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Texas SIP: 30 TAC 117.471-117.479: Boilers, Process Heaters, and Stationary Engines and Gas Turbines at Minor Sources; SIP effective 2004.04.26

Regulatory Text: 
TNRCC Chapter 117 –  Control of Air Pollution from Nitrogen Compounds
Subchapter D:  Small Combustion Sources

DIVISION 2  :  BOILERS, PROCESS HEATERS, AND STATIONARY ENGINES AND GAS TURBINES AT MINOR SOURCES

Outline:
§117.471.  Applicability.
§117.473.  Exemptions.
§117.475.  Emission Specifications.
§117.478.  Operating Requirements.
§117.479.  Monitoring, Recordkeeping, and Reporting Requirements.


§117.471.  Applicability.
As adopted by TNRCC September 26, 2001, effective October 18, 2001.
Approved by EPA November 14, 2001 (66 FR 57244) effective December 14, 2001.


     This division (relating to Boilers, Process Heaters, and Stationary Engines and Gas Turbines at Minor Sources) applies in the Houston/Galveston ozone nonattainment area to the following equipment at any stationary source of nitrogen oxides (NOx) which is not a major source of NOx:

          (1)  boilers and process heaters;

          (2)  stationary, reciprocating internal combustion engines; and

          (3)  stationary gas turbines, including duct burners.

Adopted September 26, 2001, Effective October 18, 2001
**** end tx 117.471 adopted by TNRCC 09/26/2001 (7-21)**d29*ebze***c1a**


§117.473.  Exemptions.
As adopted by TNRCC September 26, 2001, effective October 18, 2001.
Approved by EPA November 14, 2001 (66 FR 57244) effective December 14, 2001.

     (a)  This division (relating to Boilers, Process Heaters, and Stationary Engines and Gas Turbines at Minor Sources) does not apply to the following, except as may be specified in §117.478(c) and §117.479(h) - (j) of this title (relating to Operating Requirements; and Monitoring, Recordkeeping, and Reporting Requirements):

          (1)  boilers and process heaters with a maximum rated capacity of 2.0 million British thermal units per hour (MMBtu/hr) or less;

          (2)  the following stationary engines:

               (A)  engines with a horsepower (hp) rating of less than 50 hp;

               (B)  engines used in research and testing;

               (C)  engines used for purposes of performance verification and testing;

               (D)  engines used solely to power other engines or gas turbines during start-ups;

               (E)  engines operated exclusively in emergency situations, except that operation for testing or maintenance purposes is allowed for up to 52 hours per year, based on a rolling 12-month average.  Any new, modified, reconstructed, or relocated stationary diesel engine placed into service on or after October 1, 2001 is ineligible for this exemption.  For the purposes of this subparagraph, the terms "modification" and "reconstruction" have the meanings defined in §116.10 of this title (relating to General Definitions) and 40 Code of Federal Regulations (CFR) §60.15 (effective December 16, 1975), respectively, and the term “relocated” means to newly install at an account, as defined in §101.1 of this title (relating to Definitions), a used engine from anywhere outside that account;

               (F)  engines used in response to and during the existence of any officially declared disaster or state of emergency;

               (G)  engines used directly and exclusively by the owner or operator for agricultural operations necessary for the growing of crops or raising of fowl or animals;

               (H)  diesel engines placed into service before October 1, 2001 which:

                    (i)  operate less than 100 hours per year, based on a rolling 12-month average; and

                    (ii)  have not been modified, reconstructed, or relocated on or after October 1, 2001.  For the purposes of this clause, the terms "modification" and "reconstruction" have the meanings defined in §116.10 of this title and 40 CFR §60.15 (effective December 16, 1975), respectively, and the term “relocated” means to newly install at an account, as defined in §101.1 of this title, a used engine from anywhere outside that account; and

               (I)  new, modified, reconstructed, or relocated stationary diesel engines placed into service on or after October 1, 2001 which:

                    (i)  operate less than 100 hours per year, based on a rolling 12-month average, in other than emergency situations; and

                    (ii)  meet the corresponding emission standard for non-road engines listed in 40 CFR §89.112(a), Table 1 (effective October 23, 1998) and in effect at the time of installation, modification, reconstruction, or relocation.  For the purposes of this subparagraph, the terms "modification" and "reconstruction" have the meanings defined in §116.10 of this title and 40 CFR §60.15 (effective December 16, 1975), respectively, and the term “relocated” means to newly install at an account, as defined in §101.1 of this title, a used engine from anywhere outside that account; and

          (3)  stationary gas turbines rated at less than 1.0 megawatt with initial start of operation on or before October 1, 2001.

     (b)  At any stationary source of nitrogen oxides (NOx) which is not subject to Chapter 101, Subchapter H, Division 3 of this title (relating to Mass Emissions Cap and Trade Program), the following are exempt from the requirements of this division, except for the totalizing fuel flow requirements of §117.479(a), (d), and (g)(1) of this title:

          (1)  any boiler or process heater with a maximum rated capacity greater than 2.0 MMBtu/hr and less than 5.0 MMBtu/hr that has an annual heat input less than or equal to 1.8 (109) Btu per calendar year; and

          (2)  any boiler or process heater with a maximum rated capacity equal to or greater than 5.0 MMBtu/hr that has an annual heat input less than or equal to 9.0 (109) Btu per calendar year.

Adopted September 26, 2001, Effective October 18, 2001
**** end tx 117.473 adopted by TNRCC 09/26/2001 (7-21)**d29*ebze***c1a**


§117.475.  Emission Specifications.
As adopted by TNRCC September 26, 2001, effective October 18, 2001.
Approved by EPA November 14, 2001 (66 FR 57244) effective December 14, 2001.

     (a)  For sources which are subject to Chapter 101, Subchapter H, Division 3 of this title (relating to Mass Emissions Cap and Trade Program), the nitrogen oxides (NOx) emission rate values used to determine allocations for Chapter 101, Subchapter H, Division 3 of this title shall be the lower of any applicable permit limit in a permit issued before January 2, 2001; any permit issued on or after January 2, 2001 for which the owner or operator submitted an application determined to be administratively complete by the executive director before January 2, 2001; any limit in a permit by rule under which construction commenced by January 2, 2001; or the emission specifications in subsection (c) of this section.  The averaging time shall be as specified in Chapter 101, Subchapter H, Division 3 of this title.

     (b)  For sources which are not subject to Chapter 101, Subchapter H, Division 3 of this title, NOx emissions are limited to the lower of any applicable permit limit in a permit issued before January 2, 2001; any permit issued on or after January 2, 2001 for which the owner or operator submitted an application determined to be administratively complete by the executive director before January 2, 2001; any limit in a permit by rule under which construction commenced by January 2, 2001; or the emission specifications in subsection (c) of this section.  The averaging time shall be as follows:

          (1)  if the unit is operated with a NOx continuous emissions monitoring system (CEMS) or predictive emissions monitoring system (PEMS) under §117.479(c) of this title (relating to Monitoring, Recordkeeping, and Reporting Requirements), either as:

               (A)  a rolling 30-day average period, in the units of the applicable standard;

               (B)  a block one-hour average, in the units of the applicable standard, or alternatively;

               (C)  a block one-hour average, in pounds per hour, for boilers and process heaters, calculated as the product of the boiler's or process heater's maximum rated capacity and its applicable limit in pound NOx per million British thermal units (lb/MMBtu); or

          (2)  if the unit is not operated with a NOx CEMS or PEMS under §117.479(c) of this title, a block one-hour average, in the units of the applicable standard.


     (c)  The following NOx emission specifications shall be used in conjunction with subsection (a) of this section to determine allocations for Chapter 101, Subchapter H, Division 3 of this title, or in conjunction with subsection (b) of this section to establish unit-by-unit emission specifications, as appropriate:

          (1)  from boilers and process heaters, 0.036 lb/MMBtu heat input (or alternatively, 30 parts per million by volume (ppmv), at 3.0% oxygen (O2), dry basis);

          (2)  from stationary, gas-fired, reciprocating internal combustion engines:

               (A)  fired on landfill gas, 0.60 gram per horsepower-hour (g/hp-hr); and

               (B)  all others, 0.50 g/hp-hr;

          (3)  from stationary, dual-fuel, reciprocating internal combustion engines, 5.83 g/hp-hr;

          (4)  from stationary, diesel, reciprocating internal combustion engines:

               (A)  placed into service before October 1, 2001 which have not been modified, reconstructed, or relocated on or after October 1, 2001, 11.0 g/hp-hr.  For the purposes of this paragraph, the terms "modification" and "reconstruction" have the meanings defined in §116.10 of this title (relating to General Definitions) and 40 Code of Federal Regulations §60.15 (effective December 16, 1975), respectively, and the term “relocated” means to newly install at an account, as defined in §101.1 of this title (relating to Definitions), a used engine from anywhere outside that account; and

               (B)  for engines not subject to subparagraph (A) of this paragraph:

                    (i)  with a horsepower rating of less than 11 hp which are installed, modified, reconstructed, or relocated:

                         (I)  on or after October 1, 2001, but before October 1, 2004, 7.0 g/hp-hr; and

                         (II)  on or after October 1, 2004, 5.0 g/hp-hr;

                    (ii)  with a horsepower rating of 11 hp or greater, but less than 25 hp, which are installed, modified, reconstructed, or relocated:

                         (I)  on or after October 1, 2001, but before October 1, 2004, 6.3 g/hp-hr; and

                         (II)  on or after October 1, 2004, 5.0 g/hp-hr;

                    (iii)  with a horsepower rating of 25 hp or greater, but less than 50 hp, which are installed, modified, reconstructed, or relocated:

                         (I)  on or after October 1, 2001, but before October 1, 2003, 6.3 g/hp-hr; and

                         (II)  on or after October 1, 2003, 5.0 g/hp-hr;

                    (iv)  with a horsepower rating of 50 hp or greater, but less than 100 hp, which are installed, modified, reconstructed, or relocated:

                         (I)  on or after October 1, 2001, but before October 1, 2003, 6.9 g/hp-hr;

                         (II)  on or after October 1, 2003, but before October 1, 2007, 5.0 g/hp-hr; and

                         (III)  on or after October 1, 2007, 3.3 g/hp-hr;

                    (v)  with a horsepower rating of 100 hp or greater, but less than 175 hp, which are installed, modified, reconstructed, or relocated:

                         (I)  on or after October 1, 2001, but before October 1, 2002, 6.9 g/hp-hr;

                         (II)  on or after October 1, 2002, but before October 1, 2006, 4.5 g/hp-hr; and

                         (III)  on or after October 1, 2006, 2.8 g/hp-hr;

                    (vi)  with a horsepower rating of 175 hp or greater, but less than 300 hp, which are installed, modified, reconstructed, or relocated:

                         (I)  on or after October 1, 2001, but before October 1, 2002, 6.9 g/hp-hr;

                         (II)  on or after October 1, 2002, but before October 1, 2005, 4.5 g/hp-hr; and

                         (III)  on or after October 1, 2005, 2.8 g/hp-hr;

                    (vii)  with a horsepower rating of 300 hp or greater, but less than 600 hp, which are installed, modified, reconstructed, or relocated:

                         (I)  on or after October 1, 2001, but before October 1, 2005, 4.5 g/hp-hr; and

                         (II)  on or after October 1, 2005, 2.8 g/hp-hr;

                    (viii)  with a horsepower rating of 600 hp or greater, but less than or equal to 750 hp, which are installed, modified, reconstructed, or relocated:

                         (I)  on or after October 1, 2001, but before October 1, 2005, 4.5 g/hp-hr; and

                         (II)  on or after October 1, 2005, 2.8 g/hp-hr; and

                    (ix)  with a horsepower rating of 750 hp or greater which are installed, modified, reconstructed, or relocated:

                         (I)  on or after October 1, 2001, but before October 1, 2005, 6.9 g/hp-hr; and

                         (II)  on or after October 1, 2005, 4.5 g/hp-hr;

          (5)  from stationary gas turbines (including duct burners), 0.15 lb/MMBtu; and

          (6)  as an alternative to the emission specifications in paragraphs (1) - (5) of this subsection for units with an annual capacity factor of 0.0383 or less, 0.060 lb/MMBtu heat input.

     (d)  The maximum rated capacity used to determine the applicability of the emission specifications in subsection (c) of this section shall be:

          (1)  the greater of the following:

               (A)  the maximum rated capacity as of December 31, 2000; or

               (B)  the maximum rated capacity after December 31, 2000; or
          (2)  alternatively, the maximum rated capacity authorized by a permit issued under Chapter 116 of this title (relating to Control of Air Pollution by Permits for New Construction or Modification) on or after January 2, 2001 for which the owner or operator submitted an application determined to be administratively complete by the executive director before January 2, 2001, provided that the maximum rated capacity authorized by the permit issued on or after January 2, 2001 is no less than the maximum rated capacity represented in the permit application as of January 2, 2001.

     (e)  A unit's classification is determined by the most specific classification applicable to the unit as of December 31, 2000.  For example, a unit that is classified as a stationary gas-fired engine as of December 31, 2000, but subsequently is authorized to operate as a dual-fuel engine, shall be classified as a stationary gas-fired engine for the purposes of this chapter.

     (f)  The owner or operator of a unit subject to an emission specification in subsection (c) of this section which, as of December 31, 2000, combusts one or more fuel or waste streams containing chemical-bound nitrogen shall not re-direct these streams to flares or other units which are not subject to an emission specification in subsection (c) of this section.

Adopted September 26, 2001, Effective October 18, 2001
**** end tx 117.475 adopted by TNRCC 09/26/2001 (7-21)**d29*ebze***c1a**


§117.478.  Operating Requirements.
As adopted by TNRCC September 26, 2001, effective October 18, 2001.
Approved by EPA November 14, 2001 (66 FR 57244) effective December 14, 2001.

     (a)  The owner or operator shall operate any unit subject to the emission limitations of §117.475 of this title (relating to Emission Specifications) in compliance with those limitations.

     (b)  All units subject to the emission limitations of §117.475 of this title shall be operated so as to minimize nitrogen oxides (NOx) emissions, consistent with the emission control techniques selected, over the unit's operating or load range during normal operations.  Such operational requirements include the following.

          (1)  Each boiler, except for wood-fired boilers, shall be operated with oxygen (O2), carbon monoxide (CO), or fuel trim.

          (2)  Each boiler and process heater controlled with forced flue gas recirculation (FGR) to reduce NOx emissions shall be operated such that the proportional design rate of FGR is maintained, consistent with combustion stability, over the operating range.

          (3)  Each unit controlled with post combustion control techniques shall be operated such that the reducing agent injection rate is maintained to limit NOx concentrations to less than or equal to the NOx concentrations achieved at maximum rated capacity.

          (4)  Each stationary internal combustion engine controlled with nonselective catalytic reduction shall be equipped with an automatic air-fuel ratio (AFR) controller which operates on exhaust O2 or CO control and maintains AFR in the range required to meet the engine's applicable emission limits.

          (5)  Each stationary internal combustion engine shall be checked for proper operation of the engine by recorded measurements of NOx and CO emissions at least quarterly and as soon as practicable within two weeks after each occurrence of engine maintenance which may reasonably be expected to increase emissions, O2 sensor replacement, catalyst cleaning, or catalyst replacement.  Stain tube indicators specifically designed to measure NOx concentrations shall be acceptable for this documentation, provided a hot air probe or equivalent device is used to prevent error due to high stack temperature, and three sets of concentration measurements are made and averaged.  Portable NOx analyzers shall also be acceptable for this documentation.  Quarterly emission testing is not required for those engines whose monthly run time does not exceed ten hours.  This exemption does not diminish the requirement to test emissions after the installation of controls, major repair work, and any time the owner or operator believes emissions may have changed.

     (c)  No person shall start or operate any stationary diesel or dual-fuel engine for testing or maintenance between the hours of 6:00 a.m. and noon, except:

          (1)  for specific manufacturer's recommended testing requiring a run of over 18 consecutive hours; or

          (2)  to verify reliability of emergency equipment (e.g., emergency generators or pumps) immediately after unforeseen repairs.  Routine maintenance such as an oil change is not considered to be an unforeseen repair.

Adopted September 26, 2001, Effective October 18, 2001
**** end tx 117.478 adopted by TNRCC 09/26/2001 (7-21)**d29*ebze***c1a**


§117.479.  Monitoring, Recordkeeping, and Reporting Requirements.
As adopted by TNRCC September 26, 2001, effective October 18, 2001.
Approved by EPA November 14, 2001 (66 FR 57244) effective December 14, 2001.

     (a)  Totalizing fuel flow meters.

          (1)  The owner or operator of each unit subject to the emission limitations of §117.475 of this title (relating to Emission Specifications) shall install, calibrate, maintain, and operate totalizing fuel flow meters to individually and continuously measure the gas and liquid fuel usage.  A computer which collects, sums, and stores electronic data from continuous fuel flow meters is an acceptable totalizer.

          (2)  As an alternative to the fuel flow monitoring requirements of this subsection, units operating with a nitrogen oxides (NOx) and diluent continuous emissions monitoring system (CEMS) under subsection (c) of this section may monitor stack exhaust flow using the flow monitoring specifications of 40 Code of Federal Regulations (CFR) 60, Appendix B, Performance Specification 6 or 40 CFR 75, Appendix A.

     (b)  Oxygen (O2) monitors.  If the owner or operator installs an O2 monitor, the criteria in §117.213(e) of this title (relating to Continuous Demonstration of Compliance) should be considered the appropriate guidance for the location and calibration of the monitor.

     (c)  NOx monitors.  If the owner or operator installs a CEMS or predictive emissions monitoring system (PEMS), it shall meet the requirements of §117.213(e) or (f) of this title.

     (d)  Monitor installation schedule.  Installation of monitors shall be performed in accordance with the schedule specified in §117.534 of this title (relating to Compliance Schedule for Boilers, Process Heaters, and Stationary Engines and Gas Turbines at Minor Sources).

     (e)  Testing requirements.  The owner or operator of any unit subject to the emission limitations of §117.475 of this title shall comply with the following testing requirements.

          (1)  Each unit shall be tested for NOx, carbon monoxide (CO), and O2 emissions.


          (2)  Units which inject urea or ammonia into the exhaust stream for NOx control shall be tested for ammonia emissions.

          (3)  All testing shall be conducted while operating at the maximum rated capacity, or as near thereto as practicable.  Compliance shall be determined by the average of three one-hour emission test runs, using the following test methods:

               (A)  Test Method 7E or 20 (40 CFR 60, Appendix A) for NOx;

               (B)  Test Method 10, 10A, or 10B (40 CFR 60, Appendix A) for CO;

               (C)  Test Method 3A or 20 (40 CFR 60, Appendix A) for O2;

               (D)  Test Method 2 (40 CFR 60, Appendix A) for exhaust gas flow and following the measurement site criteria of Test Method 1, Section 2.1 (40 CFR 60, Appendix A), or Test Method 19 (40 CFR 60, Appendix A) for exhaust gas flow in conjunction with the measurement site criteria of Performance Specification 2, Section 3.2 (40 CFR 60, Appendix B);

               (E)  American Society of Testing and Materials (ASTM) Method D1945-91 or ASTM Method D3588-93 for fuel composition; ASTM Method D1826-88 or ASTM Method D3588-91 for calorific value; or

               (F)  EPA-approved alternate test methods or minor modifications to these test methods as approved by the executive director, as long as the minor modifications meet the following conditions:

                    (i)  the change does not affect the stringency of the applicable emission limitation; and

                    (ii)  the change affects only a single source or facility application.

          (4)  Test results shall be reported in the units of the applicable emission limits and averaging periods.  If compliance testing is based on 40 CFR Part 60, Appendix A reference methods, the report must contain the information specified in §117.211(g) of this title (relating to Initial Demonstration of Compliance).

          (5)  For units equipped with CEMS or PEMS, the CEMS or PEMS shall be installed and operational before testing under this subsection.  Verification of operational status shall, as a minimum, include completion of the initial monitor certification and the manufacturer's written requirements or recommendations for installation, operation, and calibration of the device.

          (6)  Initial compliance with the emission specifications of §117.475 of this title for units operating with CEMS or PEMS shall be demonstrated after monitor certification testing using the NOx CEMS or PEMS.
          (7)  For units not operating with CEMS or PEMS, the following apply.

               (A)  Retesting as specified in paragraphs (1) - (4) of this subsection is required within 60 days after any modification which could reasonably be expected to increase the NOx emission rate.

               (B)  Retesting as specified in paragraphs (1) - (4) of this subsection may be conducted at the discretion of the owner or operator after any modification which could reasonably be expected to decrease the NOx emission rate, including, but not limited to, installation of post-combustion controls, low-NOx burners, low excess air operation, staged combustion (for example, overfire air), flue gas recirculation (FGR), and fuel-lean and conventional (fuel-rich) reburn.

               (C)  The NOx emission rate determined by the retesting shall establish a new emission factor to be used to calculate actual emissions instead of the previously determined emission factor used to calculate actual emissions for compliance with Chapter 101, Subchapter H, Division 3 of this title (relating to Mass Emissions Cap and Trade Program).

          (8)  Testing shall be performed in accordance with the schedule specified in §117.534 of this title.

     (f)  Emission allowances.

          (1)  For sources which are subject to Chapter 101, Subchapter H, Division 3 of this title, the NOx testing and monitoring data of subsections (a) - (e) of this section, together with the level of activity, as defined in §101.350 of this title (relating to Definitions), shall be used to establish the emission factor calculating actual emissions for compliance with Chapter 101, Subchapter H, Division 3 of this title.

          (2)  The emission factor in subsection (e)(7) of this section or paragraph (1) of this subsection is multiplied by the unit's level of activity to determine the unit's actual emissions for compliance with Chapter 101, Subchapter H, Division 3 of this title.

     (g)  Recordkeeping.  The owner or operator of a unit subject to the emission limitations of §117.475 of this title shall maintain written or electronic records of the data specified in this subsection.  Such records shall be kept for a period of at least five years and shall be made available upon request by authorized representatives of the executive director, EPA, or local air pollution control agencies having jurisdiction.  The records shall include:

          (1)  records of annual fuel usage;

          (2)  for each unit using a CEMS or PEMS in accordance with subsection (c) of this section, monitoring records of:

               (A)  hourly emissions and fuel usage (or stack exhaust flow) for units complying with an emission limit enforced on a block one-hour average; and

               (B)  daily emissions and fuel usage (or stack exhaust flow) for units complying with an emission limit enforced on a rolling 30-day average.  Emissions must be recorded in units of:

                    (i)  pound per million British thermal units (Btu) heat input; and

                    (ii)  pounds or tons per day;

          (3)  for each stationary internal combustion engine subject to the emission limitations of §117.475 of this title, records of:

               (A)  emissions measurements required by §117.478(b)(5) of this title (relating to Operating Requirements); and

               (B)  catalytic converter, air-fuel ratio controller, or other emissions-related control system maintenance, including the date and nature of corrective actions taken;

          (4)  records of carbon monoxide measurements specified in §117.478(b)(5) of this title;

          (5)  records of the results of initial certification testing, evaluations, calibrations, checks, adjustments, and maintenance of CEMS, PEMS, or steam-to-fuel or water-to-fuel ratio monitoring systems; and

          (6)  records of the results of performance testing, including the testing conducted in accordance with subsection (e) of this section.

     (h)  Records for exempt engines.  Written records of the number of hours of operation for each day's operation shall be made for each engine claimed exempt under §117.473(a)(2)(E), (H), or (I) of this title (relating to Exemptions) or §117.478(b)(5) of this title.  In addition, for each engine claimed exempt under §117.473(a)(2)(E) of this title, written records shall be maintained of the purpose of engine operation and, if operation was for an emergency situation, identification of the type of emergency situation and the start and end times and date(s) of the emergency situation.  The records shall be maintained for at least five years and shall be made available upon request to representatives of the executive director, EPA, or any local air pollution control agency having jurisdiction.

     (i)  Run time meters.  The owner or operator of any stationary diesel engine claimed exempt using the exemption of §117.473(a)(2)(E), (H), or (I) of this title shall record the operating time with an elapsed run time meter.  Any run time meter installed on or after October 1, 2001 shall be non-resettable.

     (j)  Records of operation for testing and maintenance.  The owner or operator of each stationary diesel or dual-fuel engine shall maintain the following records for at least five years and make them available upon request by authorized representatives of the executive director, EPA, or local air pollution control agencies having jurisdiction:

          (1)  date(s) of operation;

          (2)  start and end times of operation;

          (3)  identification of the engine; and

          (4)  total hours of operation for each month and for the most recent 12 consecutive months.

Adopted September 26, 2001, Effective October 18, 2001
**** end tx 117.479 adopted by TNRCC 09/26/2001 (7-21)**d29*ebze***c1a**

****end tx chapter 117 subchapter d division 2 *********d29*ebze***c1a**