HomeMy WebLinkAboutAEA Air Quality Compliance Study Remote Prime Power 2016-A
16005 - Air Quality
Compliance Report
PREPARED FOR:
STATE OF ALASKA
ALASKA ENERGY AUTHORITY/
RURAL ENERGY GROUP
PREPARED BY:
Mailing Address - P.O. Box 111405
Anchorage, AK 99511-1405
(907) 349-0100 349-8001 FAX
November 4, 2016
Page i
INDEX
Index ........................................................................................................... Page i
Overview ...................................................................................................... Page 1
Regulatory Review ....................................................................................... Page 1
Tier 4 Engine Survey ................................................................................... Page 2
Regulatory Summary ................................................................................... Page 3
RICE NESHAP ...................................................................................... Page 3
NSPS .................................................................................................... Page 4
Prime Power Genset Engine Data ........................................................ Appendix A
Prime Power Engine Selection Data ..................................................... Appendix B
NSPS & RICE NESHAP Regulatory Citations .................................... Appendix C
John Deere Tier 4 Engine Data ........................................................... Appendix D
Page 1 of 4
16005 - Air Quality Compliance Report
OVERVIEW
The Alaska Energy Authority (AEA) contracted with Gray Stassel Engineering, Inc. (GSE) to
prepare this Air Quality Compliance study. The purpose of this Study is to compile and evaluate
EPA air quality regulations that apply to diesel engines in stationary prime power applications in
remote areas of Alaska.
Diesel generation provides nearly 90% of all electricity in rural Alaska. Due to the immensity and
complexity of EPA air quality rules, this Study focused primarily on diesel engines less than 800
horse power (550 kW electric prime power), located in rural Alaska utilities that consume less
than 330,900-gallons of diesel/year. This classification applies to more than 500 prime power
diesel gensets located in over 170 communities located in remote areas of Alaska.
The effort consists of three tasks:
review current EPA air quality regulations
obtain available information on final Tier 4 engines in prime power applications
prepare a report that summarizes the information obtained and provide a matrix of
pertinent regulations and how they apply to engines in prime power applications
There are a variety of makes and models of prime power diesel engines in service throughout
rural Alaska. However, John Deere, Detroit Diesel, and Caterpillar make up the majority of these
engines less than 800 HP. Although there is overlap in manufacturer and horsepower, in
general terms the market share of diesel engines can be categorized as follows:
John Deere: 35 kW to 200+ kW
Detroit Diesel: 200 kW to 350 kW
Caterpillar (CAT): over 350 kW
The information in this report applies to utilities with larger gensets and that consume more than
330,900-gallons/year of diesel, but these utilities are subject to additional air quality permit
rules, including additional reporting and other compliance requirements, that affect the
application of the information in this study, and that need to be evaluated on a case by case
basis.
Regulatory Review
Many EPA rules apply to stationary prime power applications, but the two main rules are:
40 CFR 60, Subpart IIII, New Source Performance Standards (NSPS), and
40 CFR 63, Subpart ZZZZ, Reciprocating Internal Combustion Engine, National Emissions
Standards for Hazardous Air Pollutants (RICE NESHAP).
NSPS applies to 2007 model year and newer engines, while RICE NESHAP applies to 2006
and older engines. In general terms, NSPS applies to “Tier” certified engines, while RICE
NESHAP applies to non-certified engines. In addition to these two rules, other rules are
referenced in both NSPS and RICE NESHAP. As part of this study, the most recent editions of
the following federal regulations were reviewed:
40 CFR 60: NSPS - Tier certified engines
40 CFR 63: RICE NESHAP - non-certified engines
40 CFR 80: Fuel Regulations
40 CFR 89: Marine Tier 1 & 2
40 CFR 279.11: Used Oil Specifications
40 CFR 1039: Nonroad Tier 4
40 CFR 1042: Marine Tier 3 & 4
40 CFR 1068: Highway, Stationary, Non-Road Compliance (flex/TPEM, Rebuild, Tampering)
Page 2 of 4
Tier 4 Engine Survey:
A combination of exhaust treatments are used to meet final Tier 4 emissions requirements. The
most commonly used are diesel oxidation catalyst (DOC), diesel particulate filter (DPF) and
selective catalytic reduction (SCR). Although there is a variety of different DOC/DPF/SCR
technologies available, all rely on Ultra Low Sulfur Diesel (ULSD) fuel to prevent contamination
of the exhaust filtration devices.
A DOC uses a catalyst to remove (oxidize) Hydrocarbons (HC) and Carbon Monoxide (CO). A
DPF can both remove and trap (filter) Particulate Matter (PM). A DOC can be used upstream of
a DPF to provide NO2 to reduce the exhaust temperature needed to passively regenerate
(oxidize) PM in a DPF. Although a DPF can passively regenerate, it must be manually cleaned
periodically to maintain proper operation and prevent excessive exhaust backpressure.
Selective Catalytic Reduction (SCR) injects a solution of water and urea into the exhaust stream
to reduce NOX emissions.
There is limited information available for commercially available Tier 4 prime power engines
under 800 HP. To date, GSE has only received technical data from John Deere for final Tier 4
engines.
John Deere has several models of Tier 4 certified engines ranging from 30 kW to 369 kW, prime
power. The smallest engines are equipped with a wastegated turbocharger and combination
Diesel Oxidation Catalyst / Diesel Particulate Filter (DOC/DPF). Larger engines are equipped
with series fixed and variable geometry turbochargers, cooled exhaust gas recirculation (EGR),
DOC/DPF filters, and Selective Catalytic Reduction (SCR). All engines are air-to-air aftercooled,
equipped with high pressure common rail fuel systems, and engine and emissions equipment is
managed by the engine control unit (ECU).
Neither CAT nor MTU/Detroit Diesel manufacture a final Tier 4 prime power engine package
under 800 HP, but do offer Tier 2 or Tier 3 engines with third party aftertreatment including
DOC/DPF and SCR to meet final Tier 4 emissions requirements.
Maintenance requirements for final Tier 4 engines in prime power applications are presently
uncertain, as there are no final Tier 4 engines with exhaust aftertreatment reported in operation
in Alaska or the U.S.
Since there are no final Tier 4 prime power applications reported in operation, information on
failures or reliability issues is unavailable. However, commonly reported issues associated with
final Tier 4 engines in the non-road (heavy equipment) mobile source market include failures of
the EGR valve, variable geometry turbochargers, and the equipment going into “limp” mode –
due to the DPF not regenerating properly. When this occurs, a factory trained technician is
required to reset the engine to normal operation.
The effect of final Tier 4 compliance on reliability and maintenance costs is not available for
prime power applications. However, one vendor used the term “3x” to imply it cost three times
as much to service or repair a final Tier 4 engine, compared to an engine without exhaust
aftertreatment, due to the time required to remove the exhaust components to access the actual
engine, as well as the additional cost associated with maintaining the exhaust after treatment
equipment.
Unlike earlier tier diesel engines, Tier 4 engine fuel efficiency is variable, as fuel is consumed to
increase the exhaust temperature high enough for filters to regenerate. The amount of
additional fuel consumed for regeneration varies depending on a number of factors, including
engine load and type of exhaust after treatment used. Published fuel efficiency data for John
Deere Tier 4 engines is included in the following section.
Page 3 of 4
The effect of final Tier 4 compliance on heat recovery also varies. John Deere Final Tier 4
gensets come equipped with a skid mounted radiator, which do not support heat recovery. CAT
and MTU Tier 4 compliant gensets are equipped with third party exhaust after treatment
equipment, and can be cooled with remote radiators. There is no information currently available
on the affect heat recovery may have on exhaust equipment regeneration, but if the heat
recovery system overcools the engine and lowers the exhaust temperature, problems are likely
to occur with the exhaust after treatment equipment.
REGULATORY SUMMARY:
There are two primary EPA regulations that apply to stationary diesel engines in prime power
applications in remote areas of Alaska:
RICE NESHAP – 40 CFR 63 ZZZZ (Reciprocating Internal Combustion Engine National
Emissions Standards for Hazardous Air Pollutants)
NSPS – 40 CFR 60 IIII (New Source Performance Standards)
These rules apply to stationary diesel engines throughout the United States. During the rule
making process, the state of Alaska worked with EPA to address specific, unique circumstances
that pertain to rural Alaska villages. As a result, EPA provided regulatory relief to remote areas
of Alaska under both RICE NESHAP and NSPS.
RICE NESHAP and NSPS define “Remote Areas of Alaska” as:
(1) Areas of Alaska that are not accessible by the Federal Aid Highway System (FAHS), or
(2) Areas of Alaska that meet all of the following:
(i) The only connection to the FAHS is through the Alaska Marine Highway System
(AMHS), or is within an isolated grid not connected to the Alaska Railbelt Grid.
(ii) At least 10 percent of the power generated on an annual basis is used for
residential purposes.
(iii) The generating capacity is less than 12 megawatts, or is used exclusively for
backup power for renewable energy.
RICE-NESHAP
RICE-NESHAP applies to stationary diesel engines manufactured on or before April 1, 2006
(non-certified engines). For those engines that are located in Remote Areas of Alaska, Owner’s
and Operator’s are responsible for compliance by meeting the Management Practices listed
below:
MANAGEMENT PRACTICES
a. Change oil and filter every 1,000 hours of operation or annually, whichever comes
first;
b. Inspect air cleaner every 1,000 hours of operation or annually, whichever comes first,
and replace as necessary;
c. Inspect all hoses and belts every 500 hours of operation or annually, whichever
comes first, and replace as necessary.
d. Minimize the engine’s time spent at idle and minimize the engine’s startup time at
startup to a period needed for appropriate and safe loading of the engine, not to
exceed 30 minutes.
Page 4 of 4
New Source Performance Standards
NSPS applies to stationary diesel engines manufactured after April 1, 2006, and Manufacturer's
are responsible for producing certified (tier) engines that comply with the rule. Owner’s and
Operator’s comply by purchasing a tier-certified engine, and document that certified engines are
operated and maintained in accordance with the manufacturers emissions-related written
instructions.
NSPS prohibits stockpiling earlier tier engines for installation in later years:
a new engine greater than or equal to 75 HP and less than 175 HP may not be installed
after December 31, 2013 unless it meets 2012 model year requirements (i.e., Non-Road
Interim Tier 4 or Marine Tier 2)
a new engine greater than or equal to 175 HP and less than 750 HP may not be
installed after December 31, 2012 unless it meets 2011 model year requirements (i.e.,
Non-Road Tier 3 or Marine Tier 2)
The following NSPS provisions apply only to engines located in Remote Areas of Alaska:
(b) Except as indicated in paragraph (c) diesel engines located in remote areas of Alaska may
meet the requirements of 40 CFR parts 94 or 1042 - for marine engines (see 40 CFR
60.4216(b));
(c) Diesel engines located in remote areas of Alaska may choose to meet the emission
standards for emergency engines (Nonroad Tier 3), except that MY14 and later engines must
meet final Tier 4 PM standards, or install an exhaust filter that reduces PM emission by 85
percent (see 40 CFR 60.4216(c));
(d) pre-2014 model year stationary diesel engines located in remote areas of Alaska are not
required to use ULSD fuel (see 40 CFR 60.4216(d));
(f) diesel engines located in remote areas of Alaska may mix fuel with used lubricating oil, in
volumes of up to 1.75 percent of the total fuel. The used oil sulfur content must be less than 200
ppm, and meet the on specification requirements for used oil in 40 CFR 279.11 (see 40 CFR
60.4216(f)).
The following sections of this report include information on John Deere Tier 4 engine fuel
efficiency and exhaust aftertreatment technologies, an engine selection matrix, as well as
pertinent NSPS and RICE NESHAP regulatory citations.
APPENDIX A
Prime Power Genset
Engine Data
AEA Genset Table
Genset Fuel Efficiency
Jacket Water Heat Rejection
Alaska Energy Authority Genset Table 11/2/2016Model #Model YearEPA Tier RatingPrime rating without Fan 0.8PF (kW ) rpmFuel Efficy at 75% load (kWh/gal) Turbo coolingMarine ManifoldJacketwater Heat at PRIME RATING (Btu/kWh) Particulate filter required?Urea required? AvailabilityJohn Deere 3029HFG89 MY14+ NR‐IT4 38 1800 14.2 ATAC N 1923 N N 1, 2, 3John Deere 4045TFM75 <MY13 M‐T2 67 1800 12.6 NONEY3155 N N 1, 2, 3John Deere 4045TFM85 MY13+ M‐T3 68 1800 11.9 NONEY4013 N N 1, 2, 3John Deere 4045AFM85 MY13+ M‐T3 101 1800 12.9 JWACY4159 N N 1, 2, 3John Deere RG6081AFM75 <MY13 M‐T2 179 1800 13.2 JWACY3223 N N 1, 2, 3John Deere RG6081HF070 <MY06 NR‐T2 210 1800 13.7 ATAC N 1400 N N 1, 2, 3John Deere 6090AFM75 <MY14 M‐T2 210 1800 13.5 JWACY3382 N N 1, 2, 3John Deere 6090AFM85 MY14+ M‐T3 210 1800 13.7 JWACY3984YN1, 2, 3Detroit Diesel Series 60 (12.7L) <2006 NONE 220120015 ATAC N 1376 N N 5Detroit Diesel Series 60 (12.7L) <2006 NONE 200120014.8 ATACY1950 N N 5Detroit Diesel Series 60 (12.7L) <2006 NONE 355 1800 15.2 ATAC N 1220 N N 5Detroit Diesel Series 60 (12.7L) <2006 NONE 355 1800 15.2 ATACY1945 N N 5Caterpillar 3456 <2006 Low BSFC 476 1800 15.7 ATAC N 1160 N N 4Caterpillar 3456 <2006 Low BSFC 476 1800 15.7 ATACY3000 N N 4Caterpillar 3508B <2006 Low BSFC 550120014.8 JWAC N 2053 N N 4Caterpillar 3508B <2006 Low BSFC 1030 1800 14.4 JWAC N 2425 N N 4Caterpillar 3512B <2006 Low BSFC 1050120014.8 SCAC N 1745 N N 4Caterpillar 3512C MY07+ NR‐T2 1050120014.7 SCAC N 1344 N N 4Caterpillar 3516B <2006 Low BSFC 1285 1200 14.8 JWAC N 2230 N N 4Caterpillar 3516B <2006 Low BSFC 1322 1200 15.7 SCAC N 1402 N N 4Scania DI13075M <MY14 M‐T2 400 1800 15.3 SCACY2482 N N 3Notes:Minimum recommended load varies by engine manufacturer. Typical minimum sustained load is 30% of prime rating. Verify load requirements for your applicationModel Year: <2006 and <MY06 are 2006 and older, MY07+ is a 2007 or newer, <MY13 is older than 2013, MY13+ is 2013 and newer, <MY14 is older than 2014, MY14+ is 2014 and newer EPA Tier Rating: NR‐IT4 is Non‐Road Interim Tier 4, M‐T3 is Marine Tier 3, M‐T2 is Marine Tier 2, NR‐T2 is Non‐Road Tier 2, Low BSFC is optimum fuel economy, NONE is non‐certifiedTurbo Cooling: ATAC is Air‐to‐Air Aftercooled, JWAC is Jacket Water Aftercooled, SCAC is Separately Cooled Aftercooler, NONE is no turbocharger coolingFuel Efficiency at 75%: is fuel consumption, in kW/gallon, at 75% of prime rated kW load‐ REFER TO ATTACHED FUEL CURVES FOR ADDITIONAL INFORMATIONJacket Water Heat: is heat rejected in, Btu/kW‐hour, from the jacket water to the cooling system at prime rated kW load ‐ REFER TO ATTACHED HEAT REJECTION CURVESAvailability: below are some local vendors that provide engines and engine parts1)Airport Equipment Rentals, Anchorage, AK 907‐646‐43172)Craig Taylor Equipment, Anchorage, AK 907‐276‐50503)Marsh Creek, Anchorage, AK 907‐258‐00504)NC Power Systems, Anchorage, AK 907‐561‐17665)Pacific Power Group, Anchorage, AK 907‐522‐3434
9.09.510.010.511.011.512.012.513.013.514.014.50 50 100 150 200 250kWh/galkW LoadJohn Deere Fuel Efficiency3029HFG89, 39 kWe, NonRoad iT44045TFM75, 67 kWe, Marine T24045TFM85, 68 kWe, Marine T34045AFM85, 101 kWe, Marine T36081AFM75, 179 kWe, Marine T26081HF070, 210 kWe, NonRoad T26090AFM75, 204 kWe, Marine T26090AFM85, 204 kWe, Marine T3
6.07.08.09.010.011.012.013.014.015.016.00.0 50.0 100.0 150.0 200.0 250.0 300.0 350.0 400.0kWh/GalkW LoadDetroit Diesel, Series 60 DDEC4 ‐1800 & 1200 RPM 12.7 Liter, Fuel Efficiency (kWh/gal)OEM 6063TK35, 350 kWe, NonRoad Tier 1, 1800 RPM, Dry Manifold6063TK35, 350 kWe, NonRoad Tier 1, 1800 RPM, Marine Manifold6063TK35, 200 kWe, NonRoad Tier 1, 1200 RPM, Dry Manifold6063TK35, 200 kWe, NonRoad Tier 1, 1200 RPM, Marine Manifold
9.010.011.012.013.014.015.016.00 200 400 600 800 1000 1200 1400kWh/galkW LoadCAT Fuel Efficiency3456, 476 kWe, ATAAC, Low BSFC3508B, 550 kWe, 194F SCAC, Low BFSC3508B, 1050 kWe, 194F JWAC, Low BSFC3512B, 1050 kWe, 194F JWAC, Low BSFC3512B, 1050 kWe, 194F SCAC, Low BSFC3512B, 1050 kWe, 140F SCAC, 2000 EPA3512C, 1050 kWe, 120F SCAC, Tier 23516B, 1285 kWe, 194F JWAC, Low BSFC3516B, 1322 kWe, 140F SCAC, Low BSFC
10001500200025003000350040000 50 100 150 200 250 300 350 400Btu/kWhkW LoadDetroit Diesel, Series 60 DDEC4 ‐1800 & 1200 RPM12.7 Liter, Heat Rejected to JW (Btu/kWh)6063TK35, 350 kWe, NonRoad Tier 1, 1800 RPM, Dry Manifold6063TK35, 350 kWe, NonRoad Tier 1, 1800 RPM, Marine Manifold6063TK35, 200 kWe, NonRoad Tier 1, 1200 RPM, Dry Manifold6063TK35, 200 kWe, NonRoad Tier 1, 1200 RPM, Marine Manifold
10001500200025003000350040000 200 400 600 800 1000 1200 1400Btu/kWhkW LoadCAT Heat Rejected to Jacket Water3456, 476 kWe, ATAAC, Low BSFC3456, 476 kWe, ATAAC, Low BSFC, Marine Manifold3508B, 550 kWe, 194F SCAC, Low BFSC3508B, 1050 kWe, 194F JWAC, Low BSFC3512B, 1050 kWe, 194F JWAC, Low BSFC3512B, 1050 kWe, 194F SCAC, Low BSFC3512B, 1050 kWe, 140F SCAC, 2000 EPA3512C, 1050 kWe, 120F SCAC, Tier 23516B, 1285 kWe, 194F JWAC, Low BSFC3516B, 1322 kWe, 140F SCAC, Low BSFC
APPENDIX B
Prime Power Genset
Engine Selection Data
Alaska Prime Power Genset Matrix
Matrix Application Notes
ALASKA PRIME POWER GENSET ENGINE SELECTION MATRIX < 800 HP – SEPTEMBER 2016 (Applies to Remote Areas of Alaska - 40 CFR 60.4219) 9/28/2016 ENGINE CATEGORY Purchase a New Diesel Engine (40 CFR 60.4200) Purchase a Replacement Engine (40 CFR 60.4211(i)) (40 CFR 1068.240) Purchase a Remanufactured Engine Purchase a Used Engine Rebuild your existing Engine RICE NESHAP (non-certified) NSPS (certified) RICE NESHAP (non-certified) NSPS (certified) RICE NESHAP (non-certified) NSPS (certified) YEAR OF MANUFACTURE 2014 and newer This is a brand new engine, using a new block, built to earlier Tier emissions requirements. Date of engine block manufacture: on or before April 1, 2006 (40 CFR 60.4200)Date of engine block manufacture: after April 1, 2006 (40 CFR 60.4200) Date of engine block manufacture: on or before April 1, 2006 (40 CFR 60.4200)Date of engine block manufacture: after April 1, 2006 (40 CFR 60.4200) Date of engine block manufacture: on or before April 1, 2006 (40 CFR 60.4200)Date of engine block manufacture: after April 1, 2006 (40 CFR 60.4200) HOW DOES CAPITAL COST AFFECT ENGINE TIER REQUIREMENT Not Applicable Not Applicable If cost of remanufactured engine is greater than 50% of cost of comparable new engine, must meet Tier 1 requirements (40 CFR 63.2) (40 CFR 60.15) 50% cost rule does not affect certified (Tier) engines Converting a nonroad or other non-stationary engine to stationary use does not change date of manufacture (40 CFR 60.4219) If cost to rebuild engine is greater than 50% of cost of comparable new engine, must meet Tier 1 requirements (40 CFR 63.2) (40 CFR 60.15) 50% cost rule does not affect certified (Tier) engines Deadlines for installing prior model year engines do not apply to engines that have been removed from one existing location and reinstalled at another location (40 CFR 60.4208(i)) If the cost of the remanufactured engine is greater than 75% of cost of comparable new engine, must meet Tier 4 emission requirements (40 CFR 60.4219 – Reconstructed) The capital cost of a used engine does NOT affect the date of manufacture or change the engine Tier requirement – as long as engine is not Modified or Reconstructed (40 CFR 60.4219 – Reconstructed) (40 CFR 63.2 – Construction) If the cost to rebuild engine is greater than 75% of cost of comparable new engine, must meet Tier 4 emission requirements (40 CFR 60.4219 – Reconstructed) HOW DOES AGE OF BLOCK AFFECT ENGINE TIER REQUIREMENT Must be current certified engine: Final Tier 4 or Marine Tier 3 New Block = new engine, which must meet Tier 4 block must be “used”, and at least one additional engine component remanufactured, or engine must meet Tier 4 requirements (40 CFR 60.4219 – Reconstructed) on or before April 1, 2006 (40 CFR 60.4200)after April 1, 2006 (40 CFR 60.4200) Recommend rebuild engine to same or cleaner configuration Must rebuild engine to same or cleaner certified configuration (40 CFR 1068.120) WHAT ARE MY OPERATIONS, MAINTENANCE, AND RECORD REQUIREMENT requires ULSD, Tier 4 likely includes DOC/DPF/SCR Marine Tier 3: Requires DPF Operate and Maintain IAW Manufacturers written emissions instructions (40 CFR 60.4211) limited options for use, as OEM vendor must certify and document no other certified engine available with comparable performance as engine being replaced “Replacement” engine rule unlikely to be used for prime power applications in rural Alaska Management Practices: Inspect air cleaner, change oil & filter @ 1000-hrs, Inspect hoses & belts @ 500-hrs,Operate & Maintain engine IAW Mfrs instructions or Owner mtc plan Keep Records (40 CFR 63.6603)Operate and Maintain IAW Manufacturers written emission instructions (40 CFR 60.4211) ULSD fuel: MY14 and newer engines require ULSD fuel (40 CFR 60.4216d) Management Practices: Inspect air cleaner, change oil & filter @ 1000-hrs, Inspect hoses & belts @ 500-hrs, Operate & Maintain engine IAW Mfrs instructions or Owner mtc plan Keep Records (40 CFR 63.6603)Operate and Maintain IAW Manufacturers written emission instructions (40 CFR 60.4211) ULSD fuel: MY14 and newer engines require ULSD fuel (40 CFR 60.4216d) Management Practices: Inspect air cleaner, change oil & filter @ 1000-hrs, Inspect hoses & belts @ 500-hrs, Operate & Maintain engine IAW Mfrs instructions or Owner mtc plan Keep Records (40 CFR 63.6603)Operate and Maintain IAW Manufacturers written emissions instructions (40 CFR 60.4211) ULSD fuel: MY14 and newer engines require ULSD fuel (40 CFR 60.4216d) DEADLINE FOR INSTALLING NEW ENGINES (40 CFR 60.4208) a new engine greater than or equal to 75 HP and less than 175 HP may not be installed after December 31, 2013 unless it meets 2012 model year (Non-Road Interim Tier 4 or Marine Tier 2) req’s a new engine greater than or equal to 175 HP and less than 750 HP may not be installed after December 31, 2012 unless it meets 2011 model year (i.e., Non-Road Tier 3 or Marine Tier 2) requirements
This genset engine selection chart applies to:
prime power diesel engines less than 800 horse power
operating under a Pre-approved Emissions Limit (PAEL), <330,900 gallons/year
located in Remote Areas of Alaska
What diesel engine may I use?
Will the diesel engine replace an existing engine?
o Yes, continue
o No, consult ADEC regulations
A. Replace or repower an existing genset:
1. NEW ENGINES: A new engine is an engine that has never been placed into service,
regardless of the when the engine was originally manufactured:
a. 40 CFR 60.4219 – Requirements for engines used in Alaska
i. Remote areas of Alaska
1. stationary diesel engines located in remote areas of Alaska may use
Non-road Tier 3 and Marine Tier 3 engines, except that 2014 model
year and later engines must meet Tier 4 particulate matter emissions
limits or install a particulate filter that reduces particulate matter by 85
percent.
2. 2014 model year and later engines must use ULSD fuel
b. 40 CFR 60.4208 - NSPS deadline for installing prior model year engines
i. a new engine greater than or equal to 175 HP and less than 750 HP may
not be installed after December 31, 2012 unless it meets 2011 model
year requirements (Non-Road Tier 3 or Marine Tier 2)
ii. a new engine greater than or equal to 75 HP and less than 175 HP may
not be installed after December 31, 2013 unless it meets 2012 model
year requirements (Non-Road Interim Tier 4 or Marine Tier 2)
iii. a new engine greater than or equal to 750 HP may not be installed after
December 31, 2016 unless it meets 2015 model year requirements (Non-
Road Tier 4 or Marine Tier 3 or 4)
c. Document engine model year, Tier certification, verify correct engine EPA
label, operate and maintain in accordance with manufacturers recommended
instructions
2. USED ENGINES: A used engine is an existing engine that is not new, and that:
a. has been removed from one existing location and reinstalled at another
location (relocated)
b. is rebuilt, or remanufactured
i. Relocated engine:
1. Can be a gen-drive, non-road, marine auxiliary, or marine propulsion
engine
2. The capital cost of a used engine does not change the engine Tier
a. An existing non-road, marine auxiliary, or marine propulsion
engine may be converted to a stationary engine, does not affect
engine Tier
ii. Rebuilt or Remanufactured engines:
1. For an existing engine that is a RICE NESHAP, non-certified engine
(engine manufacture date is on or before April 1, 2006),
a. If cost of rebuilt/reman engine is greater than 50% of cost of final
Tier 4 engine, engine must meet Tier 1 emissions requirements
(Tier 1 engine)
b. If cost of rebuilt/reman engine is greater than 75% of cost of final
Tier 4 engine, engine must meet Tier 4 emissions requirements
(Tier 4 engine)
c. A rebuilt/reman block must be “used”, and at least one additional
engine component must be remanufactured, or engine must be
Tier 4
d. Document engine manufacture date on or before 4/06, maintain
maintenance records, operate per RICE NESHAP “Management
Practices”
2. For an existing engine that is an NSPS, tier certified engine (engine
manufacture date after April 1, 2006 – but prior to MY14),
a. A tier certified engine must be rebuilt or remanufactured to the
same or higher Tier as the Tier of the original engine block
i. The block must be an appropriate model year for the Tier that
engine is rebuilt or remanufactured to
ii. Restore the engine to its original certified configuration
iii. May update to operate like newer certified model
iv. Must have a reasonable technical basis
b. If cost of rebuilt/reman engine is greater than 75% of cost of
final Tier 4 engine, engine must meet Tier 4 emissions
requirements (Tier 4 engine)
c. A rebuilt/reman block must be “used” and at least one
additional component must be remanufactured, or engine
must be Tier 4
d. document engine model year, Tier certification, verify
correct engine EPA label, and operate and maintain in
accordance with manufacturers recommended instructions
B. Diesel Fuel Requirements
1. All 2014 model year and later engines require ULSD fuel
2. ULSD has been in use in prime power plants in southeast Alaska, Kodiak, and
the Aleutians since 2010 due to highway and marine diesel fuel market forces.
3. ULSD #1 and ULSD Jet-A are available throughout rural Alaska
4. ULSD is compatible with prime power diesel engines
5. Cost for ULSD #1 is virtually the same as higher sulfur HF#1 & Jet-A.
6. may mix diesel fuel with used lubricating oil, in volumes up to 1.75% of the total
fuel, where the sulfur content of the used oil is less than 200 ppm and meets the
used oil specification in 40 CFR 279.11 (on-spec).
APPENDIX C
NSPS and RICE NESHAP
Regulatory Citations
Definitions:
RICE NESHAP – on or before April 1, 2006 (owner/operator responsible = operations/mtc)
NSPS ‐ after April 1, 2006 (manufacturer responsible = certified engines, Oper/mtn IAW mfrs instr’s)
Accessible to FAHS – NSPS/RICE NESHAP – currently separate but may be aligned
Reconstruct – 50% and 75% thresholds – 40 CFR 60.15 & 60.4219
Modify – 40 CFR 60.14; increase emissions, does not include increase in operating hours or load
Remanufactured / Rebuilt – 40 CFR 1068.120
Penalties –
40 CFR 89.1006 ‐ $2,750/day to $32,500/day;
40 CFR 1068.101 ‐ $3,750/day to $37,500/day
CFR Citations:
40 CFR 60 = NSPS (after April 1, 2016)
40 CFR 63 = NESHAP (on or before April 1, 2016)
40 CFR 80 = Fuel Regulations
40 CFR 89 = Nonroad Tier 1 ‐ 3
40 CFR 94 = Marine Tier 1 & 2
40 CFR 279.11 = Used Oil Specifications
40 CFR 1039 = Nonroad Tier 4
40 CFR 1042 = Marine Tier 3 & 4
40 CFR 1068 = Highway, Stationary, NR Compliance (flex/TPEM, Rebuild, Tampering)
40 CFR PART 63 – NESHAP for SOURCE CATEGORIES
§ 63.2 Definitions - The terms used in this part are defined in the Act or in this
section as follows:
Construction means the on-site fabrication, erection, or installation of an affected
source. Construction does not include the removal of all equipment comprising an
affected source from an existing location and reinstallation of such equipment at
a new location. Removal and reinstallation may be reconstruction if it satisfies the
criteria for reconstruction defined in this section. The costs of replacing minor ancillary
equipment must be considered in determining whether the existing affected source is
reconstructed.
Existing source means any affected source that is not a new source.
Reconstruction, unless otherwise defined in a relevant standard, means the
replacement of components to such an extent that:
(1) The fixed capital cost of the new components exceeds 50 percent of the fixed
capital cost that would be required to construct a comparable new source; and
(2) Upon reconstruction, an existing diesel engine is subject to relevant
standards for new sources, including compliance dates.
40 CFR 63 Subpart ZZZZ - RICE NESHAP
§ 63.6585 Am I subject to this subpart?
You are subject to this subpart if you own or operate a stationary diesel engine
§ 63.6590 What parts of my plant does this subpart cover?
(a) any existing, new, or reconstructed stationary diesel engine.
(iv) A change in ownership of an existing stationary diesel engine does not
make that engine new or reconstructed.
(c) Stationary RICE subject to 40 CFR Part 60 (NSPS).
(1) A new or reconstructed stationary diesel engine must meet the
requirements of 40 CFR part 60 subpart IIII (NSPS). No further
requirements apply under this part.
§ 63.6603 What requirements must I meet if I own or operate an existing stationary
diesel engine at an area source?
(b) Existing stationary non-emergency diesel engines located at an area source
in either (b)(1) or (2), below, must meet the management practices shown in
Table 2d of this subpart.
(1) The diesel engine is in an area of Alaska not accessible by the Federal
Aid Highway System (FAHS).
(2) The diesel engine is located where:
(i) The only connection to the FAHS is through the Alaska Marine
Highway System (AMHS), or is not connected to the Alaska Railbelt
Grid.
(ii) At least 10 percent of the power generated on an annual basis is
used for residential purposes.
(iii) The generating capacity is less than 12 megawatts, or is used
exclusively for backup power for renewable energy.
§ 63.6675 What definitions apply to this subpart?
Alaska Railbelt Grid means the service areas of the six regulated public utilities that
extend from Fairbanks to Anchorage and the Kenai Peninsula. These utilities are
Golden Valley Electric Association; Chugach Electric Association; Matanuska Electric
Association; Homer Electric Association; Anchorage Municipal Light & Power; and the
City of Seward Electric System.
Backup power for renewable energy means an engine that provides backup power to
a facility that generates electricity from renewable energy resources, as that term is
defined in Alaska Statute 42.45.045(l)(5).
§ 63.6604 What fuel requirements must I meet if I own or operate a stationary
diesel engine?
(d) Existing stationary diesel engines located …. at area sources in Alaska that
meet either § 63.6603(b)(1) or § 63.6603(b)(2) are exempt from the requirements
of this section - ULSD is not required!
§ 63.6625 What are my monitoring, installation, collection, operation, and
maintenance requirements?
(e) ..you must operate and maintain the stationary diesel engine and after-treatment
control device (if any) according to the manufacturer’s emission-related written
instructions…
Table 2d
MANAGEMENT PRACTICES
a. Change oil and filter every 1,000 hours of operation or annually, whichever
comes first;
b. Inspect air cleaner every 1,000 hours of operation or annually, whichever
comes first, and replace as necessary;
c. Inspect all hoses and belts every 500 hours of operation or annually,
whichever comes first, and replace as necessary.
Minimize the engine’s time spent at idle and minimize the engine’s startup time
at startup to a period needed for appropriate and safe loading of the engine, not
to exceed 30 minutes.
40 CFR PART 60 – Standards of Performance Standards for New Sources
§ 60.14 Modification.
any physical or operational change which results in an increase in any regulated
pollutant. Upon modification, an existing facility is subject to the standard for each
pollutant for which there is an increase in the emission rate.
(e) The following shall not, by themselves, be considered modifications under this part:
(1) Maintenance, repair, and replacement which is routine, so long as the engine
is not Reconstructed (§ 60.15)
(2) An increase in production rate of an existing facility, if that increase can be
accomplished without a capital expenditure on that facility.
(3) An increase in the hours of operation.
(6) The relocation or change in ownership of an existing facility.
§ 60.15 Reconstruction.
(a) Upon reconstruction, an existing facility (engine) is subject to NSPS.
(b) ‘‘Reconstruction’’ means the replacement of components of an existing facility
(engine) such that the fixed capital cost of the new components exceeds 50
percent of the fixed capital cost that would be required to construct a comparable
entirely new facility (Tier 4),
(c) ‘‘Fixed capital cost’’ means the capital needed to provide all the depreciable
components.
40 CFR 60 Subpart IIII - New Source Performance Standards (NSPS)
§ 60.4200 Am I subject to this subpart?
(2) Owners and operators of stationary diesel engines that are:
(i) Manufactured after April 1, 2006…
(3) Owners and operators of stationary diesel engines modified or reconstructed
after July 11, 2005, and any person that modifies or reconstructs any stationary
diesel engine after July 11, 2005.
§ 60.4204 What emission standards must I meet for non-emergency engines if I am
an owner or operator?
(a) Owners and operators of pre-2007 model year non-emergency stationary
diesel engines must comply with the emission standards in table 1, (Tier 1).
(b) Owners and operators of 2007 model year and later non-emergency
stationary diesel engines must comply with the emission standards for new
diesel engines, (Tiers 1 – 4).
(e) Owners and operators of any modified or reconstructed non-emergency
stationary diesel engine must meet the emission standards applicable to the
model year, maximum engine power, and displacement of the modified or
reconstructed engine that are specified in paragraphs (a) and (b) of this section.
§ 60.4208 What is the deadline for importing or installing a stationary diesel engine
produced in previous model years?
o a new engine greater than or equal to 175 HP and less than 750 HP may not be
installed after December 31, 2012 unless it meets 2011 model year
requirements (Non-Road Tier 3 or Marine Tier 2)
o a new engine greater than or equal to 75 HP and less than 175 HP may not be
installed after December 31, 2013 unless it meets 2012 model year
requirements (Non-Road Interim Tier 4 or Marine Tier 2)
o a new engine greater than or equal to 750 HP may not be installed after
December 31, 2016 unless it meets 2015 model year requirements (Non-Road
Tier 4 or Marine Tier 3 or 4)
60.4211 What are my compliance requirements if I am an owner or operator of a
stationary diesel engine?
(a) you must…
(1) Operate and maintain the stationary diesel engine and control device
according to the manufacturer’s emission-related written instructions;
(2) Meet the requirements of 40 CFR parts 89, 94, and/or 1068, as they
apply to you.
(c) If you are an owner or operator of a 2007 model year and later stationary
diesel engine …, you must comply by purchasing a tier certified engine. The
engine must be installed and configured according to the manufacturer’s
emission-related specifications.
§ 60.4216 What requirements must I meet for engines used in Alaska?
(b) Except as indicated in paragraph (c) diesel engines less than 10 liters per cylinder
located in remote areas of Alaska may meet the requirements of 40 CFR parts 94 or
1042 - for marine engines.
(c) Diesel engines located in remote areas of Alaska may choose to meet the emission
standards for emergency engines (Nonroad Tier 3), except that MY14 and later engines
must meet final Tier 4 PM standards, or install an exhaust filter that reduces PM
emission by 85 percent.
(d) pre-2014 model year stationary diesel engines located in remote areas of Alaska are
not required to use ULSD fuel.
(f) diesel engines located in remote areas of Alaska may mix fuel with used lubricating
oil, in volumes of up to 1.75 percent of the total fuel. The used oil sulfur content must be
less than 200 ppm, and meet the on specification requirements for used oil in 40 CFR
279.11.
§ 60.4219 What definitions apply to this subpart?
Alaska Railbelt Grid means the service area of the six regulated public utilities
that extend from Fairbanks to Anchorage and the Kenai Peninsula. These utilities
are Golden Valley Electric Association; Chugach Electric Association; Matanuska
Electric Association; Homer Electric Association; Anchorage Municipal Light &
Power; and the City of Seward Electric System.
Remote areas of Alaska means areas of Alaska that meet either paragraph (1)
or (2) of this definition.
(1) Areas of Alaska that are not accessible by the Federal Aid Highway
System (FAHS).
(2) Areas of Alaska that meet all of the following criteria:
(i) The only connection to the FAHS is through the Alaska Marine Highway
System, or the stationary CI ICE operation is within an isolated grid in
Alaska that is not connected to the statewide electrical grid referred to
as the Alaska Railbelt Grid.
(ii) At least 10 percent of the power generated by the stationary CI ICE on
an annual basis is used for residential purposes.
(iii) The generating capacity of the source is less than 12 megawatts, or the
stationary CI ICE is used exclusively for backup power for renewable
energy
Date of manufacture means one of the following things:
(1) For freshly manufactured engines and modified engines, date of
manufacture means the date the engine is originally produced.
(2) For reconstructed engines (50% rule), date of manufacture means the
date the engine was originally produced, except as specified in
paragraph (3), below.
(3) Reconstructed engines are assigned a new date of manufacture if the
fixed capital cost of the new and refurbished components
exceeds 75 percent of the fixed capital cost of a comparable
entirely new facility. If an engine is produced from a previously used
engine block using all new components except for the engine block,
the date of manufacture is the date the new engine is produced (must
meet final Tier 4).
Freshly manufactured engine means an engine that has not been placed into
service. An engine becomes freshly manufactured when it is originally produced.
Installed means the engine is placed and secured at the location where it is
intended to be operated.
Model year means the calendar year in which an engine is manufactured, except
as follows:
(1) Model year means the annual new model production period of the
engine manufacturer in which an engine is manufactured
(2) For an engine that is converted to a stationary engine after being
placed into service as a nonroad or other nonstationary engine, model
year means the calendar year or new model production period in which
the engine was manufactured.
§89.130 Rebuild Practices – applies to Tiers 1-3 (§1039.100 applies to Tier 4)
(40 CFR 60.4211(a)(3): meet part 89 requirements)
The provisions of 40 CFR 1068.120 apply to rebuilding of engines subject to the
requirements of this part 89, except Tier 1 engines rated at or above 37 kW.
§1068.120 What requirements must I follow to rebuild engines?
(a) For maintenance or service that is not “rebuilding” you do not need to keep any records.
(b) The term “rebuilding” refers to a rebuild or major overhaul that significantly increases the
service life of the engine. Rebuilding does not normally include the following:
(1) Scheduled emission-related maintenance, such as replacing fuel injectors
(2) Unscheduled maintenance, such as replacing a water pump.
(d) If you rebuild an engine, you must have a reasonable technical basis for knowing that the
rebuilt engine's emission control system performs as well or better than in its certified
configuration. Identify the model year of the resulting engine configuration. You have a
reasonable basis if you meet two main conditions:
(1) Install new, used, or rebuilt parts - so a person familiar with engine design and
function would reasonably believe that the engine with those parts will control emissions
of all pollutants to at least to the same degree as with the original parts.
(2) Adjust parameters or change design elements only according to the original engine
manufacturer's instructions. If you differ from these instructions, you must have data or
some other technical basis to show you should not expect in-use emissions to increase.
(e) If the rebuilt engine is used in the same piece of equipment, you must rebuild it to the
original configuration, except as allowed by this paragraph. You may rebuild it to a different
certified configuration of the same or later model year. You may also rebuild it to a
certified configuration from an earlier model year as long as the earlier configuration is
as clean or cleaner than the original configuration, “as clean or cleaner” means one of the
following:
(1) For engines not certified with a Family Emission Limit for calculating credits for a
particular pollutant, this means that the same emission standard applied for both model
years. This includes supplemental standards such as Not-to-Exceed standards.
(2) For engines certified with a Family Emission Limit for a particular pollutant, this
means that the configuration to which the engine is being rebuilt has a Family Emission
Limit for that pollutant that is at or below the standard that applied to the engine
originally, and is at or below the original Family Emission Limit.
(f) A rebuilt engine may replace another certified engine if the engine was rebuilt to an
equivalent or more stringent certified emission configuration standard. The following examples
illustrate these provisions:
(1) You may use a rebuilt Tier 2 engine to replace a Tier 1 engine or Tier 2 engine.
(2) You may use a rebuilt Tier 1 engine to replace a Tier 2 engine if the Tier 1 engine
has emission levels below the Tier 2 standards or if the Tier 2 engine was certified with a
Family Emission Limit for calculating emission credits.
(3) You may use a rebuilt engine that originally met the Tier 1 standards without
certification, as provided under 40 CFR 1068.265, to replace a certified Tier 1 engine.
This may occur for engines produced under a Transition Program for Equipment
Manufacturers such as that described in 40 CFR 1039.625.
(4) You may not replace a certified engine with an engine rebuilt to a configuration that
does not meet EPA emission standards.
(g) Do not erase or reset emission-related codes without diagnosing and addressing its cause.
Clear all codes from diagnostic systems when you return the rebuilt engine to service.
(h) check, clean, adjust, repair, or replace all emission-related components (listed in Appendix I)
IAW original manufacturer's recommended practice, unless you have a reasonable technical
basis for believing these components do not need replacement.
(i) If you are installing an engine that someone else has rebuilt, check all emission-related
components listed in Appendix I of this part IAW original manufacturer's recommended practice.
(j) Keep at the following records:
(1) hours of operation at the time of rebuild. These may be noted as approximate values
if the engine has no hour meter.
(2) Identify the work done on the engine and emission-related control components.
Include a list of parts used.
(3) Describe any engine parameter adjustments.
(4) Identify any emission-related codes or signals responded to and reset.
(k) Keep records for at least two years after rebuilding an engine, in any format that allows easy
review.
(1) You do not need to keep information that is not reasonably available through normal
business practices.
(2) You do not need to keep records of what other companies do.
APPENDIX D
John Deere Tier 4 Engine Data
Engine Emissions Equipment
Fuel Efficiency Graph
Exhaust Aftertreatment Table
ExhaustIntake Throttle ValveFresh AirCompressed Air From TurbochargersEGR ValveVGTFixedEGR CoolerAir-to-air CoolerDosing InjectorECUDEF TankHeader Assembly with Level and Temperature SensorDEF Supply Module and FilterDEF LineEngine Coolant LinesTemperature SensorsSCRAOCDEF InjectorNOx SensorMixerNOx SensorDOC DPF P SensorTemperature Sensors
9.09.510.010.511.011.512.012.513.013.514.014.515.00.0 25.0 50.0 75.0 100.0 125.0 150.0 175.0 200.0 225.0 250.0 275.0 300.0 325.0 350.0 375.0kWh/galkW LoadJohn Deere Fuel EfficiencyTier 4 Gensets4045HFG09_A 96 kWe Prime, Tier 46068HFG09_A 192 kWe Prime, Tier 46090HFG09_AE 271 kWe Prime, Tier 46135HFG09_AB 330 kWe Prime, Tier 4
JohnDeereFinalTier4EngineExhaustAftertreatmentModel#HPStandbyTierIVCertified?Y/PreliminaryExhaustFilter(Y/N)SCRCatalyst(Y/N)ERGCooler(Y/N)4045HFG09_B 141 Y Y Y Y4045HFG09_A 166 Y Y Y Y4045HFG06_A 172 YNYY6068HFG08_B 200 Y Y Y Y6068HFG08_A 241 Y Y Y Y6068HFG09_B 289 Y Y Y Y6090HFG09_AD 318 Y Y Y Y6068HFG09_A 322 Y Y Y Y6090HFG06_C 366 YNYY6090HFG09_AC 366 Y Y Y Y6090HFG09_AB 398 Y Y Y Y6090HFG06_B 437 YNYY6090HFG09_AA 437 Y Y Y Y6090HFG09_AE 463 Y Y Y Y6135HFG09_AC 477 Y Y Y Y6135HFG09_AB 551 Y Y Y Y6135HFG06_A 634 YNYY6135HFG09_AA 634 Y Y Y Y