(f)

63.6675

Emergency Use Requirements˃ No time limit on emergency operation˃ 100 hrs/yr* of non-emergency operation for:

Maintenance checks and readiness testing Emergency demand response (DR)

♦ For NERC-declared Energy Emergency Alert Level 2 periods

During voltage or frequency deviations of ≥ 5%

˃ 50 hrs/yr* of the 100 hrs/yr* can be used for… Any situation as long as there is no financial arrangement For existing area source emergency RICE,

♦ Local reliability

63.6640(f)

CAUTION: Local 

demand response rules vary 

widely

Remanded to EPA by May 1, 2015 D.C. Circuit Court ruling.  

Some states don’t allow some or all of these, e.g., NJ, MD, VA, D.C.

* Calendar year basis

Emergency Engine Records & Reporting

˃ Non-resettable hour meter Software (e.g., a PLC) is okay if tamper-proof /

non-resettable (unofficial determination)

˃ Reporting for emergency RICE > 100 HP if… Operated or contractually obligated to be available >

15 hours per year in emergency demand response Operated for periods where there is deviation of

voltage or frequency ≥ 5% Operated for local grid system reliability Annual reporting via EPA’s Compliance and Emissions

Data Reporting Interface beginning for operation during 2015 calendar year (due 3/31/2016)

63.6650(h)

Is it always worth the hassle?˃ No, for several types of engines, it is easier to

comply with non-emergency provisions than with emergency provisions Maintenance requirements only v.

maintenance requirements + hours records˃ Major source existing RICE < 100 hp˃ Area source existing CI RICE < 300 hp˃ Area source existing 4S RICE < 500 hp˃ Area source existing 2S RICE˃ Area source existing 4S remote RICE

Useful References˃ Flowcharts˃ EPA HQ Website: NESHAP ZZZZ reg, background info,

and implementation tools http://www.epa.gov/ttn/atw/icengines/ Reg. navigation tool

♦ Does not cover black start engines or remote/non-remote

Q&A documents; memos; cost information; etc.

˃ Some states and EPA Regions have RICE sites/tools Often difficult to navigate

Asset, Data, and Task Management

Asset Management

˃ Know what you have˃ To track hundreds of engines, O&G

companies are using Environmental Management Information Systems (EMIS) Keep track of relocations & replacements Email reminders of due dates

Engine Information To Track˃ Stationary or mobile? ˃ Is it at a major or area source facility?˃ What is its power output?

Nameplate Site-rated

˃ When was it… Manufactured? Ordered? Installed or contracted to be installed on site? Modified and/or reconstructed (if applicable)?

˃ Is it for emergencies only? Or is it limited use? Or is it a black start engine?

˃ What fuel(s) does it burn?˃ If it is spark ignited, is it 4SRB, 4SLB, or 2SLB?

For emission calculations purposes, you may also

need the efficiency or fuel consumption rate

Example Simple Inventory

Facility PRODUCTION POWER ENGINE  ENGINE  Mfg Order Startup ReconstructSITE COUNTY Type METHOD  1 SOURCE 2 MAKE / MODEL HP Date Date Date Date 3

Lonesome Dove

South comp sta Compression Gas Engine Cat. ???? 1800 <1994 <1994 1994 ?

Lonesome Dove

South comp sta Compression Gas Engine Cat. ???? 1801 <1994 <1994 1994 ?

Lonesome Dove

South comp sta Compression Gas Engine Wak. ??? 800 <1994 <1994 1994 ?

Hat Creek North gas well Compression Gas Engine Compressco ??? 14 <6/13/2003 <6/13/2003 6/13/2003 ?Hat Creek North gas well Compression Gas Engine Wak. ??? 425 <7/31/2003 <7/31/2003 7/31/2003 ?

1.  Production methods:  compression, plunger lift, rod pump2.  Power Source:  gas engine, electric, diesel engine3.  Reconstruction means more than 50% of the cost of comparable new engine

Information to Track

˃ Non-road engines: Date moved to location Date removed from location

˃ Rule applicability NSPS JJJJ/IIII, MACT ZZZZ Tier standard Monitoring/testing requirements

˃ Engine Certification (link to location)

What About Leased Engines?

˃ Treat them as if you own them˃ Some leasing companies have databases

that provide all the information you need to determine applicability and maintain compliance… But the operator is ultimately responsible to

the state and EPA

What About Contractor Engines?˃ Should you include contractor engines in

compliance program?˃ Best practices for ensuring compliance:

Request that they provide a list of engines they are bringing onsite:♦ Date log - date onsite/offsite♦ Size♦ Fuel type

Provide definition of “nonroad” ♦ Ensure engines are not used at one location for

more than 12 months

Examples, Case Studies, Interesting Dilemmas, Unresolved Questions…and some Guidance

Engine v. Compressor˃ Used to be asked a lot…˃ At a natural gas compressor station, a brand

new reciprocating compressor is coupled with an old (2001 vintage) but rebuilt engine…

˃ The compressor is subject to NSPS OOOO (standards for upstream O&G facilities)

Rod packing change-out requirements

˃ The engine is subject to MACT ZZZZ It could have also triggered NSPS JJJJ if the

rebuild had cost more than 50% of a new engine

Stationary Engines Ex. 1

˃ Common in “remote” areas:˃ An engine used to generate electric power

during initial construction until utilities are available at a site…

˃ Is not a stationary engine if it does not remain on site for more than 12 months Therefore it is not subject to NSPS or MACT May still need to be permitted

Stationary Engines Ex. 2˃ Examples common in the forest products,

metals, and minerals industries.˃ An engine that is routinely (more often than

every 12 months) moved from location to location within a facility site… e.g., portable welders, chippers, crushers, ladle

pushers, water pumps, etc.˃ Is not a stationary engine

It is a nonroad engine Therefore it is not subject to NSPS or MACT May still need to be permitted

Stationary Engines Ex. 3

˃ An engine that is temporarily (< 12 months) used in place of a stationary engine that performs the same function as the stationary engine…

˃ Is considered a stationary engine Review NSPS and MACT applicability!

˃ This is clear based on a June 7, 2013 email from Melanie King, but not all companies are adhering to the policy

NSPS Modification Example˃ Bi-fuel technology is retrofitted to a diesel engine

New equipment is external to engine itself♦ Injects natural gas into the air intake

Increases hourly CO emissions˃ Does this meet NSPS modification definition?

Yes, while it is arguably not a physical change to the engine, it is a change in the method of operation, and…

It increases hourly emissions of an NSPS regulated pollutant

˃ What if oxidation catalyst is also installed so that the CO lb/hr emission rate does not increase? The phrase, “to the atmosphere” has been clarified

by EPA guidance to be emissions after reduction by control device

Be wary of inconsistency among NSPS-delegated states

Reconstructing on purpose

˃ Existing major source 380-hp 4SRB RICE that operates ~200 hrs/yr (so not emergency or limited use)

˃ MACT ZZZZ requires continuous T and monthly ΔP monitoring

˃ Upon reconstruction, MACT ZZZZ simply points to NSPS JJJJ

˃ NSPS JJJJ requires testing but notmonitoring

MACT allows 30 minutes for startup. Why doesn’t NSPS?

˃ Are you out of compliance with NSPS during every startup until the catalyst activates?

˃ No, per Melanie King (2/2014), see 60.8(c) …nor shall emissions in excess of the level of

the applicable emission limit during periods of startup, shutdown, and malfunction be considered a violation...

60.8(c), Feb. 2014 email from Melanie King

Certificate of ConformityExpirations and Disclaimers˃ The easiest compliance requirement for many NSPS

engines is to purchase a certified engine˃ But these certifications expire˃ And some certificates have a disclaimer that

certified emissions are only good for XXX hours of operation

˃ Neither document expiration nor operation limitation exceedances results in noncompliance with the NSPS rules

˃ The NSPS requirements are to (1) purchase a certified engine and (2) operate and maintain it according to manufacturer instructions See RTC for July 11, 2005 proposed IIII rule

The Flex Program for Stationary RICE?˃ Some manufacturers are claiming that

you can comply with NSPS IIII for stationary RICE by purchasing engines built under the flex program (1039.625(e)(2)) Lower standards for nonroad engines

˃ Do not fall for it˃ EPA says “flex engines are not allowed

for stationary applications” (12/1/14 email from M. King)

Backup Stormwater Pumps

˃ A facility uses pumps during heavy rains to preventflooding

˃ Are the pump engines emergency units?˃ EPA says no …or, at least the operation counts towards

the 50 hours limitation˃ Same determination for other emergency

anticipation/prevention situations Engines use to rotate horizontal lime kilns during power

outages

Planned Outage ≠ EmergencyUnintended Consequences

˃ A power generation facility planned a 3-day (72-hour) outage to comply with new NERC standards (switchyard maint.)

˃ Power for critical systems needed to come from engines˃ Existing, on-site emergency engines could accommodate

the need, but 72 hours of operation in a single year would make them non-emergency…forever?

˃ EPA was asked for a variance – no such luck; their solution is to bring in portable engines…which is likely worse for the environment Potentially higher emitting design Extra fuel storage and transportation

What If An Emergency Engine Operates More Than The Allowable Non-Emergency Hours?

˃ Based on EPA’s Q&A document, it is then a non-emergency engine

˃ Based on EPA’s RTC 10.2.1 published with the 2013 rule amendments, “case-by-case”

Status Change: Area to Major˃ In general, a site that changes from an area

source to a major source has three years to comply with the major source requirements

˃ However, if the site status change coincides with the installation of a new engine (or engines), then compliance is required immediately (180-day demonstration period)§63.6595(b)(1)

Status Change: Major to Area˃ A major source gas plant experienced a fire and

had to replace all their engines˃ As a result the site’s emissions were going to be

less than 10/25 tpy˃ Are the new engines subject to major source or

area source requirements?...˃ The unofficial consensus was that as long as a

federally enforceable limit of <10/25 was in place before commencement of construction of the engines, then comply with area source rule

Real-life QUAD-ZILLA gap engine?

˃ CI RICE at area source Ordered on June 1, 2012

Manufactured on March 1, 2005

Contracted for on-site installation on July 1, 2012

˃ Engine is a “new” RICE MACT source since it was constructed (on-site) after June 12, 2006 RICE MACT requires compliance with NSPS IIII, as applicable

˃ NSPS IIII does not apply Ordered after July 11, 2005, but…

Manufactured prior to April 1, 2006

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Questions?