### SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT

(Adopted October 5, 1990)(Amended July 10, 1992)(Amended May 13, 1994) ( Amended September 5, 2008)( Amended November 1 , 2013 )

RULE 1146.1 EMISSIONS OF OXIDES OF NITROGEN FROM SMALL INDUSTRIAL, INSTITUTIONAL, AND COMMERCIAL BOILERS, STEAM GENERATORS, AND PROCESS HEATERS

(a) Applicability This rule applies to boilers, steam generators, and process heaters that are greater than 2 million Btu per hour and less than 5 million Btu per h our rated heat input capacity used in any industrial, institutional, or commercial operation with the exception of RECLAIM facilities (NOx emissions only )

.

( b ) Definitions (1) ADSORPTION CHILLER U NIT means any natural gas fired unit that captures and use s waste heat to provide cold water for air conditioning and other process requirements. (2) ANNUAL HEAT INPUT means the actual amount of heat released by fuels burned in a unit during a calendar year, based on the fuel's higher heating value. (3) ATMOSPHERIC UNIT means any natural gas fired unit with a non

sealed combustion chamber in which natural draft is used to exhaust combustion gases

. (4) BOILER OR STEAM GENERATOR means any combustion equipment fired with liquid and/or gaseous (including landfill and digester gas) and/or solid fossil fuel, used to produce steam or to heat water, and that is not used exclusively to produce electricity for sale. Boiler or Steam Generator does not include any open heated tank, adsorption chiller u nit,

or waste heat recovery boiler that is used to recover sensible heat from the exhaust of a combustion turbine or any unfired waste heat recovery boiler that is used to recover sensible heat from the exhaust of any combustion equipment. (5) BTU means B ritish thermal unit or units. (6) COMMERCIAL OPERATION means any office building, lodging place, or similar location designed for tenancy by one or more business entities or residential occupants.

1146.1

- 1Rule 1146.1 (Cont.) (Amended November 1, 2013)

(7) HEALTH FACILITY has the same meaning as defined in Sec tion 1250 of the California Health and Safety Code

. (8) INDUSTRIAL OPERATION means any entity engaged in the production and/or provision of chemicals, foods, textiles, fabricated metal products, real estate, personal services or other kindred or allied pro ducts or
services. (9) INSTITUTIONAL OPERAT ION means any public or private establishment constituted to provide medical

, educational, governmental, or other similar services to promote safety, order, and welfare. (10) NOx EMISSIONS means the sum of nitric oxide and nitrogen dioxide in the flue gas, collectively expressed as nitrogen dioxide. (11) OPEN HEATED TANK means a non

- pressurized self

- heated tank that may include a cover or doors that can be opened or detached to put in or
remove parts, components or other material for processing in the tank. Tanks heated solely by an electric heater, boiler, thermal fluid heater or heat recovered from another process using heat exchangers are excluded
from this definition. (12) PROCESS HEATER means any combustion equipment fired with liquid and/or gaseous (including landfill and digester gas) and/or solid fossil fuel and which transfers heat from combustion gases to water or process streams. Process Heater does not include any kiln or oven used for drying, curing, baking, cooking, calcining, or vitrifying; or any unfired waste heat recovery heater that is used to recover sensible heat from the exhaust of any combustion equipment. (13) RATED HEAT INPUT CAPACITY means the heat inp ut capacity specified on the nameplate of the combustion unit. If the combustion unit has been altered or modified such that its maximum heat input is different than the heat input capacity specified on the nameplate, the new maximum heat input shall be c onsidered as the rated heat input capacity. (14) SCHOOL means any public or private school, including juvenile detention facilities with classrooms, used for purposes of the education of more than 12 children at the school, including in kindergarten and gr ades 1 to 12, inclusive, but does not include any private school in which education is primarily conducted in private homes. The term includes any building or structure, playground, athletic field, or other area of school property, but
does not include un improved school property

.

1146.1

- 2Rule 1146.1 (Cont.) (Amended November 1, 2013)

(15) THERM means 100,000 Btu. (16) THERMAL FLUID HEATER means a PROCESS HEATER in which a process is heated indirectly by a heated fluid other than water. (17) UNIT means any boiler, steam generator, or process heater as defined i n paragraph ( b )( 4 ) or ( b )( 12 ).

(c) Requirements (1) On or after September 5 , 2008 , t he owner or operator of any unit subject to subdivision ( a ) shall operate such unit so that it discharges into the atmosphere no more than 30 ppm of NOx emissions or for natural gas
fired units 0.037 pound NOx per million Btu of heat input, as specified in the permit to operate. (2) An owner or operator of any unit subject to subdivision (a) must select to comply with one of the following NOx emission limits specified in Table
1146.1

- 1 and apply for a permit to construct to operate such unit in compliance with the selected emission limit and the corresponding permit application and full compliance dates.
Table 1146.1

- 1

Category Limit Submit Application for Permit to Construct on or before Unit Shall be in Full Compliance on or before Any Units Fired on Landfill Gas 25 ppm January 1, 2014 January 1, 2015 Any Units Fired on Digester Gas 15 ppm January 1, 2014 January 1, 2015 Atmospheric Units 12 ppm or 0.015 lbs/10 6 Btu January 1, 2013 January 1, 2014

Any Units Fired on Natural Gas, Excluding Units Located at Schools and Universities

, Atmospheric Units

, and Thermal Fluid Heaters 9 ppm or January 1, 2011 January 1, 2012

Any Units Fired on Natural Gas Located at Schools and Universities

, Excluding Atmospheric Units, and Thermal Fluid Heaters 0.011 lbs/10 6 Btu January 1, 2013 January 1, 2014

1146.1

- 3Rule 1146.1 (Cont.) (Amended November 1, 2013)

( 3 ) For dual fuel co

- fired combustion units a weighted average limit calculated by Equation 1146.1

- 1 may be used provided a totalizing fuel flow meter is installed pursuant to paragraph (c)( 7 ), for units burning a
combination of both fuels.

Weighted Limit =

______________________ Equation 1146 .1

- 1
Q A + Q B

Where:
CL A = compliance limit for fuel A
CL B = compliance limit for fuel B Q A = heat input from fuel A Q B = heat input from fuel B ( 4 ) The owner or operator of any unit(s) with a heat input capacity greater than 2 million Btu per hour shall not discharge into the at mosphere carbon monoxide (CO) emissions in excess of 400 ppm or for natural gas fired
units 0.30 lbs/10 6 Btu

. ( 5 ) In lieu of complying with the applicable emission limits specified in paragraph (c)(1)

, (c)(2) , (c)(3), and (c)(4) any unit(s) subject to subdivision ( a ) in operation prior to September 5, 2008 , and with an annual heat input of less than or equal to 18,000 therms per calendar year,
shall: (A) be operated in a manner that maintains stack

- gas oxygen concentrations at less than or equal to 3 percent on a dry basis for any 15

- consecutive

- minute averaging period; or (B) be tuned at least twice per year, (at intervals from four to eight months apart) in accordance with the procedure described in Attachment 1 or the unit manufacturer's specified tuneup procedure. If a different tuneup procedure from that described in attachment 1 is used then a copy of this procedure shall be kept on
site. The operator of any unit(s) selecting the tune

- up option shall maintain records for a rolling of twenty fou r month period verifying that the required tune

- ups have been performed. If the unit does not operate throughout a continuous six

- month period (CL A x Q A ) + (CL B x Q B )

1146.1

- 4Rule 1146.1 (Cont.) (Amended November 1, 2013)

within 12 month period , only one tuneup is required for the twelve month period that includes the entire period o f non

- operation

. For this case, the tune

- up shall be conducted within 30 days of start

- up. No tune

- up is required during a rolling twelve month period for any unit that is not operated during that rolling 12 month period ; this unit may be test fired to verify availability of the unit for its intended use but once test firing is completed it shall be shutdown. Records of test firings shall be maintained for a rolling twenty four
month period, and shall be made accessible upon request from an
authorized D istrict representative upon request

. ( 6 ) An owner or operator that has installed or modified a natural gas fired unit prior to September 5, 2008 complying with the applicable BACT emission limit of 12 ppm or less of NOx may defer compliance with paragraph (c)(2) until the unit’s burner(s) replacement. ( 7 ) Any owner or operator who chooses the pound per million Btu of heat input compliance option in paragraph (c)(1), (c)(2), or (c)(4) for natural gas fired units or chooses the weighted average emission limit using Equation 1146.1

- 1 under paragraph (c )( 3 ) shall install a non

- resettable, totalizing fuel meter for each fuel used on an individual unit basis, as approved by the Executive Officer. (8) On or after January 1 , 2015, an owner operator of any landfill or digester gas (biogas) unit co

- fired with natural gas shall not operate the unit in a
manner that exceeds the applicable landfill or digester gas emission concentration limits specified in paragraph (c)( 2 ), provi ded that the facility monthly average biogas usage by the biogas units is 90% or more, based on the higher heating value of the fuels used. (A) The Executive Officer may approve the burning of more than 10% up to: (i) 25% natural gas in a biogas fired unit at the 15 ppm (digester gas) or 25 ppm (landfill gas) NOx level, when it is necessary, if the only alternative to limiting natural gas to 10% would be shutting down the unit and flaring more biogas. (ii) 50% natural gas in a digester gas

- fired unit at the 15 ppm NOx level, when it is necessary as specified in clause (c) ( 8 )(A)(i) and for units installed on or after September 5,

1146.1

- 5Rule 1146.1 (Cont.) (Amended November 1, 2013)

2008 provided the unit has demonstrated compliance with the NOx limits in paragraph (c)( 2 ) applicable to units fired exclusively o n natural gas. For units subject to this subparagraph, the percent natural gas usage shall be based on the facility monthly average biogas usage by the biogas units and the higher heating value of the
fuels used. (B) Any biogas

- fired unit burning more than the approved percent natural gas as determined under subparagraph (c)( 8 )(A) shall comply with the weighted average NOx limit specified in paragraph (c)(3).

(d) Compliance Determination (1) Owners or operators of any units shall have the option of complyi ng with either the pound per million Btu of heat input or parts per million emission limits specified in paragraph (c) (1)

, (c)(2), (c)( 3 ) , or (c)( 4 )

. (2) All emission determinations shall be made in the as

- found operating condition, except no compliance determination shall be established during unit start up, shutdown, or under breakdown conditions. Start up or shutdown intervals shall not last longer than is necessary to reach stable temperatures. In no case shall the start up or shutdown interval last longer than six hours or the time specified in the permit to operate, whichever is
less. Start

- ups and shutdowns shall not last longer than is necessary to
reach stable conditions

. An compliance determination as specified in paragraph (d)(6) shall be co nducted at least 250 operating hours, or at least thirty days subsequent to the tuning or servicing of any unit , unless it is an
unscheduled repair

. (3) All parts per million emission limits specified in subdivision (c) are referenced at 3 percent volume s tack

- gas oxygen on a dry basis averaged over a period of 15 consecutive minutes. (4) Compliance with the NOx and CO emission requirements of paragraph s (c)(1) through (c)( 4 ) and the stack

- gas oxygen concentration requirement
of sub paragraph (c)( 5 )(A) shall be determined using a District approved contractor under the Laboratory Approval Program according to the following procedures :

1146.1

- 6Rule 1146.1 (Cont.) (Amended November 1, 2013)

(A) District Source Test Method 100.1

- Instrumental Analyzer Procedures for Continuous Gaseous Emission Sampling (March 1989) ; or (B) District Source Test Method 7.1

- Determination of Nitrogen Oxide Emissions from Stationary Sources (March 1989) and Method 10.1

- Carbon Monoxide and Carbon Dioxide by Gas Chromatograph/Non

- Dispersive Infrared Detector (GC/NDIR)

- Oxygen by Gas Chromatograph

- Thermal Conductivity (GC/TCD) (March 1989 ); or (C) United States Environmental Protection Agency Conditional Test
Method CTM

- 030, Determination of Nitrogen Oxides, Carbon Monoxide, and Oxygen Emissions from Natural Gas

- Fired Engines,
Boilers and Process Heaters Using Portable Analyzers; or (D) ASTM D6522

- 00(2005) Standard Test Method for Determination of Nitrogen Oxides, Carbon Monoxide, and Oxygen Concentrations
in Emissions from Natural Gas

- Fired Reciprocating Engines, Combustion Turbines, B oilers, and Process Heaters Using Portable Analyzers ( E ) any other test method determined to be alternative and approved before the test in writing by the Executive Officers of the District and the California Air Resources Board and the Regional
Administra tor of the United States Environmental Protection Agency, Region IX. Records of all source tests shall be maintained for a period of two years (five years for Title V facilities) and shall be made available to District personnel upon request. Emissions de termined to exceed any limits established by this rule through the use of any of the above

- referenced test
methods shall constitute a violation of this rule. (5) For any owner or operator who chooses the pounds of per million Btu of heat input compliance o ption of paragraph (c)(1)

, (c)(2) , or (c)( 4 ) for natural gas fired units

, NOx emissions in pounds per million Btu of heat input shall be calculated using the procedures in 40 CFR Part 60, Appendix A, Method 19, Sections 2 and 3 and CO emissions in pounds

p er million Btu of heat input shall be calculated according to the Protocol for the Periodic Monitoring of Nitrogen Oxides, Carbon Monoxide, and

1146.1

- 7Rule 1146.1 (Cont.) (Amended November 1, 2013)

Oxygen from Units Subject to South Coast Air Quality Management
District Rules 1146 and 1146.1

. (6) Compliance d etermination with the NOx emission requirements specified in paragraph (d)(4) shall be conducted once every five years. (7) Any owner or operator of units subject to this rule shall perform diagnostic
emission check s of NOx emissions with a portab le NOx, CO and oxygen analyzer according to the Protocol for the Periodic Monitoring of Nitrogen Oxides, Carbon Monoxide, and Oxygen from Units Subject to South Coast Air Quality Management District Rules 1146 and 1146.1 according to the following schedule: (A) On or aft er July 1, 2009

, the owner or operator of units subject to paragraphs (c)(1) through (c)(4) shall check NOx emissions at least quarterly or every 2,000 unit operating hours, whichever occurs
later

. If a unit is in compliance for four consecutive required diagnostic emission checks, without any adjustments to the oxygen sensor set points, then the unit may be checked semi

- annually or
every 4 ,000 unit operating hours, whichever occurs later, until the diagnostic emission check exceeds the applicable limit specified in paragraphs (c)(1), (c)(2), or (c)(3)

. (B) On or after January 1, 2015 or during burner replacement, whichever occurs later, units subject to paragraph (c)(5) shall check NOx emissions according to the tune

- up schedule specified in subparagraph (c) (5)(B)

. (C) Records of all monitoring data required under subparagraphs (d)(7)(A) and (d)(7)(B) shall be maintained for a rolling twelve month period of two years ( five years for Title V facilities) and shall be made available to District personnel upon reques t. (D) The portable analyzer diagnostic emission checks required under subparagraphs (d)(7)(A) and (d)(7)(B) shall only be conducted by a person who has completed an appropriate District

- approved training program in the operation of portable analyzers and has received a certification issued by the District. (8) An owner or operator shall comply with the requirements as applied to CO emissions specified in paragraph s (d)(6) and (d)(7). ( 9 ) A diagnostic emission check conducted under the requirements specified in paragraph (d)(7) that finds emissions in excess of those allowed by this

1146.1

- 8Rule 1146.1 (Cont.) (Amended November 1, 2013)

rule or a permit condition shall not constitute a violation of this rule if the
owner or operator correct s the problem and demonstrate compliance with
another emission check within 72 hours from the time the owner or operator knew of excess emissions, or reasonably should have known, or shut down the unit by the end of an operating cycle, whichever is sooner

. (10) Notwithstan ding the requirements specified in paragraph (d)(9) any diagnostic emission check conducted by District staff that finds emissions in excess of those allowed by this rule or a permit condition is a violation. ( 11 ) A n owner or operator may opt to lower the unit’s rated heat input capacity.
The lower ed rated heat input capacity shall not be less than or equal to 2 million Btu per hour and shall be based on manufacturer’s identification or rating p late or permit condition.

(e) Compliance Schedule (1) O wners o r operators of units shall comply with the applicable schedule specified in paragraph s (c)(1) and (c)(2). ( 2 ) On or after January 1, 201 5 or during burner replacement, whichever is
later , no person shall operate in the District any unit subject to paragrap h (c)( 5 ) which does not meet the emissions limits specified in paragraph (c)(1)

. ( 3 ) If any unit subject to paragraph (c)( 5 ) exceeds 18,000 therms of annual heat input from all fuels used in any twelve month period, the owners or operators shall: (A) within 4 months after exceeding 18,000 therms of heat input in any twelve month period, submit required applications for permits to construct and operate; and (B) within 18 months after exceeding 18,000 therms of heat input in any twelve month period, demonstrate and maintain compliance with all applicable requirements specified in paragraphs (c)(1) through (c)( 4 ) for the life of the unit. ( 4 ) The Executive Officer shall grant a time extension to the full compliance date with the applicable NOx complian ce limits for any natural gas fired units specified in paragraph (c)(2) for any health facility as defined in Section 1250 of the California Health and Safety Code that can demonstrate that the Office of Statewide Health Planning and Development has approv ed an extension of time to comply with seismic

1146.1

- 9Rule 1146.1 (Cont.) (Amended November 1, 2013)

safety requirements pursuant to Health and Safety Code Sections 130060
and 130061.5. The extension of time granted by the Executive Officer shall be consistent with the time extension granted pursuant to Heal th and Safety Code Section 130060 but not to exceed January 1, 2015 and shall be consistent with the time extension granted pursuant to Health and Safety Code Section 130061.5 but not to exceed January 1, 2020. Those health facilities granted a time exten sion shall submit a compliance plan to the Executive Officer on or before January 1, 2010.

1146.1

- 10Rule 1146.1 (Cont.) ( Amended November 1, 2013 )

ATTACHMENT 1

A. Equipment Tuning Procedure 1 for Forced

- Draft Boilers, Steam Generators, and Process Heaters Nothing in this Equipment Tuning Procedure shall be construed to require any act or
omission that would result in unsafe conditions or would be in violation of any regulation or requirement established by Factory Mutual, Industrial Risk Insurers, National Fire Prevention Association, the California Department of Industrial Relations (Occupational Safety and
Health Div ision), the Federal Occupational Safety and Health Administration, or other relevant regulations and requirements.
1. Operate the unit at the firing rate most typical of normal operation. If the unit experiences significant load variations during normal o peration, operate it at its average firing rate.
2. At this firing rate, record stack gas temperature, oxygen concentration, and CO concentration (for gaseous fuels) or smoke

- spot number 2 (for liquid fuels), and observe flame conditions after unit operatio n stabilizes at the firing rate selected. If the excess oxygen in the stack gas is at the lower end of the range of typical minimum
values 3 , and if CO emissions are low and there is not smoke, the unit is probably operating at near optimum efficiency

- at this particular firing rate.
3. Increase combustion air flow to the furnace until stack gas oxygen levels increase by one to two percent over the level measured in Step 2. As in Step 2, record the stack gas temperature, CO concentration (for gaseous fu els) or smoke

- spot number (for liquid fuels), and observe flame conditions for these higher oxygen levels after boiler operation stabilizes. However, complete the remaining portion of this procedure to determine whether still lower oxygen levels are practi cal.

1 This tuning procedure is based on a tune

- up procedure developed by KVB, Inc. for the United States EPA. 2 The smoke

- spot number can be determined with ASTM Test Method D

- 2156 or with the Bacharach method.

ASTM Test Method D

- 2156 is included in a tuneup kit that can be purchased from the Bacharach Company. 3 Typical minimum oxygen levels for boilers at high firing rates are: 1. For natural gas: 0.5%

- 3% 2. For liquid fuels: 2%

- 4%

1146.1

- 11R ule 1146.1 (Cont.) (Amended November 1, 2013 )

4. Decrease combustion air flow until the stack gas oxygen concentration is at the level measured in Step 2. From this level gradually reduc e the combustion air flow, in small increments. After each increment, record the stack gas temperature, oxygen concentration, CO concentration (for gaseous fuels) and smoke

- spot number (for liquid fuels). Also observe the flame and record any changes in its condition.
5. Continue to reduce combustion air flow stepwise, until one of these limits is reached:

a. Unacceptable flame conditions

- such as flame impingement on furnace walls or burner parts, excessive flame carryover, or flame instability.
b. Stac k gas CO concentrations greater than 400 ppm.

c. Smoking at the stack.
d. Equipment

- related limitations

- such as low windbox/furnace pressure differential, built in air

- flow limits, etc.
6. Develop an O 2 /CO curve (for gaseous fuels) or O 2 /smoke curve (for liquid fuels) similar to those shown in Figures 1 and 2 using the excess oxygen and CO or smoke

spot number data obtained at each combustion air flow setting.

1146.1

- 12R ule 1146.1 (Cont.) (Amended November 1, 2013 )

7. From the curves prepared in Step 6, find the stack gas oxygen levels where the CO
emissions or smoke

- spot number equal the following values:
Fuel Measurement Value
Gaseous CO Emissions 400 ppm #1 and #2 oils smoke

- spot number number 1 #4 oil smoke

- spot number number 2 #5 oil smoke

- spot number number 3 Other oils smoke

- spot number number 4

The above conditions are referred to as the CO or smoke thresholds, or as the minimum excess oxygen level. Compare this minimum value of excess oxygen to the expected value provided by the
combustion unit manufacturer. If the minimum level fou nd is substantially higher than the value provided by the combustion unit manufacturer, burner adjustments can probably be made to improve fuel and air mixing, thereby allowing operation with
less air.
8. Add 0.5 to 2.0 percent O2 to the minimum excess oxy gen level found in Step 7 and reset burner controls to operate automatically at this higher stack gas oxygen level. This margin above the minimum oxygen level accounts for fuel variations, variations in atmospheric conditions, load changes, and nonrepeata bility or play in automatic
controls.
9. If the load of the combustion unit varies significantly during normal operation, repeat Steps 1

- 8 for firing rates that represent the upper and lower limits of the range of the load. Because control adjustments at one firing rate may affect conditions at other firing rates, it may not be possible to establish the optimum excess oxygen level at all firing rates. If this is the case, choose the burner control settings that give best performance over the range of firi ng rates. If one firing rate predominates, settings should optimize conditions at that rate.
10. Verify that the new settings can accommodate the sudden load changes that may occur in daily operation without adverse effects. Do this by increasing and
dec reasing load rapidly while observing the flame and stack. If any of the conditions in Step 5 result, reset the combustion controls to provide a slightly higher level of excess oxygen at the affected firing rates. Next, verify these new settings in a simi lar

1146.1

- 13R ule 1146.1 (Cont.) (Amended November 1, 2013 )

fashion. Then make sure that the final control settings are recorded at steady

- state operating conditions for future reference.
11. When the above checks and adjustments have been made, record data and attach combustion analysis data to boiler, steam generator, or heater records indicating name and signature of person, title, and date the tuneup was performed.

B. Equipment Tuning Procedure for Natural Draft

- Fired Boilers, Steam Generators, and Process Heaters. Nothing in this Equipment Tuning Procedure shall be construed to require any act or omission that would result in unsafe conditions or would be in violation of any regulation or requirement established by Factory Mutual, Industrial Risk Insurers, National Fire Prevention Association, the California Department of Industrial Relations (Occupational Safety and Health Division), the Federal Occupational Safety and Health Administration, or other relevant codes, regulations, and equipment manufacturers specifications and operating
manuals.

Sho uld a different tuning procedure be used, a copy of this procedure should be kept with the unit records for two years and made available to the District personnel on request.

1146.1

- 14R ule 1146.1 (Cont.) (Amended November 1, 2013 )

1. PRELIMINARY ANALYSIS

a. CHECK THE OPERATING PRESSURE OR TEMPERATURE. Opera te the boiler, steam generator, or heater at the lowest acceptable pressure or temperature that will satisfy the load demand. This will minimize heat and radiation losses. Determine the pressure or temperature that will be used as a basis for comparative combustion analysis before and after tuneup.
b. CHECK OPERATING HOURS. Plan the workload so that the boiler, steam generator, or process heater operates only the minimum hours and days necessary to perform the work required. Fewer operating hours will reduce fuel use and emissions. For units requiring a tuneup to comply with the rule, a totalizing non

- resettable fuel meter will be required for each fuel used and for each boiler, steam generator, and heater to prove fuel consumption is less than the hea t input limit in therms per year specified in the rule.

c. CHECK AIR SUPPLY. Sufficient fresh air supply is essential to ensure optimum combustion and the area of air supply openings must be in compliance with applicable codes and regulations. Air openi ngs must be kept wide open when the burner is firing
and clear from restriction to flow.
d. CHECK VENT. Proper venting is essential to assure efficient combustion. Insufficient draft or overdraft promotes hazards and inefficient burning. Check to be su re that vent is in good condition, sized properly and with no obstructions.

e. COMBUSTION ANALYSIS. Perform an "as is" combustion analysis (CO, O 2 , etc.) with a warmed up unit at high and low fire, if possible. In addition to data obtained from combusti on analysis, also record the following:
i. Inlet fuel pressure at burner (at high & low fire)
ii. Draft at inlet to draft hood or barometric damper 1) Draft hood: high, medium, and low 2) Barometric Damper: high, medium, and low
iii. Steam pressure, water temperature, or process fluid pressure or temperature entering and leaving the boiler, steam generator, or process heater.

1146.1

- 15R ule 1146.1 (Cont.) (Amended November 1, 2013 )

iv. Unit rate if meter is available.

With above conditions recorded, make the following checks and corrective actions as

necessary :

2. CHECKS & CORRECTIONS

a. CHECK BURNER CONDITION. Dirty burners or burner orifices will cause boiler, steam generator, or process heater output rate and thermal efficiency to decrease. Clean burners and burner orifices thoroughly. Also, ensure th at fuel filters and moisture traps are in place, clean, and operating properly, to prevent plugging of gas orifices. Confirm proper location and orientation of burner diffuser spuds, gas canes, etc. Look for any burned

- off or missing burner parts, and re place as needed.
b. CHECK FOR CLEAN BOILER, STEAM GENERATOR, OR PROCESS
HEATER TUBES & HEAT TRANSFER SURFACES.
External and internal build

- up of sediment and scale on the heating surfaces creates an insulating effect that quickly reduces unit efficiency . Excessive fuel cost will result if the unit is not kept clean. Clean tube surfaces, remove scale and soot, assure proper process fluid flow and flue gas flow.

c. CHECK WATER TREATMENT & BLOWDOWN PROGRAM. Soft water and the proper water or process fl uid treatment must be uniformly
used to minimize scale and corrosion. Timely flushing and periodic blowdown must be employed to eliminate sediment and scale build

- up on a boiler, steam generator or process heater.
d. CHECK FOR STEAM, HOT WATER OR PROCESS FLUID LEAKS Repair all leaks immediately since even small high

- pressure leaks quickly lead to considerable fuel, water and steam losses. Be sure there are no leaks through the blow

- off, drains, safety valve, by

- pass lines or at the feed pump, if
used.
3. SAFETY CHECKS

a. Test primary and secondary low water level controls.
b. Check operating and limit pressure and temperature controls.

c. Check pilot safety shut off operation.

1146.1

- 16R ule 1146.1 (Cont.) (Amended November 1, 2013 )

d. Check safety valve pressure and capacity to meet boiler, steam generator or process heater requirements.

e. Check limit safety control and spill switch.
4. ADJUSTMENTS While taking combustion readings with a warmed up boiler, steam generator, or process heater at high fire perform checks and adjustments as follows:

a. Adjust unit to fire at rate; record fuel manifold pressure.
b. Adjust draft and/or fuel pressure to obtain acceptable, clean combustion at both high, medium and low fire. Carbon Monoxide (CO) value should always be below 400 parts per million (PPM) a t 3% 0 2 . If CO is high make necessary adjustments. Check to ensure boiler, steam generator, or process heater light offs are smooth and safe. A reduced fuel pressure test at both high and low fire should
be conducted in accordance with the manufacturer s instructions and
maintenance manuals.

c. Check and adjust operation of modulation controller. Ensure proper, efficient and clean combustion through range of firing rates.

When above adjustments and corrections have been made, record all data.
5. FIN AL TEST Perform a final combustion analysis with a warmed up boiler, steam generator, or process heater at high, medium and low fire, whenever possible. In addition to data from combustion analysis, also check and record:

a. Fuel pressure at burner (Hig h, Medium, and Low).
b. Draft above draft hood or barometric damper (High, Medium and Low).

c. Steam pressure or water temperature entering and leaving boiler, steam generator, or process heater.
d. Unit rate if meter is available.

When the above checks and adjustments have been made, record data and attach combustion analysis data to boiler, steam generator, or process heater records indicating name and signature of person, title, company name, company address and date the tuneup was performed.

1146.1

- 17