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HomeMy WebLinkAboutDAQ-2024-0112361 DAQC-1078-24 Site ID 10556 (B5) MEMORANDUM TO: CEM FILE – CHEVRON MARKETING TERMINAL THROUGH: Harold Burge, Major Source Compliance Section Manager FROM: Rob Leishman, Environmental Scientist DATE: October 21, 2024 SUBJECT: Source: Marketing Terminal Primary and Secondary VRU Contact: Shane Partain – 503-939-1197 Christopher Roberge – 916-956-1270 Location: 2351 North 1100 West, Salt Lake City, Salt Lake County, UT Test Contractor: Alliance Technical Group, LLC FRS ID#: UT0000004903500240 Permit/AO#: Approval Order (AO) DAQE-AN105560017-15 dated May 18, 2015 Subject: Review of RA/PST Protocol dated October 21, 2024 On October 21, 2024, Utah Division of Air Quality (DAQ) received a protocol by email for a RA/PST (relative accuracy/performance specification test) of the Chevron Marketing Terminal Primary and Secondary VRU in Salt Lake City, Utah. Testing will be performed on December 26-27, 2024, to determine the relative accuracy of the NMHC monitoring systems. PROTOCOL CONDITIONS: 1. RM 25B used to determine total gaseous organic concentration by flame ionization detector: OK DEVIATIONS: No deviations were noted. CONCLUSION: The protocol appears to be acceptable. RECOMMENDATION: Send attached protocol review and test date confirmation notice. 1 8 2 Shane Partain OE/HSE Specialist Portland ORSalt Lake City UTEureka CA Chevron Products Company 5531 NW Doane Ave Portland OR 97210 Tel 503-221-7855 Cell 503-939-1197 prtn@chevron.com Oct 21, 2024Rob LeishmanUtah DEQPO Box 14480 Salt Lake City UT 84114 Mr Leishman, Please see the attached RATA test plan submitted to us by Alliance. If approved, we plan on conducting the RATA testing on or about Dec 26 and 27 at our Terminal located at 2351N 1100W Salt Lake City 84116. Please let me know if you need any further details or have any questions. Thank you and looking forward to your reply. Respectfully, Shane Partain OE/HES Specialist Continuous Emissions Monitoring System Relative Accuracy Test Protocol Chevron Products Company Salt Lake City Terminal 2351 North 1100 West Salt Lake City, UT 84116 Source to be Tested: VRU Proposed Test Dates: December 26 & 27, 2024 Project No. AST-2024-4946 Prepared By Alliance Technical Group, LLC 3683 W 2270 S, Suite E West Valley City, UT 84120 Site Specific Test Plan Test Program Summary AST-2024-4946 Chevron – North Salt Lake, UT Page i Regulatory Information Permit No. UDAQ DAQE-AN 105560017-15 Regulatory Citation 40 CFR Part 60, Appendix B – Performance Specification 8 Source Information Source Name Target Parameter VRU (Primary and Secondary) NMHC Contact Information Test Location Test Company Chevron Products Company Salt Lake City Terminal 2351 North 1100 West Salt Lake City, UT 84116 Facility Contacts Christopher Roberge christopher.roberge@chevron.com (916) 956-1270 Cary Freeman freeman.cary@chevron.com (801) 539-7298 Shane Partain sparta@chevron.com (503) 939-1197 Alliance Technical Group, LLC 3683 W 2270 S, Suite E West Valley City, UT 84120 Project Manager Charles Horton charles.horton@alliancetg.com (352) 663-7568 Field Team Leader Tobias Hubbard tobias.hubbard@alliancetg.com (605) 645-8562 (subject to change) QA/QC Manager Kathleen Shonk katie.shonk@alliancetg.com (812) 452-4785 Test Plan/Report Coordinator Delaine Spangler delaine.spangler@alliancetg.com Site Specific Test Plan Table of Contents AST-2024-4946 Chevron – North Salt Lake, UT Page ii TABLE OF CONTENTS 1.0 Introduction ................................................................................................................................................. 1-1 1.1 Process/Control System Descriptions .......................................................................................................... 1-1 1.2 Project Team ............................................................................................................................................... 1-1 1.3 Safety Requirements ................................................................................................................................... 1-1 2.0 Summary of Test Program .......................................................................................................................... 2-1 2.1 General Description ..................................................................................................................................... 2-1 2.2 Process/Control System Parameters to be Monitored and Recorded ........................................................... 2-1 2.3 Proposed Test Schedule............................................................................................................................... 2-1 2.4 Emission Limits ........................................................................................................................................... 2-2 2.5 Test Report .................................................................................................................................................. 2-2 3.0 Testing Methodology .................................................................................................................................. 3-1 3.1 U.S. EPA Reference Test Method 25B – Non-Methane Hydrocarbons ...................................................... 3-1 3.2 U.S. EPA Reference Test Method 205 – Gas Dilution System Certification .............................................. 3-2 4.0 Quality Assurance Program ......................................................................................................................... 4-1 4.1 Equipment ................................................................................................................................................... 4-1 4.2 Field Sampling ............................................................................................................................................ 4-2 LIST OF TABLES Table 1-1: Project Team ........................................................................................................................................... 1-1 Table 2-1: Program Outline and Tentative Test Schedule ........................................................................................ 2-1 Table 2-2: Relative Accuracy Requirements and Limits .......................................................................................... 2-2 Table 3-1: Source Testing Methodology .................................................................................................................. 3-1 LIST OF APPENDICES Appendix A Example Field Data Sheets Site Specific Test Plan Introduction AST-2024-4946 Chevron – North Salt Lake, UT Page 1-1 1.0 Introduction Alliance Technical Group, LLC (Alliance) was retained by Chevron Products Company (Chevron) to conduct performance specification (PS) testing at the North Salt Lake, Utah facility. Portions of the facility are subject to provisions of the 40 CFR 60, Appendix B, PS 8 and the Utah Department of Environmental Quality, Division of Air Quality (UDAQ) Permit No. DAQE-AN105560017-15. Testing will include conducting a relative accuracy test audit (RATA) to determine the relative accuracy (RA) of the non-methane organic compounds (NMHC) continuous emissions monitoring systems (CEMS) installed on the Primary and Secondary Vapor Recovery Units (VRU). This Continuous Emissions Monitoring System Relative Accuracy Test Protocol has been prepared to address the notification and testing requirements of the UDAQ permit. 1.1 Process/Control System Descriptions A Continuous Vapor Processing System (CVPS) is used to collect the vapors displaced during product loading. The vapors are transported through airtight collection systems to VRU for volatile organic compound (VOC) emissions control. The VRU are John Zink carbon bed systems equipped with infrared (IR) VOC analyzers. Emissions from the carbon adsorption vapor collection and processing systems shall be maintained at less than the established operating limit of 11,000 parts per million (ppm) of VOC. 1.2 Project Team Personnel planned to be involved in this project are identified in the following table. Table 1-1: Project Team Chevron Personnel Shane Partain Cary Freman Christopher Roberge Regulatory Agency UDAQ Alliance Personnel Tobias Hubbard other field personnel assigned at time of testing event 1.3 Safety Requirements Testing personnel will undergo site-specific safety training for all applicable areas upon arrival at the site. Alliance personnel will have current OSHA or MSHA safety training and be equipped with hard hats, safety glasses with side shields, steel-toed safety shoes, hearing protection, fire resistant clothing, and fall protection (including shock corded lanyards and full-body harnesses). Alliance personnel will conduct themselves in a manner consistent with Client and Alliance’s safety policies. A Job Safety Analysis (JSA) will be completed daily by the Alliance Field Team Leader. Site Specific Test Plan Summary of Test Programs AST-2024-4946 Chevron – North Salt Lake, UT Page 2-1 2.0 Summary of Test Program To satisfy the requirements of the UDAQ permit, the facility will conduct a performance test program to determine the compliance status of the VRU primary and secondary CEMS. 2.1 General Description All testing will be performed in accordance with specifications stipulated in U.S. EPA Reference Test Method 25B. Table 2-1 presents an outline and tentative schedule for the emissions testing program. The following is a summary of the test objectives. • Testing will be performed to demonstrate compliance with the 40 CFR 60, Appendix B, PS 8 and the UDAQ permit. • Emissions testing will be conducted on the exhaust of the VRU primary and secondary CEMS. • Performance testing will be conducted at least 50% operating load. • Each of the twelve (12) test runs will be 21 minutes in duration. 2.2 Process/Control System Parameters to be Monitored and Recorded Plant personnel will collect operational and parametric data at least once every 15 minutes during the testing. The following list identifies the measurements, observations and records that will be collected during the testing program: • CEMS Data • Product Loaded 2.3 Proposed Test Schedule Table 2-1 presents an outline and tentative schedule for the emissions testing program. Table 2-1: Program Outline and Tentative Test Schedule Testing Location Parameter US EPA Method No. of Runs Run Duration Est. Onsite Time DAY 1 – December 23, 2024 Equipment Setup & Pretest QA/QC Checks 6 hr DAY 2 – December 26, 2024 Primary VRU NMHC 25B 12 21 min 8 hr DAY 3 – December 27, 2024 Secondary VRU NMHC 25B 12 21 min 8 hr Site Specific Test Plan Summary of Test Programs AST-2024-4946 Chevron – North Salt Lake, UT Page 2-2 2.4 Emission Limits Emission limits for each pollutant are below. Table 2-2: Relative Accuracy Requirements and Limits Source CEMS Required Relative Accuracy Applicable Standard / Limit Citation VRU (Primary) NMHC RA: ≤20% of RM or ≤10 % of AS 11,000 ppmvw as propane 60, Appendix B, PS 8 VRU (Secondary) NMHC RA: ≤20% of RM or ≤10 % of AS 11,000 ppmvw as propane 2.5 Test Report The final test report must be submitted within 60 days of the completion of the performance test and will include the following information. • Introduction – Brief discussion of project scope of work and activities. • Results and Discussion – A summary of test results and process/control system operational data with comparison to regulatory requirements or vendor guarantees along with a description of process conditions and/or testing deviations that may have affected the testing results. • Methodology – A description of the sampling and analytical methodologies. • Sample Calculations – Example calculations for each target parameter. • Field Data – Copies of actual handwritten or electronic field data sheets. • Quality Control Data – Copies of all instrument calibration data and/or calibration gas certificates. • Process Operating/Control System Data – Process operating and control system data (as provided by Chevron) to support the test results. Site Specific Test Plan Testing Methodology AST-2024-4946 Chevron – North Salt Lake, UT Page 3-1 3.0 Testing Methodology This section provides a description of the sampling and analytical procedures for each test method that will be employed during the test program. All equipment, procedures and quality assurance measures necessary for the completion of the test program meet or exceed the specifications of each relevant test method. The emission testing program will be conducted in accordance with the test methods listed in Table 3-1. Table 3-1: Source Testing Methodology Parameter U.S. EPA Reference Test Methods Notes/Remarks Non-Methane Hydrocarbons Compounds 25B Instrumental Analysis Gas Dilution System Certification 205 -- All stack diameters, depths, widths, upstream and downstream disturbance distances and nipple lengths will be measured on site with an EPA Method 1 verification measurement provided by the Field Team Leader. These measurements will be included in the test report. 3.1 U.S. EPA Reference Test Method 25B – Non-Methane Hydrocarbons Total hydrocarbon (THC) concentrations will be measured in accordance with EPA RM 25B using an infrared hydrocarbon analyzer. Each sampling period will consist of extracting a hot, wet gas sample from a single centrally located point in the stack at a constant flow rate of approximately two liters per minute using a heated Teflon line. The gas will be directed into a column of the California Analytical (or equivalent) infrared total hydrocarbon analyzer. THC concentrations will be displayed on the analyzer front panel in units of ppmvw as C3H8 and logged to a computerized data acquisition system (CDAS). Prior to sampling, the analyzer will be challenged with the zero and high-level EPA Protocol 1 calibration gases to linearize the instrument. Then the low and mid-level calibration gases will be introduced through the sampling system. The sampling system is acceptable, if the linear relationship between the zero and high-level calibration gases predict the low and mid-level calibration gas measurement system response within 5% of the respective calibration gas value. The system response time will be determined as the time required for the analyzer reading to reach 95 percent of the high gas concentration through the sampling system. After each sampling period, the measurement system will be challenged with the zero and mid-level calibration gas. If the analyzer drift exceeds 3% of the analyzer span (80-90% of high-level calibration gas), then the system will be re-linearized with the zero and high-level calibration gases, and the measurement system verified with the low and mid-level calibration gases. If the drift limits are exceeded, the results will be reported using both sets of calibration data. Following sampling, the CDAS data will be averaged in one-minute increments and reported as average THC emission concentrations in units of ppmvw as C3H8 for each sampling period. The THC RM emissions data from each sampling period will be compared with CEMS data from the same period to calculate the RA of the system in units of ppmvw as C3H8. Site Specific Test Plan Testing Methodology AST-2024-4946 Chevron – North Salt Lake, UT Page 3-2 3.2 U.S. EPA Reference Test Method 205 – Gas Dilution System Certification A calibration gas dilution system field check will be conducted in accordance with U.S. EPA Reference Method 205. An initial three (3) point calibration will be conducted, using individual Protocol 1 gases, on the analyzer used to complete the dilution system field check. Multiple dilution rates and total gas flow rates will be utilized to force the dilution system to perform two dilutions on each mass flow controller. The diluted calibration gases will be sent directly to the analyzer, and the analyzer response will be recorded in an electronic field data sheet. A mid-level supply gas, with a cylinder concentration within 10% of one of the gas divider settings described above, will be introduced directly to the analyzer, and the analyzer response recorded in an electronic field data sheet. The cylinder concentration and the analyzer response must agree within 2%. These steps will be repeated three (3) times. The average analyzer response must agree within 2% of the predicted gas concentration. No single injection shall differ more than 2% from the average instrument response for that dilution. Site Specific Test Plan Quality Assurance Program AST-2024-4946 Chevron – North Salt Lake, UT Page 4-1 4.0 Quality Assurance Program Alliance follows the procedures outlined in the Quality Assurance/Quality Control Management Plan to ensure the continuous production of useful and valid data throughout the course of this test program. The QC checks and procedures described in this section represent an integral part of the overall sampling and analytical scheme. Adherence to prescribed procedures is quite often the most applicable QC check. 4.1 Equipment Field test equipment is assigned a unique, permanent identification number. Prior to mobilizing for the test program, equipment is inspected before being packed to detect equipment problems prior to arriving on site. This minimizes lost time on the job site due to equipment failure. Occasional equipment failure in the field is unavoidable despite the most rigorous inspection and maintenance procedures. Therefore, replacements for critical equipment or components are brought to the job site. Equipment returning from the field is inspected before it is returned to storage. During the course of these inspections, items are cleaned, repaired, reconditioned and recalibrated where necessary. Calibrations are conducted in a manner, and at a frequency, which meets or exceeds U.S. EPA specifications. The calibration procedures outlined in the U.S. EPA Methods, and those recommended within the Quality Assurance Handbook for Air Pollution Measurement Systems: Volume III (EPA-600/R-94/038c, September 1994) are utilized. When these methods are inapplicable, methods such as those prescribed by the American Society for Testing and Materials (ASTM) or other nationally recognized agency may be used. Data obtained during calibrations is checked for completeness and accuracy. Copies of calibration forms are included in the report. The following sections elaborate on the calibration procedures followed by Alliance for these items of equipment. • Dry Gas Meter and Orifice. A full meter calibration using critical orifices as the calibration standard is conducted at least semi-annually, more frequently if required. The meter calibration procedure determines the meter correction factor (Y) and the meter’s orifice pressure differential (ΔH@). Alliance uses approved Alternative Method 009 as a post-test calibration check to ensure that the correction factor has not changed more than 5% since the last full meter calibration. This check is performed after each test series. • Pitot Tubes and Manometers. Type-S pitot tubes that meet the geometric criteria required by U.S. EPA Reference Test Method 2 are assigned a coefficient of 0.84 unless a specific coefficient has been determined from a wind tunnel calibration. If a specific coefficient from a wind tunnel calibration has been obtained that coefficient will be used in lieu of 0.84. Standard pitot tubes that meet the geometric criteria required by U.S. EPA Reference Test Method 2 are assigned a coefficient of 0.99. Any pitot tubes not meeting the appropriate geometric criteria are discarded and replaced. Manometers are verified to be level and zeroed prior to each test run and do not require further calibration. • Temperature Measuring Devices. All thermocouple sensors mounted in Dry Gas Meter Consoles are calibrated semi-annually with a NIST-traceable thermocouple calibrator (temperature simulator) and verified during field use using a second NIST-traceable meter. NIST-traceable thermocouple calibrators are calibrated annually by an outside laboratory. • Nozzles. Nozzles are measured three (3) times prior to initiating sampling with a caliper. The maximum difference between any two (2) dimensions is 0.004 in. • Digital Calipers. Calipers are calibrated annually by Alliance by using gage blocks that are calibrated annually by an outside laboratory. Site Specific Test Plan Quality Assurance Program AST-2024-4946 Chevron – North Salt Lake, UT Page 4-2 • Barometer. The barometric pressure is obtained from a nationally recognized agency or a calibrated barometer. Calibrated barometers are checked prior to each field trip against a mercury barometer. The barometer is acceptable if the values agree within ± 2 percent absolute. Barometers not meeting this requirement are adjusted or taken out of service. • Balances and Weights. Balances are calibrated annually by an outside laboratory. A functional check is conducted on the balance each day it is use in the field using a calibration weight. Weights are re-certified every two (2) years by an outside laboratory or internally. If conducted internally, they are weighed on a NIST traceable balance. If the weight does not meet the expected criteria, they are replaced. • Other Equipment. A mass flow controller calibration is conducted on each Environics system annually following the procedures in the Manufacturer’s Operation manual. A methane/ethane penetration factor check is conducted on the total hydrocarbon analyzers equipped with non-methane cutters every six (6) months following the procedures in 40 CFR 60, Subpart JJJJ. Other equipment such as probes, umbilical lines, cold boxes, etc. are routinely maintained and inspected to ensure that they are in good working order. They are repaired or replaced as needed. 4.2 Field Sampling Field sampling will be done in accordance with the Standard Operating Procedures (SOP) for the applicable test method(s). General QC measures for the test program include: • Cleaned glassware and sample train components will be sealed until assembly. • Sample trains will be leak checked before and after each test run. • Appropriate probe, filter and impinger temperatures will be maintained. • The sampling port will be sealed to prevent air from leaking from the port. • Dry gas meter, ΔP, ΔH, temperature and pump vacuum data will be recorded during each sample point. • An isokinetic sampling rate of 90-110% will be maintained, as applicable. • All raw data will be maintained in organized manner. • All raw data will be reviewed on a daily basis for completeness and acceptability. Appendix A THC Summary Location: Source: Project No.: Reference Method CEMS Average THC (as C3H8) Concentration THC (as C3H8) Concentration Difference Start End ppmvd ppmvd ppmvd 1 -- -- 2 -- -- 3 -- -- 4 -- -- 5 -- -- 6 -- -- 7 -- -- 8 -- -- 9 -- -- 10 * -- -- 11 * -- -- 12 * -- -- - RA ≤ 20% PS 8 Confidence Coefficient, CC where, t0.975 #N/A = degrees of freedom n 0 = number of runs selected for calculating the RA Sd = standard deviation of difference CC = confidence coefficient Relative Accuracy, RA where, d = average difference of Reference Method and CEMS CC = confidence coefficient RM = reference method, ppmvd RA = relative accuracy, % Standard Deviation (Sd) Applicable Source Standard (AS) DateRun No. Time Average * Delimiter for runs not used in RA calculations Confidence Coefficient (CC) THC data reported as propane (C3H8). Performance Required - Mean Reference Method Performance Specification Method Relative Accuracy (RA) Emissions Calculations Location: Source: Project No.: 1 2 3 4 5 6 7 8 9 10 11 12 Date ------------ Start Time ------------------------ Stop Time ------------------------ Calculated Data THC (as C3H8) Concentration ppmvw CTHCw ------------------------ Run Number - - - Run 1 Data Location: Source: Project No.: Date: Time THC Unit ppmvw Status Valid -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- THC Uncorrected Run Average (Cobs)- Cal Gas Concentration (CMA)-- Pretest System Zero Response Posttest System Zero Response Average Zero Response (Co)- Pretest System Cal Response Posttest System Cal Response Average Cal Response (CM)- Corrected Run Average (Corr)NA Parameter - Pollutant QA Data Location: Source: Project No.: THC -- -- -- Cylinder Number ID LOW MID HIGH Cylinder Certified Values LOW MID HIGH Make Model S/N Operating Range Parameter Calibration Data Location: Source: Project No.: Date: THC Expected Average Concentration Span Should be between: Low - High - Desired Span -- Low Range Gas Should be between Low - High - Mid Range Gas Should be between Low - High - High Range Gas Should be between Low - High - Actual Concentration (% or ppm) Zero 0.0 Low -- Mid -- High -- Response Time (seconds) Upscale Calibration Gas (CMA)Mid Instrument Response (% or ppm) Zero Low Mid High Performance (% of Span or Calibration Gas) Zero 0.0 Low - Mid - High - Status Zero - Low - Mid - High - Parameter -- Runs 1-3 Bias/Drift Determinations Location: Source: Project No.: Date: THC Span Value - Instrument Zero Cal Response - Instrument Mid Cal Response - Pretest System Zero Response - Posttest System Zero Response - Pretest System Mid Response - Posttest System Mid Response - Bias or System Performance (%) Pretest Zero NA Posttest Zero NA Pretest Span NA Posttest Span NA Drift (%) Zero - Mid - Span Value - Instrument Zero Cal Response - Instrument Mid Cal Response - Pretest System Zero Response - Posttest System Zero Response - Pretest System Mid Response - Posttest System Mid Response - Bias (%) Pretest Zero NA Posttest Zero NA Pretest Span NA Posttest Span NA Drift (%) Zero - Mid - Span Value - Instrument Zero Cal Response - Instrument Mid Cal Response - Pretest System Zero Response - Posttest System Zero Response - Pretest System Mid Response - Posttest System Mid Response - Bias (%) Pretest Zero NA Posttest Zero NA Pretest Span NA Posttest Span NA Drift (%) Zero - Mid - Run 1 Run 2 Run 3 - Parameter Location: Source: Project No.: Date EPA O2 -- -- -- -- Cylinder Number ID Zero NA Mid -- High -- Cylinder Certified Values Zero 0.0 Mid -- High -- Instrument Response (% or ppm) Zero -- Mid -- High -- Calibration Gas Selection (% of Span) Mid -- High -- Calibration Error Performance (% of Span) Zero -- Mid -- High -- Linearity (% of Range) -- (%) lpm (%) (%) (%) (%) (%) (%) (%)( ± 2 %) 10L/10L* 90.0 7.0 ---- 10L/10L* 80.0 7.0 ---- 10L/5L 80.0 5.0 ---- 10L/5L 50.0 5.0 ---- 10L/1L 20.0 4.0 ---- 10L/1L 10.0 4.0 ---- (%)( ± 2 %)( ± 2 %)( ± 2 %) ---- ---- ---- ---- ---- ---- Mid-Level Supply Gas Calibration Direct to Analyzer Calibration Injection 1 Injection 2 Injection 3 Average Gas Analyzer Analyzer Analyzer Analyzer Concentration Concentration Concentration Concentration Concentration (%) (%) (%) (%) (%) (%)( ± 2 %) - --- Analyzer Make: -- -- - -- -- -- Parameter Make Model S/N Span Method Criteria Analyzer Model: -- Analyzer SN: -- Environics ID: -- Component/Balance Gas: O2/N2 Cylinder Gas ID (Dilution): Cylinder Gas Concentration (Dilution), %: *Not all AST Environics Units have 2-10L Mass Flow Controllers. For these units the 90% @ 7lpm and 80% @ 7lpm injections will not be conducted. Cylinder Gas ID (Mid-Level): Cylinder Gas Concentration (Mid-Level), %: Target Mass Flow Contollers Target Dilution Target Flow Rate Target Concentration Actual Concentration Injection 1 Analyzer Concentration Injection 2 Analyzer Concentration Injection 3 Analyzer Concentration Average Analyzer Concentration Difference Average Error Average Analyzer Concentration Injection 1 Error Injection 2 Error Injection 3 Error Difference Average Error