10/12 RULE 74.15.1: 1

VENTURA COUNTY AIR POLLUTION CONTROL DISTRICT

RULE 74.15.1 - BOILERS, STEAM GENERATORS, AND PROCE SS HEATERS (Adopted 5/11/93, Revised 6/13/95, 6/13/00, 9/11/12 )

A. Applicability

The provisions of this rule apply to any boiler, st eam generator, or process heater with a rated heat input capacity equal to or greater than 1 million BTU per hour and less than 5 million BTU per hour.

B. Requirements

1. No person shall allow the discharge into the atm osphere, from any boiler, steam generator, or process heater with an annual heat in put rate of equal to or greater

than 1.8 x 10 9 BTU, oxides of nitrogen (NOx) emissions in excess of 30 parts per million volume (ppmv). Carbon monoxide (CO) emissi ons from units subject to this rule shall not exceed 400 ppmv.

2. After January 1, 2013, no person shall allow the discharge into the atmosphere, from any new boiler, steam generator, or process he ater with a rated heat input capacity of equal to or greater than 1,000,000 BTU/ hr and less than or equal to 2,000,000 BTU/hr, oxides of nitrogen emissions in e xcess of 20 ppmv. Carbon monoxide emissions shall not exceed 400 ppmv. In a ddition, each device shall be certified by the South Coast Air Quality Management District in accordance with the requirements of SCAQMD Rule 1146.2, adopted May 5, 2006.

3. Any boiler, steam generator, or process heater w ith an annual heat input rate of equal to or greater than 0.3 x 10 9 BTU and less than 1.8 x 10 9 BTU shall comply with one of the following requirements: a. The unit shall be tuned every 6 months or after 750 hours of operation since the previous tune-up, whichever occurs last, but in no case less than once per calendar year. The unit shall be tuned in accordance with the procedure described in Attachment 1 for forced draf t-fired equipment or Attachment 2 for natural draft-fired equipment; or

b. The unit shall comply with the emission and test ing requirements of

Subsection B.4.

4. Test Requirements a. Units with a rated heat input capacity of greate r than 2 million BTU/hr, and subject to the provisions of Subsection B.1, sh all test for compliance upon initial installation and then not less than on ce every 24 months.10/12 RULE 74.15.1: 2 b. Units with a rated heat input capacity of less t han or equal to 2 million BTU/hr, and subject to the provisions of Subsection B.1 or B.2, shall test for compliance upon initial installation and then n ot less than once every

48 months. The first source test on this test sche dule shall be 48 months after the last source test conducted prior to Septe mber 11, 2012.

c. All units shall perform an annual screening anal ysis of NOx and CO emissions unless a source test specified in either Subsection B.4.a or B.4.b is required that year. The operator shall notify t he APCD by telephone 24 hours prior to any screening analysis.

C. Exemptions

The provisions of Section B of this rule shall not apply to any unit operated on alternate fuel under the following conditions: 1. Alternate fuel use is required due to the curtai lment of natural gas service to the individual unit by the natural gas supplier. Alter nate fuel use in this case shall not exceed the period of natural gas curtailment.

2. Alternate fuel use is required to maintain the a lternate fuel system. Alternate fuel use in this case shall not exceed 50 hours per year

.

D. Recordkeeping Requirements

1. Any person owning and/or operating a boiler, ste am generator, or process heater with an annual heat input rate of less than 1.8 x 1 0 9 BTU and not complying with the requirements of Subsection B.1 shall install a totalizing fuel meter for each applicable unit and for each fuel. Meters shall be accurate to ± one (1) percent, as certified by the manufacturer in writing. Fuel con sumption for each unit shall be compiled monthly into a rolling twelve (12) calenda r month report.

2. Any person subject to the provisions of Subsecti on B.3.a shall submit a report to the Air Pollution Control Officer (APCO) within for ty-five (45) days after achieving first compliance with Subsection B.3.a. Reports shall continue to be submitted every twelve (12) months. The report sha ll verify that each tune-up has been performed and the results were satisfactory. The report shall contain all information and or documentation that the APCO may determine, in writing, to be

necessary.

3. Any person subject to the provisions of Subsecti on B.4.c shall submit a report to the APCO within forty-five (45) days after first ac hieving compliance with the subsection. Reports shall continue to be submitted every twelve (12) months. The report shall contain all information and or doc umentation that the APCO may determine, in writing, to be necessary.10/12 RULE 74.15.1: 3

4. Any person utilizing alternate fuel, pursuant to the provisions of Subsection C.1 of this rule, shall maintain daily records of each occ urrence. Each record shall include the type of fuel, the quantity of fuel, and the duration of the occurrence.

5. All records required by Subsections D.1 and D.4 shall be maintained for a period of four (4) years and shall be available for inspec tion by the APCO upon request.

E. Test Methods

1. Compliance with the emission requirements in Sec tion B shall be determined using ARB Method 100 for Oxides of Nitrogen, Carbon Monoxide, and Stack Gas Oxygen.

2. Emission tests resulting in compliance determina tions for the requirements of

Subsection B.1 shall be conducted on units in "As-f ound" operating condition.

3. The NOx parts per million emission limitation sp ecified in Subsection B.1 and B.2 is expressed as nitrogen dioxide. The limitati ons for both NOx and CO are referenced at three (3) percent volume stack gas oxygen on a dry basis averaged

over 15 consecutive minutes.

4. Screening analyses required pursuant to Subsect ion B.4.c shall be performed using

a portable analyzer calibrated, maintained, and ope rated in accordance with the manufacturer’s specifications or as approved in wri ting by the APCO. Portable analyzer operators shall undergo training, on the o peration and maintenance of the analyzer.

F. Violations

1. Failure to comply with any provision of this rul e shall constitute a violation of this

rule.

2. Any unit subject to the provisions of Subsection B.3 shall comply with the provisions of Subsection B.1 if the unit operates d uring any rolling twelve (12) month period at a total annual heat input rate grea ter than the applicable annual heat input rate specified in Subsection B.3.

3. Any unit previously operating at an annual heat input rate of less than 0.3 x 10 9
BTU shall comply with the applicable provisions of Subsection B.1 or Subsection B.3 if the unit operates during any rolling twelve (12) month period at a total annual heat input rate greater than 0.3 x 10 9 BTU.

4. An applicable unit shall be in violation if, acc ording to a screening analysis, it is operated out-of-compliance with the requirements of either Subsection B.1 or B.2 as follows. An out-of-compliance screening analysi s shall be reported to the10/12 RULE 74.15.1: 4 District within seven (7) calendar days. The unit shall be corrected and a second screening analysis or source test shall be performe d within fourteen (14) calendar days of the initial screening analysis. The result s of the second analysis shall be reported to the District within seven (7) days. Ifthe unit remains out-ofcompliance, a violation has occurred.

G. Definitions

1. "Alternate Fuel": Any fuel that is not natural g as.

2. "Annual Heat Input": The actual amount of heat r eleased by fuels burned in a unit during a twelve (12) calendar month rolling period, based on the fuel's higher heating value. The annual heat input shall be calc ulated as the sum of the previous 12 monthly fuel use rates multiplied by th e fuel's higher heating value.

3. "Boiler or Steam Generator": Any external combus tion equipment fired with liquid and/or gaseous fuel and used to produce stea m or to heat water. Boiler or Steam Generator does not include any unfired waste heat recovery boiler that is

used to recover sensible heat from the exhaust of a ny combustion equipment.

4. "New Boiler, Steam Generator, or Process Heater" : Any applicable unit sold, offered for sale, or installed after January 1, 201 3.

5. "Process Heater": Any external combustion equipm ent fired with liquid and/or gaseous fuel and which transfers heat from combusti on gases to water or process streams. Process Heater does not include any kiln or oven used for drying, baking, cooking, calcining or vitrifying, any unfir ed waste heat recovery heater

that is used to recover sensible heat from the exha ust of any combustion equipment, or any fuel-fired degreasing or metal fi nishing equipment.

6. "Rated Heat Input Capacity": The heat input capa city 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 h eat input capacity specified on the nameplate, the new maximum heat input shall be considered as the rated heat input capacity. This alteration or modification ca n be through either burner

alteration or modification or installation of a fix ed orifice. The new maximum heat input must be certified, in writing, by the ma nufacturer or installer and engineering calculations supporting the new maximum heat input rating must be

submitted to the APCO.

7. "Therm": 100,000 BTU.

8. "Unit": Any boiler, steam generator, or process heater as defined in Subsections

G.2 and G.3 of this rule.7/95 ATTACHMENT 1 RULE 74.15.1: 5 ATTACHMENT 1

Equipment Tuning Procedure for Forced Draft-fired Equipment 1

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 Insu rers, National Fire Prevention Association, the California Department of Industrial Relations (Occu pational Safety and Health Division), the Federal Occupational Safety and Health Administrati on, 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 norm al operation, operate it at its average firing rate.

2. At this firing rate, record stack gas temperatur e, oxygen concentration, and CO concentration (for gaseous fuels) or smoke-spot num ber 2 (for liquid fuels), and observe flame conditions after unit operation 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 the CO emissions are low and there is not smoke, th e unit is probably operating at near optimum efficiency - at this particular firing rate . However, complete the remaining portion of this procedure to determine whether stil l lower oxygen levels are practical.

3. Increase combustion air flow to the furnace unti l 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 fuels) o r smoke-spot number (for liquid fuels), and observe flame conditions for these high er oxygen levels after boiler operation

stabilizes.

4. Decrease combustion air flow until the stack gas oxygen concentration is at the level measured in Step 2. From this level gradually redu ce the combustion air flow, in small increments. After each increment, record

1 . This tuning procedure is based on a tune-up proce dure developed by KVB, Inc. for the

EPA.

2 . The smoke-spot number can be determined with ASTM Test Method D-2156 or with the

Bacharach method.

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%7/95 ATTACHMENT 1 RULE 74.15.1: 6

the stack gas temperature, oxygen concentration, CO concentration (for gaseous fuels) and smoke-spot number (for liquid fuels). Also obs erve the flame and record any changes in its condition.

5. Continue to reduce combustion air flow stepwise, until one of these limits in reached:

a. Unacceptable flame conditions - such as flame i mpingement on furnace walls or

burner parts, excessive flame carryover, or flame i nstability.

b. Stack gas CO concentrations greater than 400 pp m.

c. Smoking at the stack.

d. Equipment-related limitations - such as low win dbox/furnace pressure differential,

built in air-flow limits, etc.

6. Develop an 0 2 /CO curve (for gaseous fuels) or 0 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.

7. From the curves prepared in Step 6, find the sta ck gas oxygen levels where the CO emissions or smoke-spot number equal the following values:

Fuel Measurement Value

Gaseous CO Emissions 400 ppm

#1 & #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 CO or smok e threshold, 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 found is substantially higher than the value provided by the combustion unit manufactu rer, burner adjustments can probably be made to improve fuel and air mixing, thereby all owing operation with less air.

8. Add 0.5 to 2.0 percent to the minimum excess oxy gen level found in Step 7 and reset burner controls to operate automatically at this hi gher stack gas oxygen level. This7/95 ATTACHMENT 1 RULE 74.15.1: 7

margin above the minimum oxygen level accounts for fuel variations, variations in atmospheric conditions, load changes, and nonrepeat ability or play in automatic controls.

9. If the load of the combustion unit varies signif icantly 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 exc ess oxygen level at all firing rates. If this is the case, choose the burner control setting s that give best performance over the range of firing rates. If one firing rate predomin ates, settings should optimize conditions

at that rate.

10. Verify that the new settings can accommodate th e sudden changes that may occur in daily operation without adverse effects. Do this by incr easing and decreasing 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 le vel of excess oxygen at the affect firing rates. Next, verify these new settings in a simila r fashion. Then make sure that the final control settings are recorded at steady-state opera ting conditions for future reference.7/95 ATTACHMENT 1 RULE 74.15.1: 8 Figure 1

Oxygen/CO Characteristic Curve

Figure 2

Oxygen/Smoke Characteristic Curve7/95 ATTACHMENT 2 RULE 74.15.1: 9 ATTACHMENT 2

Equipment Tuning Procedure for Natural Draft-Fired Equipment

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 Insu rers, National Fire Prevention Association, the California Department of Industrial Relations (Occu pational Safety and Health Division). the Federal Occupational Safety and Health Administrati on, or other relevant regulations and requirements. Steps in the Procedure not applicabl e to specific units may be omitted.

1. Preliminary Analysis

a. Verify that the boiler, steam generator, or pro cess heater (unit) is operating at the

lowest pressure or temperature that will satisfy lo ad demand. This pressure or temperature will be used as a basis for comparative combustion analysis before and after tune-up.

b. Verify that the unit operates for the minimum n umber of hours and days necessary

to perform the work required.

c. Verify that the size of air supply openings is in compliance with applicable codes

and regulations. Air supply openings must be fully open when the burner is firing

and air flow must be unrestricted.

d. Verify that the vent is in good condition, prop erly sized and free from obstruction.

e. Perform a combustion analysis (CO, O 2 , etc.) at both high and low fire, if

possible. Record all data, as well as the followin g:

(1) Inlet fuel pressure at burner at high and low firing rates. (2) Pressure above draft hood or barometric dampe r at high, medium and low

firing rates. (3) Steam pressure, water temperature, or process fluid pressure or

temperature entering and leaving the unit. (4) Inlet fuel use rate if meter is available.

2. Checks & Corrections

a. Clean all dirty burners or burner orifices. Ve rify that fuel filters and moisture

traps are in place, clean, and operating properly. Confirm proper location and7/95 ATTACHMENT 2 RULE 74.15.1: 10 orientation of burner diffuser spuds, gas canes, et c. Replace or repair damaged or missing burner parts.

b. Remove external and internal sediment and scale from heating surfaces.

c. Verify that the necessary water or process flui d treatment is being used. Confirm

flushing and/or blowdown schedule.

d. Repair all leaks. In addition to the high-pres sure lines, check the blow-off, drain,

safety valve, bypass lines and, if used, the feed p ump.

3. Safety Checks

a. Test primary and secondary low water level cont rols.

b. Check operating and limit pressure and temperat ure controls.

c. Check pilot safety shut off operation.

d. Check safety valve pressure setting and verify that the setting is consistent with

unit load requirements.

e. Check limit safety control and spill switch.

4. Adjustments

Perform the following checks and adjustments on a warm unit at high fire:

a. Adjust unit to fire at the maximum inlet fuel u se rate: record fuel manifold

pressure.

b. Adjust draft and/or fuel pressure to obtain acc eptable, clean combustion at both

high, medium and low firing rates. The carbon mono xide (CO) value should not exceed 400 parts per million (PPM) at 3% O 2

.

Verify that unit light-offs are smooth and safe. Perform a reduced fuel pressure

test at both high and low firing rates in accordanc e with the manufacturers

instructions.

c. Check and adjust the modulation controller. Ve rify proper, efficient and clean

combustion through the range of firing rates.

When optimum performance has been achieved, record all data.

5. Final Test7/95 ATTACHMENT 2 RULE 74.15.1: 11

Perform a final combustion analysis on the warm un it at high, medium and low firing rates, if possible. Record data obtained from comb ustion analysis, as well as the following:

a. Inlet fuel pressure at burner at high and low f iring rates.

b. Pressure above draft hood or barometric damper at high, medium and low firing

rates.

c. Steam pressure, water temperature, or process f luid pressure or temperature entering and leaving the unit.

d. Inlet fuel use rate if meter is available.