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HomeMy WebLinkAboutDAQ-2025-0013761 DAQC-241-25 Site ID 16140 (B4) MEMORANDUM TO: STACK TEST FILE – CRUSOE ENERGY SYSTEMS, INC. – Mullins Tap Facility THROUGH: Rik Ombach, Minor Source Oil and Gas Compliance Section Manager FROM: Paul Bushman, Environmental Scientist DATE: March 3, 2025 SUBJECT: Sources: Five (5) Waukesha 9394 GSI generator engines; Unit IDs: 1320, 1454, 2026-01, 1452, 1453 Location: Duchesne County, UT Contact: Kaitlin Meszaros: 631-245-0308. Tester: Great Plains Analytical Services, Inc. Site ID #: 16140 Permit/AO #: DAQE-AN161400001-23, dated August 9, 2023 Subject: Review of Pretest Protocol dated February 28, 2025 On February 28, 2025, Utah Division of Air Quality (DAQ) received the protocol for the testing of five (5) Waukesha 9394 GSI generator engines at Crusoe Energy Systems, Incorporated Mullins Tap Facility in Duchesne County, UT. Testing will be performed during the week of March 31, 2025, to determine compliance with the emission limits found in Condition II.B.2 of Approval Order DAQE-AN161400001-23 and 40 CFR Part 60 Subpart JJJJ. PROTOCOL CONDITIONS: 1. RM 1 used to determine sample velocity traverses: OK 2. RM 2 used to determine stack gas velocity and volumetric flow rate: OK 3. RM 3A used to determine dry molecular weight of the gas stream: OK 4. ASTM D6348-03 used to determine H2O content; NOx, CO, and VOC emissions: OK DEVIATIONS: None. CONCLUSION: The protocol appears to be acceptable. RECOMMENDATION: Send protocol review and test date confirmation notice. ATTACHMENTS: Crusoe Energy Systems’ pretest protocol and test notification. 303 West 3rd Street ● Elk City, Oklahoma 73644 ● 580-225-0403 GAS Inc. www.gasinc.us February 28, 2025 Utah Department of Environmental Quality State Office Building – Air Quality Division 195 North 1950 West Salt Lake City, Utah 84114 RE: Crusoe Energy Systems, Inc. 40 CFR Part 60 Subpart JJJJ – Test Notification To Whom It May Concern, We are notifying you of performance testing dates for 40 CFR Part 60, Subpart JJJJ on behalf of Crusoe Energy Systems, Inc. Please see below for the information pertinent to the testing. The testing will take place the week of March 31, 2025. Facility Unit # Serial # Location Crusoe Mullins Tap Facility 1320 WAU -1632087 Duchesne County, Utah Crusoe Mullins Tap Facility 1454 WAU -1651084 Duchesne County, Utah Crusoe Mullins Tap Facility 2026-01 WAU -1641324 Duchesne County, Utah Crusoe Mullins Tap Facility 1452 WAU -1651044 Duchesne County, Utah Crusoe Mullins Tap Facility 1453 WAU -1651075 Duchesne County, Utah Our testing protocol is included, for information regarding our protocol or the performance test, you can contact me by email at mholsapple@gasinc.us or by phone at 580-225-0403. For information regarding engine or location information, please contact Kaitlin Meszaros by email at meszaros@pinyon-env.com or by phone at (631)-245-0308. Regards, Macie Holsapple Client Services Supervisor GAS Inc. Great Plains Analytical Services, Inc. TypeAnnual Prepared on behalf ofCrusoe Energy Systems, Inc. Unit IDs 1320, 1454, 2026-01, 1452, 1453 Prepared by 303 West 3rd StreetElk City, OK 73644 Performance Test Protocol40 CFR Part 60 Subpart JJJJ Facility: Crusoe Mullins Tap Facility State of Utah Permit ID: #DAQE-AN161400001-23 Great Plains Analytical Services, Inc. 1.0 Introduction………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….3 1.1 Contact Information………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….3 2.0 Test Information………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….3 3.0 Method Synopsis………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….5 4.0 Emission Point Information………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….6 4.1 Target Analytes………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….6 4.2 Test Quality Objectives………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….6 5.0 Quality Control Information………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….7 6.0 Additional Information and Reporting………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….8 7.0 Example Calculations………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….8 8.0 Health and Safety Concerns………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….9 1.1 Contact Information………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….3 2.0 Source Information and Testing Dates………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….3 2.1 Testing Limits and Parameters (Federal)………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….4 2.2 Testing Limits and Parameters (State)………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….4 2.3 Additional Parameters………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….4 4.2 Test Specific Target Analytes and Data Quality Objectives………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….6 5.0 QA/QC………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….7 5.1 Measurement System Capabilities………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….7 3.1 Sample Port Location………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….5 3.2 Sample locations inside the stack………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….5 9.0 Sampling Schematic Diagram………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….9 10.0 Engine Parameter Data Sheet Diagram………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….10 11.0 Velocity Field Data Diagram………………………………………………………………………………………………………………………………………………………………………………………………….…………………………………………………………………………………………………….10 Table of Contents Table(s) Figure(s) Protocol Attachment(s) 3 Great Plains Analytical Services, Inc. 2.0 Test Information (continued) 2026-01 1452 1453 1320 1454 Week of 03/31/2025 WAU-1641324 Crusoe Mullins Tap Facility Waukesha 9394 GSI 2500Week of 03/31/2025 WAU-1651084 Crusoe Mullins Tap Facility Waukesha 9394 GSI 2500 GAS has been contracted by Crusoe Energy Systems, Inc. to conduct source testing services at Crusoe Mullins Tap Facility located in Duchesne County, Utah. The purpose of this test plan is to document the test methods and procedures that will be employed to collect and analyze exhaust gas emissions during performance testing of the internal combustion engines fueled by Natural Gas. Contact Macie Holsapple Physical Address 303 W 3rd St. Elk City, OK 73644GAS580-225-0403 Table 1.1 Contact Information Kaitlin Meszaros Serial Number Location/Facility Name Make and Model Site Rated Horsepower Application Telephone Email Address Source ID WAU-1632087 Crusoe Mullins Tap Facility Waukesha 9394 GSI 2500 Test Dates Week of 03/31/2025 mholsapple@gasinc.us Crusoe Energy Systems, Inc.720-614-5598 Meszaros@pinyon-env.com Table 2.0 Test Information and Testing Dates WAU-1651044 Crusoe Mullins Tap Facility Waukesha 9394 GSI 2500Week of 03/31/2025 Waukesha 9394 GSI 2500Week of 03/31/2025 1.1 Contact Information 2.0 Test Information WAU-1651075 Crusoe Mullins Tap Facility 1.0 Introduction Tests will consist of (3) 60 minute test runs. The test will be conducted using a multi component gas analyzer that incorporates a Fourier Transform Infrared (FTIR) spectrometer. FTIR is state of the art technology. It is designed to military specifications and allows simple calibration using only single component calibration gases. 4 Great Plains Analytical Services, Inc. g/hp-hr lb/hr TPY ppm @15% O2 g/hp-hr lb/hr TPY ppm @15% O2 g/hp-hr lb/hr TPY ppm @15% O2 1.00 2.00 0.70 1.00 2.00 0.70 1.00 2.00 0.70 1.00 2.00 0.70 1.00 2.00 0.70 g/hp-hr lb/hr TPY ppm @15% O2 g/hp-hr lb/hr TPY ppm @15% O2 g/hp-hr lb/hr TPY ppm @15% O2 0.15 0.83 0.30 1.65 0.03 0.170 0.15 0.83 0.30 1.65 0.03 0.170 0.15 0.83 0.30 1.65 0.03 0.170 0.15 0.83 0.30 1.65 0.03 0.170 0.15 0.83 0.30 1.65 0.03 0.170 3A D6348-03 1/1A 1452 1453 1320 1454 2026-01 NOx CO Reference Method ASTM D6348-03Reference Method ASTM D6348-03 Table 2.1 Testing Limits and Parameters (Federal) Reference Method ASTM D6348-03Source ID VOC (NMNEHC) Table 2.2 Testing Limits and Parameters (State) Source ID NOx CO VOC (NMNEHC) Reference Method ASTM D6348-03 Reference Method ASTM D6348-03 Reference Method ASTM D6348-03 1320 1454 2026-01 1452 1453 CH2O 320 Reduction % Table 2.4 Testing Limits and Parameters (Reduction) 1453 1320 1454 2026-01 1452 Source ID Table 2.3 Additional Parameters Reduction % Reference Method 10/2 COOxygen (O2)%vd Moisture % H2O Sample Location Inches (") CO2, H2O, NOx, CO, VOC, and CH2O will be measured using a Gasmet multigas FTIR analyzer in accordance with ASTM Method D6348 when applicable analytes are being tested for. Footnote 5 Great Plains Analytical Services, Inc. 3.0 Method Synopsis For all stacks greater than 6" in diameter, GAS will sample at 3 points within the stack. These points will be located at 83.3%, 50%, and 16.7% of the stack diameter. 1/2 diameter upstream 2 diameters downstream Figure 3.2. Sample locations inside the stack Actual diameter Figure 3.1. Sample Port Location EPA Method 1/1A Figure 3.1 Figure 3.2 The purpose of the method is to provide guidance for the selection of sampling ports and traverse points at which sampling for air pollutants will be performed pursuant to regulations set forth in this part. Method 1 may be modified as allowed in Subpart JJJJ & ZZZZ. Alternatively, for NOx, CO, VOC, O2, and moisture measurement, ducts ≤6 inches in diameter may be sampled at a single point located at the duct centroid and ducts >6 and ≤12 inches in diameter may be sampled at 3 traverse points located at 16.7, 50.0, and 83.3% of the measurement line ('3-point long line'). If the duct is >12 inches in diameter and the sampling port location meets the two and half-diameter criterion of Section 11.1.1 of Method 1 of 40 CFR part 60, Appendix A, the duct may be sampled at '3-point long line'; otherwise, conduct the stratification testing and select sampling points according to Section 8.1.2 of Method 7E of 40 CFR part 60, Appendix A." For all stacks greater than 6" in diameter, GAS will use a sampling port that is located at a minimum of 2 stack diameters downstream from any disturbance, and 1/2 stack diameter upstream from any disturbance. 6 Great Plains Analytical Services, Inc. 4.1 Target Analytes 4.2 Test Quality Objectives EPA Method 2/2C EPA Method 3A This method is applicable for the determination of the average velocity and the volumetric flow rate of a gas stream. Method 2 will be used for stacks greater than 12 inches. Method 2C will be used for stacks with a diameter of 12 inches or less. This is a procedure for measuring oxygen (O2) and carbon dioxide (CO2) in stationary source emissions using a continuous instrumental analyzer. Quality assurance and quality control requirements are included to assure that the tester collects data of known quality. Documentation to these specific requirements for equipment, supplies, sample collection and analysis, calculations, and data analysis will be included. NO 1875-2138 0-1000 ppm 0.20 ppm 2 ppm ASTM D6348-03 This extractive FTIR based field test method is used to quantify gas phase concentrations of multiple target analytes from stationary source effluent. Because an FTIR analyzer is potentially capable of analyzing hundreds of compounds, this test method is not analyte or source specific. The analytes’ detection levels, and data quality objectives are expected to change for any particular testing situation. It is the responsibility of the tester to define the target analytes, the associated detection limits for those analytes in the particular source effluent, and the required data quality objectives for each specific test program. Provisions are included in this test method that require the tester to determine critical sampling system and instrument operational parameters, and for the conduct of QA/QC procedures. Testers following this test method will generate data that will allow an independent observer to verify the valid collection, identification, and quantification of the subject target analytes. A heated sample line is used to collect the sample on a wet basis per ASTM D6348. Effluent Moisture content is determined to within a 2% accuracy using the FTIR analytical algorithm. 4.0 Emissions Point Information 4 ppm1 ppm0-1200 ppm2000-2200 2700-2950 0-100 ppm 0.03 ppm 2 ppmNO2 *. Measured flue gas conditions at the sampling location including temperature, moisture content, and volumetric flow rate will be included in test results. Interfering CompoundsCO2 926-1150 0-10%0%n/aWater Vapor 3200-3401 0-22%0.2%n/a VOC as defined in 40 CFR Part 60 subpart JJJJ 2600-3200 0-100 ppm 0.9 ppm 1 ppm910-11502550-2950 Section 12.5 of this method will be utilized to determine the molecular weight of the stack on a wet basis. The formula found in Method 3 section 12.3 will be utilized to determine the molecular weight of the stack gas on a dry basis. CO Target Analytes Exhaust emission testing will be conducted for the following compounds: carbon monoxide (CO), oxides of nitrogen (NOx), volatile organic compounds (VOCs), and oxygen (O2%). Table 4.2 summarizes the test quality objectives specific that will be used to evaluate test data to a known degree of accuracy. Compounds Table 4.2. Test Specific Target Analytes and Data Quality Objectives Infrared Analysis Expected Concentration Range Measurement System Achievable Minimum Detectable Concentrations Required Measurement System Accuracy and Precision for Test Application (cm-1) 7 Great Plains Analytical Services, Inc. Path Length Dilution Factor % Recovery 4.93 10 92 A1) A2)A3)A4)A5)A6)A7) Stainless Steel Every Test Velocity Flow Measurement (2) Manometer is leveled and visual inspected Sample Point Selection (1/1A)1/2 stack diameter downstream and 2 stack diameters upstream.Every test Sample Extraction (D6348)Placed after heated probe Changed weekly Heated to 180°C, introduces calibration into sampling system at the probe outlet Every testProbe Box Sample Extraction (3A/D6348)Sample kept above dew point at all times. Temp kept to 180°C at all times. Visible digital gaugeSample Extraction (1/1A) Every test run Manometer Manometer Velocity Flow Measurement (2) System is back purged after last sample. Another sample is taken and must be within 5% of the last sample Every test System Performance (D6348) Verify line positions have not shifted by more than 15% of the resolution, and the resolution has not changed by more than 15% of that determined prior to testing. Post TestLine position System Performance (3A)Within 5%Before first test and after last Calibration System bias check System Performance (D6348)Within Tolerance Pre and post test System Zero CTS Check direct to analyzer System Performance (D6348)Within Tolerance Pre Test System Performance (D6348)Within 30% of effluent concentration Every test run System Performance (3A)Within 10% of the Sample collected Every test 5.0 Quality Control Information The following is a list of the QA/QC procedures performed. It is listed as to the process and method it pertains to. Calibration sheets, calibration gases and any other testing equipment will be made available prior to the start of testing. Upon completion of the assembled sampling system, a leak check will be conducted under pressure or partial vacuum conditions to ensure the integrity of the sample collection system. QA/QC Element Traceability protocol Probe material Particulate filter Table 5.0 QA/QC Multiple Sample Points Simultaneously (1/1A)83.3%, 50%, 16.6% from stack walls All stacks under 6" Measurement from disturbances Distance from stack walls Sample Extraction (D6348) Heated line Manifold material Process or Element (Method)Acceptance Criteria Frequency Calibration Gas 2% Certainty Every Test Sample Extraction (1/1A)Pass system bias check Every test run Propane 101.9 37 Table 5.1. Measurement System Capabilities Parameter Measured Gas Concentration Equilibration Time Path Length Ethylene 101.2 Analyte Spike Recovery Propane 101.9 50 CTS Check entire system System Recovery (Spike) Data generated during the bench scale pre-test procedures will be presented in Table 5.1. Please note that Table 5.1 will be presented in the final report with data collected from the actual field-testing source. System Performance (3A/D6348)Determines minimum sampling time During bias check System Performance (3A)Within 3%During bias check System response time Drift System Performance (D6348)Less than 2 % of permit limit Pre test 5.0 Quality Control Information (continued) Mechanical Response Time Ethylene 101.2 42 System Response Time Determination of System Performance Parameters - Noise Equivalent Absorbance, Line Position, Resolution, and Analyte Spiking TechniqueRequired Pre-Test ProceduresFTIR Reference Spectra Preparation of Analytical Quantification Algorithm Determination of FTIR Measurement System Minimum Detectable ConcentrationTest Plan Requirements All information required per ASTM D6348, Annexes 1-7 will be provided in the final report. This information shall cover: System Zero Nitrogen 65 8 Great Plains Analytical Services, Inc. * Elevation, Barometric pressure ("HG), Ambient temperature °F, Humidity %, Dew Point °F * Catalyst Inlet Temp °F, Catalyst Outlet Temp °F, Manifold Temp °F * Exhaust Gas Temp °C * RPM, Manifold Pressure ("HG) * Horsepower (BHP) and Fuel Flow Rate (dscfh) * Stack Diameter (") * Sample location (" Downstream from Disturbance & " Upstream from Disturbance) * Catalyst Pressure Drop ( Inches H2O) * Moisture Percentage * Volumetric Flow Rate * AFR setpoints and reading * Catalyst Manufacturer * Number of elements * Date of installation * Date of last reconditioning or cleaning 1. Exhaust Volumetric flow Rate Determination by EPA Method 2 Qsd=3600*(1-B(ws))*V(s)*A*(T(std)/T(s))*P(s)/P(std) V(s)= Absolute Stack Gas Velocity A= Cross Sectional Area of Stack T(std)= Standard Absolute Temperature T(s)= Absolute Stack Temperature P(s)= Absolute Stack Pressure P(std)= Standard Absolute Pressure (When Method 2 is used) K=Pitot tube velocity Constant (85.49) C=Velocity Pressure Coefficient √ΔP= Square Root of differential Pressure of stack gas (inH2O) T(s(avg))= Average Stack temp °R M=Molecular Weight of stack gas, wet basis P= Absolute stack gas Pressure 3. Mass Emission Rates (G./HP.-HR.) K*C*√(ΔP)*√(T(s(avg))+460)/√(M*P)V(s)= 6.0 Additional Information and Reporting Additional parameters and atmospheric information will also be provided in the final report and will include: The final report will contain all field test data including all pre and post calibration information. Final concentrations will be reported in the permitted units of measure. 7.0 Example Calculations 2. Absolute Stack Gas Velocity V(s) 3. Mass Emission Rates (LBS./HR.) ((Mol Wgt)*(Qd dscfh)*(concentration (385*106)(LB/HR)*454Engine Horsepower (LB/HR)*24(HRS/DAY)*365(Days/YR)2000(LB/TON) 3. Mass Emission Rates (TPY) TPY = g/hp-hr = lb/hr = 9 Great Plains Analytical Services, Inc. * Hardhat* Steel-Toed Boots* Safety Glasses* Hearing Protection* Fire-Retardant Clothing* 4 - Safety Gloves* 4 Gas Monitor * * * * * * * * * Control Panel: Allows the control of flow throughout the system as required by ASTM D6348 and Method 3A. Allows for introduction of calibration standards into the sampling system at the probe outlet, upstream of the primary particulate filter. Due to the remote location of the source unit, additional health & safety precautions will be observed such as avoidance of slips, trips, falls, and heat exhaustion. Figure 9.0 Sampling Schematic Diagram Figure 9.0 Schematic Diagram In addition, GAS will use the following safety equipment: O2 Sensor: Zirconium Dioxide sensor to measure Oxygen per method 3A. Gasmet FTIR: FTIR Analyzer for use with ASTM D6348 Flow Meter: Allows proper measurement of flow. Data: Data acquisition system that allows for the acquisition of the infrared data, Oxygen data and analysis of the resulting spectra. Gas: Required calibration gases per ASTM D6348 and Method 3A. 8.0 Health and Safety Concerns In accordance with 40 CFR Part 60.8, the client must provide safe access to the unit for testing and observance. Due to the nature of the source and the exposure to high temperatures, extreme caution will be observed in order to avoid contact with the unit which may result in burns and or inhalation of exhaust emissions. GAS personnel will sign in and out at all facilities, as well as undergo site specific safety training. Probe: Heated probe assembly required by ASTM D6348. Heated Line: Used for "Hot/Wet" sample to keep line above any dew point that would cause moisture to drop out.PSS: Allows precise heating of the sampling system. Breakdown Of Schematic Diagram: ! 10 Great Plains Analytical Services, Inc. **Note: Actual note parameters may differ due to the availability of such parameters at specific locations. Attachment 10.0 Engine Parameter Data Sheet Diagram Attachment 11.0 Velocity Field Data 1/53 Great Plains Analytical Services, Inc. 10.0 Engine Parameter Data Sheet Company Facility Date Elevation (ft) Unit ID Make Model Serial Number Technician Run 1 Run 2 Run 3 AverageTime:9:06 AM 10:17 AM 11:28 AM N/A Engine Speed (RPM)1601 1600 1603 1601Engine Hours 10568 10569 10570 10571Catalyst (Yes or No)Yes Yes Yes YesCatalyst Manufacturer Murphy Murphy Murphy Murphy# of Catalyst installed 1 1 1 1Catalyst Element Installation date 7/22/16 7/22/16 7/22/16 7/22/16Catalyst Inlet Temp °F 847 845 846 846Catalyst Outlet Temp °F 878 879 780 846Catalyst Pressure Drop H2O 1.50 1.50 1.50 1.50Catalyst reconditioning or cleaning date New New New NewAFR Manufacturer/Type Murphy Murphy Murphy MurphyAFR Setting (Targets Right Bank)17.00 17.00 17.00 17.00AFR Readings NA NA NA NA Intake Manifold Pressure (psi)4.40 4.50 4.50 4.47Ambient Temp °F 76.00 79.00 83.00 79.33Exhaust Gas Temp °F (From Probe)785.00 784.00 783.00 784.00Intake Manifold Temp °F 85.00 85.00 85.00 85.00Barometric Press ("HG)30.13 30.13 30.11 30.12Fuel Flow Rate (dscf)587.00 586.63 587.73 587.12Engine Load (BHP)72.05 72.00 72.14 72.06 Cottonwood 08E Cummins 4,724 Whiting Oil & Gas Company 7/26/2016 73697207 ENG-01 5.9 Noel Arnim