John Caudell and Scott McQuiston present the Boiler MACT and Preventative Maintenence/Malfunction Abatement Plans

1. West Michigan Air & Waste
Management Association
Spring Conference
GVSU Eberhard Center
April 26, 2012

2. Scott McQuiston, P.E. John Caudell, P.E.
Lansing Board of Water & Light Fishbeck, Thompson, Carr, & Huber
sdm@lbwl.com jfcaudell@ftch.com

3. Boiler MACT Compliance Options
Small & Hardly-Used Leads
to Expensive Solutions
Scott McQuiston, P.E.

4. Limited-Use Category
1. Rated capacity of greater than 10
MMBtu/hr
2. No more than 876 hours per year of
operation

5. Why Not A Hardly Used Category?
• Actual operation is less than 10% of:
– Emissions (PTE)
– Fuel Usage
– Capacity Factor
– 3-year average of hours of operation

6. Emission Limits
Emissions Must Not Exceed, except
Pollutant
during startup and shutdown…
CO 10 ppmvd @ 3% O2
PM 0.0075 lb/MMBtu
HCl 0.00033 lb/MMBtu
Hg 3.6 × 10-6 lb/MMBtu
D/F 4 ng/dscm (corrected to 7% O2)

7. Carbon Monoxide
• EPA Database
– Results range from 1.67 ppm to 700+ ppm
• 58 Stack Tests
– 8 Below 10 ppm
– 27 reported at 100 ppm (Detection Limit?)

8. Control Options
• Low Emissions Retrofit Kit • Catalytic Oxidizer
– $150,000 Solution – $350,000 Solution
– “Expected” CO = 10 ppm – 95% “Removal”
– Expected PM = 0.025 ppm
– PM Controls = $320,000

9. Control Options
• Gas is King!
– Only Requirement is an Annual Tune-Up
– No Emission Limits for Gas
– No Annual Stack Tests or Fuel Analyses
– No Requirement for an “Energy Assessment”
– Conversion Costs Only $300,000
– Future Gas will be Cheap, Right?

10. Questions?
Scott McQuiston, P.E.
Lansing Board of Water & Light
sdm@lbwl.com

11. Equipment Maintenance
We Don’t Need No Stinkin’
Equipment Maintenance
John Caudell, P.E.

12. New Equipment

13. 5 Years Later – Good Maintenance

14. 5 Years Later – Poor Maintenance

15. Malfunction Abatement Plan
• Preventative Maintenance
• Malfunction Response

16. Malfunction Abatement Plan
• Focus on Detailed Summary Tables
– Less on Lengthy Narratives That
Most Will Probably Not Read
• Summary Tables – Simplifies MAP
Requirements for Plant Staff and
AQD Personnel

17. Preventive Maintenance (Baghouse)
Control Device Spare Parts on
PM Activity Daily Weekly Annually
(Emission Unit) Hand
CE004 (baghouse)
Visible
Check photohelic Replacement
Emissions,
gauge for proper belts, Bearings,
CE008 (baghouse) Visual Non-certified Check oil /
operation and and Filter bags
Inspections, VE readings replace bags
pressure drop for each
Maintenance
range Baghouse model
Activities
CE010 (baghouse)

18. Malfunction Response (Baghouse)
Possible Corrective Steps to
Control Device Operating Parameter
Malfunction Possible Malfunctions Return Unit to Proper
(Emission Unit) Parameters Range
Detection Operation
Unit will be brought off-
0 - 20% Visible Emission Bag(s) may have failed or
Baghouses Opacity line and the bags
max. exceed 20% are not properly seated
checked
Unit will be brought off-
One or more bags may
CE004 line and the bags
be plugged or blinded
checked
Unit will be brought off-
Air to the cleaning jets line and air pulse
CE008 Differential 0.5 - 5" Pressure drop
maybe plugged cleaning system will be
Pressure water above 5"
inspected
Maintain spare
Magnehelic unit may
CE010 magnehelic gauge for
have failed
possible replacement

19. Preventive Maintenance (Scrubber)
Control Device Spare Parts on
PM Activity Daily Weekly Monthly
(Emission Unit) Hand
Visible
Emissions, Level
Check site gauges
Fermentation Visual Non-certified Pump oil transmitter,
for liquid flow
Scrubber Inspections, VE readings reservoir full Pump rebuild
and liquid level
Maintenance kit, Valve
Activities
Visible
Emissions, Pressure
Check site gauges
Visual Non-certified Pump oil transmitter,
Vent Gas Scrubber for liquid flow
Inspections, VE readings reservoir full Pump rebuild
and liquid level
Maintenance kit
Activities

20. Malfunction Response (Scrubber)
Possible Corrective Steps to
Control Device Operating Parameter
Malfunction Possible Malfunctions Return Unit to Proper
(Emission Unit) Parameters Range
Detection Operation
Water flow loop
Pressure less
Water flow to scrubber instrumentation will be
Vent Gas Differential 50 -150" than 50
repaired
Scrubber Pressure water
Pressure greater
Plugged packing Unit will be cleaned
than 150
Visible Emissions
Opacity 0 - 20% Loss of water flow
exceed 20%
Pressure less
Water flow to scrubber
Differential 50 -150" than 50 Water flow loop
Fermentation Pressure water instrumentation will be
Scrubber Pressure greater repaired
Plugged packing
than 150
Water 50 - 100
Flow rate <50 Flow loop failure
Flowrate gpm

21. Questions?
John Caudell, P.E.
Fishbeck, Thompson, Carr, & Huber
jfcaudell@ftch.com