Test reports are required to show that subject equipment was operating at an acceptable condition for all test runs. This requirement is equipment and district specific. Standard practice is minute averages of the required parameters. However, certain applications, such as tests requiring load banks, are more likely to only have data in ~15-minute intervals.
This equipment largely determines operating condition through the total heat input to the unit, in terms of MMBtu/hr. This calculation is performed using fuel flow rate and fuel properties. Fuel properties may be tracked onsite with a gas chromatograph, but additional fuel samples will be needed for sources that do not combust pipeline quality natural gas. Steam pressure, steam flow rate, flare temperature and assist gas flow are additional useful parameters.
This equipment can show operating condition with fuel flow, but electrical output is usually used. Generation is quantified in kilowatts or megawatts. Emission limits for these sources may also be written in terms of the operating condition (i.e., g/bhp-hr, lb-MW-hr). As with boilers, fuel properties will be needed if the unit combusts fuel other than pipeline quality natural gas. Engine L/R bank vac, air to fuel ratios, catalyst temperature, and urea/ammonia flow rate are common process parameters.
Quite a few types of oxidizers exist: direct fire, catalytic, recuperative, regenerative, and rotary concentrator. Each one is used to control emissions from a process. Operating condition, then, is based on the preceding process. Weight produced, gallons produced, or items painted are all process parameters that that may be required. Fuel flow may be tracked. Measured fuel flow tends to be less useful, as these types of equipment utilize the inlet VOC to sustain at least part of the chamber temperature necessary for pollutant combustion.
Data delivery is as crucial as recording. Process data acquisition systems may record hundreds of useful parameters that ultimately mean nothing if the data cannot be transferred off facility servers. Prior to testing, ask your test firm what data they need and ensure your system will allow you to provide it. If software allows, include averages for each parameter over the test period as well.
Not all operating devices or processes will fall into these categories. Understand the emission limits your source is subject to and how to demonstrate compliance with associated operating parameters. Questions? Please reach out to our team!
