SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT

RULE 2012 - CHAPTER 5 - LARGE SOURCES AND PROCESS UNITS - SOURCE TESTING
(Amended February 14, 1997)(Amended April 9, 1999)

TABLE OF CONTENTS

A. Test Methods ................................................................................2012A-5-1

B. Summary of Testing Requirements ..................................................2012A-5-2

C. Testing Frequency .........................................................................2012A-5-3

D. Concentration Limit .......................................................................2012A-5-4

E. Guidelines for Testing to Establish Emission Rate for Large Sources 2012A-5-4

F. Guidelines for Testing to Establish Emission Rate for Process Units .2012A-5-8

G. Equipment Tune-up Procedures ....................................................2012A-5-11

This chapter contains the source testing frequency requirements for large sources. Also included are the source testing methods and procedures necessary for a Facility Permit holder of a large NOx source or process unit to establish an alternative emission factor. The Facility Permit holder of a large source or process unit may use a statistically equivalent methodology upon approval by the Executive Officer. Statistically equivalent methodologies shall be submitted to the Federal Environmental Protection Agency as an amendment to the State Implementation Plan (SIP).

Large sources and process units differ in the methodology used to evaluate source test data and determine the validity of the results.

Every large NOx source shall be source tested no later than December 31, 1996 for Cycle 1 facilities and June 30, 1997 for Cycle 2 facilities, and every three years thereafter. In lieu of submitting the first source test report, the Facility Permit holder may submit the results of a source test not more than three years old which meets the requirements of this Chapter. The Facility Permit holder of a large source or NOx process unit shall substantiate the emission rate according to the requirements set forth in this chapter.

All required source tests for RECLAIM NOx sources and process units shall be performed by testing firms/laboratories who have received approval under the Districtís Laboratory Approval Program.

A. Test Methods

The Facility Permit holders of all RECLAIM NOx sources, when required, shall source test each equipment using the following test methods and procedures referenced in the District Source Test Manual and 40 CFR Part 60, Appendix A:

    1. Determinations and measurements prior to sampling:

    2. Nitrogen oxides concentration:

    3. Oxygen concentration:

    4. [Reserved for methodology to measure NOx emissions from process units.]

B. Summary of Testing Requirements

The Facility Permit holder is required to source test all Super Compliant major NOx sources, all large NOx sources, and all NOx process units which opt for a concentration limit or emission rate as follows:

    1. Super Compliant Major NOx Sources

    Once a Super Compliant major NOx source has been approved, the Facility Permit holder shall source test the equipment once every two calendar quarters. The test shall include a single 60 minute NOx concentration test and a relative accuracy audit of the fuel measuring device. If four consecutive bi-quarterly tests all show compliance, the testing frequency may be reduced to once per year.

    2. Large NOx Sources

    A large NOx source is required to determine emissions based on the concentration limit in the Facility Permit. The Facility permit holder also has the option to determine emissions based on an emission rate. All large NOx sources shall be source tested according to one of the following:

    3. NOx Process Units

    Emission factors are assigned to process units when the Facility Permit is issued. No source testing is required for a process unit, unless the Facility permit holder opts for either a concentration limit or an emission rate.

C. Testing frequency

The operator of all NOx sources shall source test or tune-up their equipment according to the schedule in Table 5-B.

D. Concentration Limit

To verify compliance for a concentration limit for super compliant major NOx sources, large NOx sources, or process units, all of the following shall be met:

    1. Submit a source testing plan to the District and receive written approval of the plan or follow a District standard source testing protocol;

    2. Conduct the source test for a minimum of 60 minutes at a load within the normal operating range of the source which will represent the highest NOx concentration level;

    3. Conduct a relative accuracy audit (RAA) for stack flow rate following the procedures in Appendix A, Chapter 3, Paragraph A(6) for super compliant major NOx sources and large NOx sources, and Appendix A, Chapter 4, Paragraph A(5) for process units; and

    4. Perform these tests at the frequency specified in Table 5B.

E. Guidelines for Testing to Establish an Equipment Specific Emission Rate for Large Sources

    1. For large sources the Facility Permit holder may elect to establish an equipment specific emission rate that accurately represents the emissions from the source over the range of operation under which the testing was done. The equipment specific emission rate shall be used to determine compliance with the facility's annual emission cap.

    2. The criterion for acceptability of the equipment specific emission rate shall be a 95% confidence interval that the tested emission rates will be within 20% of the equipment specific emission rate. If a single equipment specific emission rate does not meet this criterion over the entire range of operation, the District will allow up to three equipment specific emission rates to cover a "normal operating range", a "high operating rate and a "low operating range," respectively. The "normal operating range" shall cover operations for at least 80% of the entire operating time. The equipment specific emission rate at the entire range or at respective low, normal, and high operating range shall be determined according to:

         

    n

       
    ERc = (1/n)

    Undisplayed Graphic

    ER i

    (Eq.32)

         

    i=1

       
       

    n

     

     
    SER =

    Undisplayed Graphic

    (ERi - ERc)2/(n - 1) ] 1/2

    (Eq.33)

       

    i=1

     

     
    CC = t0.975 SER/(n)1/2

    (Eq.34)

       

    |CC|

     

     
    C.I. (%) =

     

     

    (Eq.35)

       

    ERc

     

     
    where:
    SER = The standard deviation (lb/mmBtu)
    i = Each testing.
    n = The number of testing data points to determine the equipment specific emission rate at entire range or low, normal, and high operating range, respectively
    ER = The emission rate (lb/mmBtu) determined at each testing under each condition at the entire range or low, normal, and high operating range, respectively.
    CC = The confidence coefficient
    t0.975 = The t value (one-tailed) determined from Table 5-A
    ERc = The equipment specific emission rate (lb/mmBtu) determined over an entire range, or determined at low, normal, and high operating range, respectively.
    C.I. = The confidence interval with 95 % confidence level (%)

    Table 5-A - Table of the Factor t0.975 for Obtaining One-Tailed Confidence Interval for the Mean*

    n*

    t0.975

    n*

    t0.975

    n*

    t0.975

    6 2.571 9 2.306 12 2.201
    7 2.447 10 2.262 13 2.179
    8 2.365 11 2.228 14 2.160

    * The values in this table are already corrected for n-1 degrees of freedom. Use n equal to the number of individual values. 40 CFR Part 60, App B, Spec. 1.

    3. The Facility Permit holder shall identify the monitoring parameter(s) to establish the allowable operating range of process variables to be specified in the Facility Permit for the affected sources from Table 3-A in Chapter 3 for large sources. This list is not intended to be all inclusive and the Facility Permit holder may identify additional parameters not listed in Table 3-A. The test conditions are typically related to percent of load; however, the Facility Permit holder may propose any other monitoring parameters as deemed necessary and propose the operating range of these monitoring parameters to ensure that the equipment specific emission rate(s) and control efficiency continue to fall within the confidence criterion.

    4. The Facility Permit holder shall conduct source tests to verify the amended equipment specific emission rate according to the methods identified in Chapter 5, Subdivision A, or statistically equivalent methodologies. The testing shall be done in three phases.

    5. Phase I testing shall constitute "normal operating range" testing. From the "normal operating range" the equipment specific emission rate shall be calculated by using the tested emission rates. To determine a tested equipment specific emission rate the Facility Permit holder shall test at four conditions that span the "normal operating range". At each condition an emission rate shall be tested three times, but not consecutively. If there are two (or more) monitoring parameters the Facility Permit holder shall identify the primary parameter (i.e. having the greatest effect on emission rate variation) and secondary monitoring parameter(s), (i.e. having the least effect on emission rate variation). The Facility Permit holder shall test at four conditions that span the "normal operating range" of the primary monitoring parameter and at each primary monitoring parameter condition, test at least two secondary monitoring parameter test conditions that span the "normal range" of the secondary operating monitoring parameter(s). Each test shall be conducted for a period of at least 30 minutes. On this basis, the equipment specific emission rate and the 95% confidence interval shall be calculated. If the 95% confidence interval meets the 20% criterion, the unit shall be allowed to use this rate for "normal operating range" upon the approval of the Executive Officer. If the criterion is not met the Facility Permit holder shall reduce the "normal operating range" and conduct any additional tests to provide the required data sets.

    6. Phase II testing shall constitute "high operating range" testing. The Facility Permit holder shall test at two conditions that span the "high operating range". At each condition an emission rate shall be tested three times, but not consecutively. Multiple operating conditions shall be addressed in a similar manner as described for Phase I testing. The values from these tests shall be added to the data from "normal operating range" testing and a test equipment specific emission rate and test 95% confidence interval shall be generated. If the 95% confidence interval for the test equipment specific emission rate meets the 20% criterion, then the test equipment specific emission rate shall become the allowed rate for both the "normal and high" operating ranges. If the criterion is not met, then a "high operating range" equipment specific emission rate and 95% confidence interval shall be calculated from the data. If the 20% criterion is met then the facility shall use this as a "high operating range" equipment specific emission rate. If the 20% criterion is not met then tests at two additional conditions within the high range shall be conducted and the 20% criterion again applied to the "high operating range" data set only. If the 20% criterion is still not met, then the "high operating range" shall be reduced.

    7. Phase III testing shall constitute "low operating range" testing. This Phase testing is carried out in the same manner as Phase II testing. If a single "normal/high operating range" equipment specific emission rate has been determined from Phase II testing, then all of the data for "normal and high" operating range testing shall be included. If not, then only data from the "normal operating range" testing shall be included to create the "test equipment specific emission rate". The same acceptance criteria apply as specified under Phase II testing.

    8. If the equipment specific emission rate in each phase complies with the Confidence Interval, the Facility Permit holder may use up to three equipment specific emission rates, each representing a different phase, provided that load duration for each specified phase equipment specific emission rate is monitored and recorded at the facility.

Example calculation:
In order to establish the equipment specific emission rate, the Facility Permit holder selected four operating conditions over the entire operating range. The results are as follows:
   

Data 1

Data 2

Data 3

 
  Condition 1

0.15

0.20

0.50

 
  Condition 2

0.30

0.24

1.00

 
  Condition 3

0.40

0.20

0.50

 
  Condition 4

0.50

0.40

0.30

 
The confidence interval calculations are as follows:
  ERc = (0.15 + 0.20 + 0.50 + 0.30 + 0.24 + 1.00 +
0.40 + 0.20 + 0.50 + 0.50 + 0.40 + 0.30)/12
= 0.39083
  SER = 0.219196 (according to Eq.32)    
  CC = (2.201) * 0.219196/(11)1/2 = 0.1454    
  C.I.(%) = 0.1454/0.39083 = 37.2 % > 20 %    
The proposed data set failed the confidence interval test, therefore the Facility Permit holder shall select low, normal, or high range, whichever is representative of their typical operating range according to Paragraphs 6.A.5.c.d.e.f. or g.

F. Guidelines for Testing to Establish Emission Rate for process units

    1. Equipment Specific Emission Rate (ESER)

    2. Category Specific Emission Rate (CSER)

G. Equipment tune-up procedures

Follow the "Equipment Tuning Procedure" as specified in Attachment D.

TABLE 5-B

SOURCE TESTING AND TUNE-UP FREQUENCY (1)

EQUIPMENT

TEST PER Q.A. PROGRAM

TEST EVERY THREE YEARS

TUNE-UP ONCE A YEAR

TUNE-UP TWICE A YEAR

TEST EVERY TWO CALENDAR QUARTERS

TEST EVERY FIVE YEARS

Boilers and Heaters

 

 

 

 

 

 

Process Units

 

 

 

X4

 

 

Large Sources

 

X

 

X4

 

 

Major Sources

X

 

 

 

 

 

I.C.E.

 

 

 

 

 

 

Process Units

 

 

X2,5

 

 

 

Large Sources

 

X

 

X2,5

 

 

Major Sources

X

 

 

 

 

 

Kilns/Calciners

 

 

 

 

 

 

<10 TONS/HR

 

X

 

 

 

 

>10 TONS/HR

X

 

 

 

 

 

Tail Gas Units

X

 

 

 

 

 

FCCU

X

 

 

 

 

 

Portable Equipment

 

 

X

 

 

 

All Other Equipment 3

 

 

X

 

 

 

Super Compliant Major Source

 

 

 

 

X6

 

Process Unit with Concentration Limit

 

 

 

 

 

X

  1. Does not include Rule 219 Exempt Equipment.
  2. To Manufacturer's Specification.
  3. Does not include Equipment where combustion gases produce reducing and oxidizing conditions as part of the process (for example, metal melting furnaces which provide various alloys.
  4. If a boiler or heater does not operate at all during a continuous six-month period within a compliance year, only one tune-up is required for that compliance year. No tune-up is required during a compliance year for any boiler or heater that is not operated at all during the entire compliance year. Test firings are not considered operation for the purposes of these tune-up requirements so long as such test firings are done to verify availability of the unit for their intended use and once such test firings are completed the units are shutdown. Records of the date and duration when the unit is test fired shall be maintained for a period of three years, and shall be made accessible to the Executive Officer upon request.
  5. If an ICE classified as a large NOx source does not operate at all during a continuous six-month period within a compliance year, only one tune-up is required for that compliance year. No tune-up is required during a compliance year for an ICE classified as a large NOx source or a NOx process unit that is not operated at all during the entire compliance year. Records of any operation shall be maintained for a period of three years, and shall be made accessible to the Executive Officer upon request.
  6. If four consecutive bi-quarterly tests all show compliance, the testing frequency may be reduced to once per year.