COMPRESSION SYSTEMS

RAISING PERFORMANCE. TOGETHERTM

Introduction to Engine Testing

Gas Machinery Research Council

Engine Emissions Stack Testing

and Analyzer Workshop

Bruce Chrisman Ajax October 30, 2012

GMRC Engine Emissions Stack Testing and Analyzer Workshop 10/30/2012

Introduction to Engine Testing 1. Pollutants and Test Methods

1.1 Description of pollutants and approved test methods 1.2 Analyzers and sample handling 1.3 Calculation of exhaust emissions rate 1.4 Determining the exhaust flow rate

2. Exhaust Emissions Control Methods 2.1 Emissions controls used by various engine manufacturers 2.2 Prechambered engines 2.3 Fuel rich engines 2.4 Catalytic converters

3. Determining the Conditions of the Engine and Compressor 3.1 Factors which affect exhaust emissions 3.2 Cylinder balance and combustion stability 3.3 Analysis of power cylinder cards 3.4 Power cylinder health report

4. Determining the Power Output 4.1 Performance prediction and compressor loading curves 4.2 Compressor cylinder health report 4.3 Analysis of compressor cylinder cards

5. Effects of Operating Conditions 5.1 Effects of torque and speed on emissions 5.2 Effects of site elevation, ambient temperature, and speed on emissions

6. Evaluation and Reporting of Test Results 6.1 Examples of well documented reports 6.2 Wyoming format for reporting test results 6.3 Documentation of test variables

7. Ajax Engine Information 7.1 Design features of Ajax engines

7.2 Two stroke, loop scavenged power cylinder 7.3 Air fuel control system

COMPRESSION SYSTEMS

Introduction to Engine Testing

Pollutants and Test Methods

Criteria Pollutants and Exhaust Parameters Reference: EPA CFR 40, Part 60

Test Methods Analyzer

Hazardous Air Pollutants

Pollutants and Test Methods

CH2O 301 FTIR CH2O 323 Acetyl Acetone

NOx 7e, 20 ChemiluminescentCTM-022, -030, -034 Electrochemical Cell

CO 10 NDIRCTM-030, -034 Electrochemical Cell

THC 25a FIDNMHC 18 Chromatograph

O2 3a Paramagnetic CellCTM-030, -034 Electrochemical Cell

Exhaust Flow Rate 2 Pitot Tube19 Calculated from fuel flow, gas comp. and O2

Exhaust Emissions Regulations Affecting Stationary Gas Fueled Engines 8/20/2010 BC

Federal 2004 NESHAP For engines > 500 BHP at major sources: H2CO < 12 ppmvd (for 2SLB) or 14 ppmvd (for 4SLB) @ 15% O2 in exhaust or 58% CO removal across a converter (for 2S engines) or 93% CO removal across a converter (for 4S engines)

NSPS For engines > 100 BHP: Effective 2008: NOX < 2.0 Effective 2011: NOX < 1.0 CO < 4.0 CO < 2.0 VOC < 1.0 VOC < 0.7

2010 NESHAP For existing engines at major sources: SI 2SLB 100 500 BHP: CO < 225 ppmvd SI 4SLB 100 500 BHP: CO < 47 ppmvd SI 4SRB 100 500 BHP: H2CO < 10.3 ppmvd For existing engines at area sources: SI 2SLB All BHPs: Defined maintenance practices. SI 4SLB > 500 BHP: CO < 47 ppmvd SI 4SRB > 500 BHP: H2CO < 10.3 ppmvd

State Many states require NOX < 2.0 gm/BHP-hr A few states, like CA & WY, require NOX < 1.0 gm/BHP-hr Other state regulations restrict CO & VOC levels.

Emissions Analyzers and Sample Handling Systems

Stack/ Source

Calculation of Exhaust Emissions Rate

Mp= (Cp) (Qe) (r p)

Where: Mp= Mass flow rate of pollutant

Cp= Volume concentration of pollutant

Qe= Volume flow rate of exhaust

r p= Density of pollutant

BSE= Brake specific emissions rate

BHP= Engine brake HP

BSE= Mp/BHP

Calculations of Exhaust Emissions Rate

Methods for Determining Exhaust Flow

Air Nozzle for intake + fuel flow Pitot tube for exhaust flow (2)

Carbon Balance:

Balance carbon content of fuel with carbon content of exhaust

F factor (19):

Calculate exhaust flow from fuel flow, gas composition and O2 in exhaust

Summary of Emissions Test Data ENGINE FUEL DATA: Fuel Consumption Rate` 7837 (BTU/BHP/HR-LHV) Fuel Consumption Rate SCFH 2610

STACK FLOW DATA: (EPA Method 19): (EPA Method 2) Stack Flow (DSCFM) 1246 1331 Stack Flow (DSCFH) 74776 79832 O2 F-Factor (DSCF/MMTBTU 8659

EMISSIONS CONCENTRATIONS (Volume Dry Base Corrected): NOx (PPMV) 39 CO (PPMV) 159 O2 % 13.99 THC (PPMV) 599 H2O % 6.80

EPA Method 19 O2 F Factor Dry Basis Calculations Per Fuel Gas Analysis

O2Fd = O2 F factor (dry) SCF/million BTU

K = Conversion Factor

Khd = 3.64 SCF of exhaust / lb of hydrogen burned / (% hydrogen)

Kc = 1.53 SCF of exhaust / lb of carbon burned / (% carbon)

Ks = 0.57 SCF of exhaust / lb of sulphur burned / (% sulphur)

Kn = 0.14 SCF of exhaust / lb of nitrogen burned / (% nitrogen)

Ko = 0.46 SCF of exhaust / lb of oxygen burned / (% oxygen)

GCV = Gross caloric value of the fuel based on fuel gas analysis in BTU/lb

GCV = 23047.1

% of fuel gas which is made up of the following elements: H = 23.42518 % C = 74.66305 % S = 0 % N = 1.556136 % O = 0.355788

O2Fd = [(Khd x H) + (Kc x C) + (Ks x S) + (Kn x N) (Ko x O2)] x 1000000 GCV O2Fd = [(3.64 x 23.42518) + (1.53 x 74.66305) + (0.57 x 0) + (0.14 x 1.556136) (0.46 x 0.355788)] x 1000000 / 23047.1 O2Fd = 8659

(1,000,000 BTU)

%

Summary of Emissions Test Data

Mass Emissions Rates

NO x (lbs/hr) NA Permit Limit 0.351 0.374 NO x (tons/yr) NA Permit Limit 1.536 1.639 NO x (g/BHP-hr) NA Permit Limit 0.483 0.516 CO (lbs/hr) NA Permit Limit 0.865 0.923 CO (tons/yr) NA Permit Limit 3.789 4.043 CO (g/BHP-hr) NA Permit Limit 1.193 1.274

EPA Method 19 Calculations:

EPA Method 2 Calculations:

Introduction to Engine Testing

Exhaust Emissions Control Methods

Introduction to Engine Testing

Determining the Conditions of the Engine and Compressor

Mechanical Condition Operating Parameters Cylinder Balance

Factors Which Affect Exhaust Emissions

Air-Fuel Ratio (A/F Control System) f = (Actual F/A) / (Stoichiometric F/A) l = (Actual A/F) / (Stoichiometric A/F) = 1/f % Theoretical Air Ignition Timing Cylinder Balance Air-Fuel Mixing Engine Speed and Speed Variation Engine Load and Load Variation Mechanical Condition of Engine Condition of Ignition System Condition of Catalyst and Control Environmental Conditions Temperature Barometric Pressure Humidity

Introduction to Engine Testing

Determining the Power Output Compressor Loading Curves

Use of Engine/ Compressor Analyzer

Elevation (ft) 4900 Ambient Temperature (deg F) 35 Gas Gravity .5835 Super Compressibility Used YES BHPAvailable for Compression 323.0 Barometric Pressure (psia) 12.28 Gas to be Compressed NATURAL Ratio of Specific Heats 1.2891 RPM 440 Non-lube Factor 1.00

Model: 2802LE Cylinders: YK11MA 2300 1 Poppet Valves YK11F 1300 1 Poppet Valves Standard Conditions 14.65 psia & 60 deg F.

Suction and Discharge Pressures are at the Skid Edge

Z Suction 0.997 0.993

Z Discharge 0.997 0.993

HE Vol. Eff (%) 62.3 87.2

CE Vol. Eff (%) 84.1 88.0

PS (psig) 7.0 38.4

PD (psig) 41.0 90.0

TS (deg F) 66.0 65.0

TD (deg F) 200.5 159.9

Cooler TD (deg F) 65.0 55.0

Compression Ratio 2.76 2.10

BHP Utilized/Stage 188.2 134.8

BHP Utilized/Unit 323.0 .0

BHP/MMSCFD 59.23 42.42

MMSCFD 3.178 3.178

Condition 49. 49.

Stage 1. 2.

Active Head Ends 1. 1.

Active Crank Ends 1. 1.

Bore (in) 23.00 13.00

Stroke (in) 11.00 11.00

Rod Load-C (lb) 14140. 7575.

Rod Load-T (lb) 13905. 6924.

Rod Dia. (in) 2.50 2.50

HE Normal Clr (%) 10.80 12.60

HE Set Clr (%) 28.94 12.60

Pocket Setting 6.24 .00

CE Clearance (%) 10.80 11.60

FC Clearance (%) 19.92 12.11

Four 6.500 Double Acting Compressor Cylinders

Constant Discharge Pressure 1000.0 PSIG Capacities at 900 RPM

B

rake

Hor

sepo

wer

M

MS

CFD

at 1

4.70

0 P

SIA

&

60

.0 D

EG

F

1400

1200

1000

800

600

400

200

60.0

50.0

40.0

30.0

20.0

10.0

0.0

30.0

10.0

0.0

20.0

200 300 400 500 600 700 800

Suction Pressure - PSIG

Var

iabl

e V

olum

e P

ocke

t Set

ting

- Inc

hes

Compressor Capacity and Power Curve

191.0 4.0 52.25 47.38 0.997 0.998 0.999 1.294

192.5 2.5 10.85 9.02 0.997 0.998 0.999 1.294

148.2 61.8 23.89 23.82 0.996 0.994 0.999 1.299

154.2 55.8 11.20 12.14 0.995 0.994 0.999 1.299

1 0.69 82.0 45.0 1 1.00 1.07

1 0.97 86.8 100.3 1 2.22 2.11

1 0.96 81.4 50.5 2 1.58 1.40

1 1.03 87.1 56.7 2 1.67 1.48

(F) (delta) Suc Dis Z dis Z suc Z std K Theo Dis Temp

Total IHP = 297.5 @ 438.3 average RPM Total BHP = 313.1 @ 95% efficiency with 0.0Hp auxiliary load Current Load = 98.2% Rated BHP = 320.0 @ 440.0 RPM

Clearances (percent) Compressibility

1> Comp 1 H Pressure

2> Comp 1 C Pressure

3> Comp 2 H Pressure

4> Comp 2 C Pressure

1> Comp 1 H Pressure

2> Comp 1 C Pressure

3> Comp 2 H Pressure

4> Comp 2 C Pressure

Load Step Exp/Comp EFF HP STG Suc Dis Theoretical Capacity

Stage 1 Capacity 3.1992 (MMSCFD) Stage 2 Capacity 3.0662 (MMSCFD)

N Ratio

Compressor Cylinder ID

Introduction to Engine Testing

Effects of Operating Conditions

Introduction to Engine Testing Evaluating and Reporting Results Evaluation of the Test Data (Logic Checks) Comparison with Manufacturers Data Comparison with Similar Units Correlation of Test Variables and Data Reporting Results Engine Operating Data Compressor Operating Data Ambient Conditions Test Methods Calculations

Summary of Emission Test Data

Customer: Ajax Date: 06/01/2001 Source: Ajax DPC-2802-LE

Test Run No. 1 Time Start: 02:57 PM Time End: 03:16 PM

Ambient Conditions: Temperature Wet Bulb (F) 87 Temperature Dry Bulb (F) 94 Relative Humidity (%) 74% Barometric Press. ("Hg) 26.25 Elevation (Ft.) 4450

Engine Operational Data: Speed (RPM) 440 Spark Setting (BTDC) 3 Manifold Press NA Intake Manifold Temp. (F) 102 Fuel Header Pressure (PSIG) NA Engine Horsepower (BHP) 329

Compressor Operational Data: Suction Pressure (PSIG) 225 Final Discharge Press. (PSIG) 1130 Compressor Volume (MMCF/D) 3.29 Compressor Horsepower (BHP) 323

STATE OF WYOMING Department of Environmental Quality Air Quality Division

Reciprocating Engine Form

Operating Conditions Suction/ Discharge Pressures

Engine RPM

Engine Gas Throughput

Engine Fuel Consumption

Fuel Heat Content Btu/cf

Engine Specific Fuel Consumption (Btu/hp-hr)

Engine Tested Horsepower

3.5/82 439 70 947.54 9,400 316

O2 Average Tested O2 %

O2corrected %

Average Tested CO ppm

CO corrected ppm

CO Tested gm/hp-hr

Tested lb/hr

CO Allowable gm/hp-hr

14.34 14.34 113.97 113.35 0.97 0.68 2

NOx (NO + NO2) Average Tested NO ppm

NOcorrected ppm

Average Tested NO2 ppm

NO2corrected ppm

NOXcorrected ppm

NOX Tested gm/hp-hr

Tested lb/hr

NOX Allowable gm/hp-hr

3.31 3.29 28.68 16.07 19.36 0.27 0.19 1

Source Tested: Unit 4 Date: 07/31/01 Source Manufacturer/Model #: Ajax 2802-LE Site Rated Horsepower: 316 Source Serial #: 84632 Analyzer Manufacturer/Model #: Enerac 3000

Form D-1

Reciprocating Engine Test Results

Ajax 2802LE Performance for Site Elevation = 5000 ft.

Introduction to Engine Testing

Ajax Engine Information General Description

Design Features

Two-Stroke, Loop Scavenged Power Cylinder

Intake Air Valve Gas Injection Valve

Prechamber

Exhaust Port