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HomeMy WebLinkAboutAQ_F_0400056_20190529_CMPL_InspRpt NORTH CAROLINA DIVISION OF Fayetteville Regional Office AIR QUALITY Piedmont Natural Gas-Wadesboro Compressor Station Inspection Report NC Facility ID 0400056 Date: 06/03/2019 County/FIPS:Anson/007 Facility Data Permit Data Piedmont Natural Gas -Wadesboro Compressor Station Permit 10097/TO 259 Pleasant Grove Church Road Issued 9/15/2014 Wadesboro,NC 28170 Expires 8/31/2019 Lat: 35d 1.4834m Long: 80d 1.6830m Class/Status Title V SIC: 4922/Natural Gas Transmission Permit Status Active NAICS: 48621 /Pipeline Transportation of Natural Gas Current Permit Application(s)TV-Renewal Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SIP/Title V MACT Part 63: Subpart ZZZZ Christopher Friel Adam Long Cynthia Winston NSPS: Subpart JJJJ Lead EHS Professional Director, Gas Pipeline Manager, Permitting and (336)682-3122 Operations Compliance (704)731-4130 (919)546-5538 Compliance Data Comments: o Inspection Date 05/29/2019 Inspector's Name Abdul Kadir Inspector's Signature: Operating Status Operating Compliance Code Compliance-inspection / Action Code FCE Date of Signature: O61O V/6 On-Site Inspection Result Compliance Total Actual emissions{{{in TONS/YEAR: TSP SO2 NOX VOC CO PM10 * HAP 2017 1.11 0.0800 12.92 5.09 0.9400 1.11 1860.30 2016 1.60 0.0800 18.51 7.24 1.31 1.60 2667.43 2015 1.43 0.0800 15.22 6.30 1.20 1.43 15288.34 * Highest HAP Emitted(in pounds) Five Year Violation History:None Date Letter Tyne Rule Violated Violation Resolution Date Performed Stack Tests since last FCE: Date Test Results Test Method(s) Source(s)Tested 05/08/2019 Pending 1. DIRECTIONS TO SITE: From FRO,take US Hwy 401 South through Raeford and Wagram. Just past Wagram,turn right onto Old Wire Road(NC 144). Follow Old Wire Road across US 151501 and through Laurel Hill to US 74. Turn right onto US 74. Follow US 74 35 miles to Wadesboro,then turn right onto N. Greene SUNC Hwy 109. Drive 4.9 miles, then turn left onto Pleasant Grove Church Road. The Piedmont facility is located approximately 0.3 miles on the left side of the road. 2. SAFETY CONSIDERATIONS: The usual FRO safety gear is required,including hard hat,safety shoes,safety glasses,and hearing protection. There may be numerous pieces of equipment operating on site, including forklifts,personnel lifts,trucks,cars, and others. 3. FACILITY DESCRIPTION: The facility is a large natural gas pipeline compressor station. The facility accepts natural gas from the Trans- Continental distribution pipeline at 500-800 psig pressure,and compresses this gas to 800-1,000 psig for injection into the Piedmont pipeline to transport it to its destination. The gas pipeline leads eventually to the Duke Sutton electrical power generation plant in Wilmington. The Piedmont facility consists of four(4)natural gas-fired 4,735 HP compressors(8 are permitted at the facility),plus a 770 HP natural gas-fired emergency generator. All the engines are fueled by natural gas pulled directly from the gas transmission pipeline. 4. FACILITY INSPECTION SUMMARY: On 29 May 2019 I,Abdul Kadir and Greg Reeves,both with DAQ FRO visited the Piedmont Natural Gas— Wadesboro Compressor Station plant site in Wadesboro. We met with Richard Wentland and Delmar Keith, both are Compressor Technician. We explained that we were at the site to conduct an air quality permit compliance inspection. We showed Mr. Wentland the FacFinder and he indicated some changes and the update were made in IBEAM. Records for operating hours and operating loads on the engines is kept on the computerized control system. The operator was able to show us the records of operating hours for each of the permitted engines. Operating hours for each engine were as follows: M 41 yl a.11'�� #1 Compressor 7,496 9,894 (COMP01 #2 Compressor 7,480 9,891 (COMP02) #3 Compressor 7,496 9,812 (COMP03) #4 Compressor 7,489 9,812 (COMP04) Emergency Generator 142 165 (EGO1) 5. PERMITTED EQUIPMENT: Emission Emission Source Description Control Control Device Description Source Device ID No. ID No. COMPOI One four-stroke lean burn natural gas- COMPOI C Catalytic oxidizer(24.0 cubic NSPS fired reciprocating internal feet of oxidation catalyst) MACT combustion engine(4,735 horsepower rating)powering a compressor NOT OPERATING COMP02 One four-stroke lean burn natural gas- COMP02C Catalytic oxidizer(24.0 cubic NSPS fired reciprocating internal feet of oxidation catalyst) MACT combustion engine(4,735 horsepower rating)powering a compressor NOT OPERATING COMP03 One four-stroke lean burn natural gas- COMP03C Catalytic oxidizer(24.0 cubic NSPS fired reciprocating internal feet of oxidation catalyst) MACT combustion engine(4,735 horsepower rating)powering a compressor OPERATING, VE 0%Opacity COMP04 One four-stroke lean burn natural gas- COMP04C Catalytic oxidizer(24.0 cubic NSPS fired reciprocating internal feet of oxidation catalyst) MACT combustion engine(4,735 horsepower rating)powering a compressor NOT OPERATING COMP05 One four-stroke lean burn natural gas- COMP05C Catalytic oxidizer(24.0 cubic NSPS fired reciprocating internal feet of oxidation catalyst) MACT combustion engine(4,735 horsepower rating)powering a compressor NOT YET INSTALLED COMP06 One four-stroke lean burn natural gas- COMP06C Catalytic oxidizer(24.0 cubic NSPS fired reciprocating internal feet of oxidation catalyst) MACT combustion engine(4,735 horsepower rating)powering a compressor NOT YET INSTALLED COMP07 One four-stroke lean burn natural gas- COMP07C Catalytic oxidizer(24.0 cubic NSPS fired reciprocating internal feet of oxidation catalyst) MACT combustion engine(4,735 horsepower rating)powering a compressor NOT YET INSTALLED COMP08 One four-stroke lean burn natural gas- COMP08C Catalytic oxidizer(24.0 cubic NSPS fired reciprocating internal feet of oxidation catalyst) MACT combustion engine(4,735 horsepower rating)powering a compressor NOT YET INSTALLED EGO 1 One four-stroke lean burn natural gas- MACT fired emergency generator(770 hp N/A N/A maximum rating) NOT OPERATING 6. SPECIFIC PERMIT CONDITIONS: A. Eight 4,735 Four Stroke Lean Burn Natural Gas-fired Compressor Engines (ID Nos. COMPOI through COMP08) i. 15A NCAC 2D.0516 SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES— Emissions of sulfur dioxide from the eight 4,735 HP compressor engines shall not exceed 2.3 pounds per million Btu heat input. APPEARS IN COMPLIANCE—The engines use only natural gas,with an EPA AP-42 emission factor of 0.001 lb/mmBtu. As long as the engines only combust natural gas,they should not exceed the limitation. Only the#3 Compressor engine was operating during the inspection. Only 4 of the permitted compressor engines have been installed. ii. 15A NCAC 2D .0521 CONTROL OF VISIBLE EMISSIONS—Visible emissions from the eight compressor engines shall not exceed 20 percent opacity when averaged over a 6-minute period. 6- minute averaging periods may exceed 20 percent opacity no more than once in any hour and not more than four times in any 24-hour period. In no event shall the 6-minute average exceed 87 percent opacity. APPEARS IN COMPLIANCE—The typical opacities for these engine exhausts are zero. The facility should have no difficulty complying with these limits. We observed no visible emissions from the#3 Compressor engine exhaust during the inspection. iii. 15A NCAC 2D .1423 LARGE INTERNAL COMBUSTION ENGINES—The Permittee shall not cause to be emitted into the atmosphere nitrogen oxides(NOx)in excess of 125 ppm, corrected to 15 percent by volume stack gas oxygen on a dry basis, averaged over a rolling 30-day period. This limit may be adjusted basis the engine efficiencies. Compliance with the limits will be demonstrated by conducting stack testing at the engine exhausts. A report is required by October 31 of each year, documenting the total nitrogen oxide emissions during the period May 1 through September 30 of each year,beginning with the year of the first ozone season that the engines operate. Records are required to be maintained for each engine for ID and location of each engine;number of hours of operation of each engine each day,including startups, shutdowns, and malfunctions,and the type and duration of maintenance and repairs;date and results of any emissions corrective maintenance taken;results of compliance testing. Emission standards do not apply during periods of start-up and shutdown and periods of malfunctions,not to exceed 36 consecutive hours, or regularly scheduled maintenance activities. APPEARS IN COMPLIANCE—The facility maintains all records electronically through the DCS control system, which maintains hours of operation and other data. Some paper records are also maintained for the preventative maintenance activities. The last ozone season report was received at FRO on 11/05/18. B. 880 HP Four Stroke Lean Burn Natural Gas-fired Emergency Generator(ID No. EGO1) i. 15A NCAC 2D.0516 SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES— Emissions of sulfur dioxide from the emergency generator engine shall not exceed 2.3 pounds per million Btu heat input. APPEARS IN COMPLIANCE—The engine combusts only natural gas. The EPA AP-42 emission factor for sulfur dioxide for natural gas combustion is 0.001 Ib/mmBtu. As long as this engine only combusts natural gas,it should easily meet this limitation.The engine was not operating during the inspection. ii. 15A NCAC 2D.0521 CONTROL OF VISIBLE EMISSIONS-Visible emissions from the emergency generator engine shall not exceed 20 percent opacity when averaged over a 6-minute period. 6-minute averaging periods may exceed 20 percent opacity no more than once in any hour and not more than four times in any 24-hour period. In no event shall the 6-minute average exceed 87 percent opacity. APPEARS IN COMPLIANCE—Typical visible emissions for this engine during operation are zero opacity. The facility should have no difficulty complying with the permit limitation. The engine was not operating during the inspection. C. Compressor Engines(COMPOI through COMP04)and Emergency Generator Engine(EGO I) i. 40 CFR 63,Subpart ZZZZ STATIONARY RECIPROCATING INTERNAL COMBUSTION ENGINES—The engines meet the requirements of Subpart ZZZZ by meeting all the requirements of NSPS Subpart JJJJ"Stationary Spark Ignition Internal Combustion Engines" APPEARS IN COMPLIANCE—The engines demonstrate compliance by complying with the requirements of NSPS Subpart JJJJ. ii. 40 CFR 60,Subpart JJJJ STATIONARY SPARK IGNITION INTERNAL COMBUSTION ENGINES—The compressor engines must meet the following emission limits: NOx— 1.0 g/HP-hr and 82 ppmvd @ 15%oxygen; CO 2.0 g/HP-hr and 270 ppmvd @ 15%oxygen;VOC 0.7 g/HP-hr and 60 ppmvd @ 15%oxygen. The emergency engine must meet the following emission limits: NOx— 2.0 g/HP-hr and 160 ppmvd @ 15%oxygen;CO 4.0 g/HP-hr and 540 ppmvd @ 15%oxygen;VOC— 1.0 g/HP-hr and 86 ppmvd @ 15%oxygen. VOCs do not include formaldehyde. The nine engines are not certified engines,and therefore the facility must conduct initial stack testing to demonstrate initial compliance on each engine. Records of maintenance plans and records of conducted maintenance must be maintained, as well as records of the stack testing. Subsequent stack testing must be conducted every 8,760 hours or 3 years,whichever comes first. Results of stack testing must be submitted within 60 days after the testing is performed. Initial notification is required. APPEARSIN COMPLIANCE—Stack testing was performed on the emergency generator engine on 05/21/13, 05/12/16 and on 05/08/19. Results of the first two tests demonstrated compliance with the emission limits and results of the last stack test has yet to be submitted by the facility. Stack tests for the four compressor engines were conducted on 11/25-11/27/14,and again on 08/17-08/18/16. The stack testing results indicated compliance with the emission limits(see the table below for stack testing results for the engines). The operating hours of the four compressor engines were as noted in the table below. The emergency engine is seldom run except for operational checks,and will be due for stack testing in May 2022. Maintenance records are readily accessible in the operations office. The initial notification for the 5 current engines was received at FRO on 03/04/13. Engine Hours of Operation: 4;i h`�y i i s d st yy i 1 at��fi Ny' �St 9 91 NMI � JLi COMPOI 08/17/16 4,047 7,496 9,894 COMP02 08/17/16 4,198 7,480 9,891 COMP03 68/18/16 4,132 7,496 9,812 COMP04 08/18/16 4,193 7,489 9,812 EGO 65/08/19 NA 142 165 Stack testing of the compressor engines will be required in August 2019. Stack Testing Results: W y nil e#1 fin!§ la its ,a 5/ Q / 6, s, s� 6. ��. �_. �" 8•. �� NOx 1.0 g/hp-hr 0.33 0.28 82 ppm 22 20.4 CO 2.0 hp-hr 0.02 0.03 270 ppm 1.8 3.4 VOC 0.7 hp-hr 0 0.09 60 ppm 0 1 6.2 T30 IN i NOx 1.0 g/h -hr 0.42 82 ppm 30.9 CO 2.0 h -hr 0.02 270 m 2.6 VOC 0.7 g/hp-hr 0.49 0.25 60 p m 34.2 18 Itis NOx 1.0 g/hp-hr 0.39 0.44 82 ppm 22 33.4 CO 2.0 g/hp-hr 0.03 0.03 270 ppm 2.5 3.3 VOC 0.7 g1 -hr 0.10 0.26 60 ppm 5.0 18.8 �iWl k MA IsMM NOx 1.0 h -hr 0.43 0.44 82 ppm 24 29.8 CO 2.0 h -hr 0.03 0.03 270 m 2.4 3.0 VOC 0.7 h -hr 0 0.02 60 ppm 0 1.0 9 i b ^ ° NOx 2.0 g/hp-hr 1.5 1.0 160 ppm 99 58 CO 4.0 g/hp-hr 1.6 1.8 540 pm 168 174 VOC 1.0 g/hp-hr 0.14 0.1 86 ppm 26 15 iii. 15A NCAC 2Q.0317 AVOIDANCE CONDITION FOR 40 CFR 63 SUBPART ZZZZ(HAP MAJOR CLASSIFICATION AVOIDANCE)—The facility has accepted an emission limit of no more than 10 tons of formaldehyde per consecutive 12-month period to avoid the Title III Major Source rules for this Subpart. This requirement is met by conducting the required monitoring, recordkeeping,and reporting of emissions of CO based on stack testing. APPEARS IN COMPLIANCE—The review of the potential controlled emissions during the permit review process showed that this limit should not be exceeded. Proper operation and maintenance of the catalytic oxidizers on the engines is required to comply with this limit. The stack testing results indicated compliance with the emission limits. iv. PERMIT GENERAL CONDITION 3.I.A—EXCESS EMISSIONS REPORTING REQUIREMENTS 115A NCAC 2D.0535 and 2Q .0508(f)(2)1—Requires notification to DAQ when an excess emission event occurs that lasts more than 4 hours, or when a deviation from the permit conditions occurs. For excess emissions events, must be reported by 9 AM the following business day. Deviations from permit conditions must be reported quarterly. APPEARS IN COMPLIANCE—Mr. Wentland stated that no excess emission events have occurred, and therefore no notifications have been required. v. PERMIT GENERAL CONDITION 3.P-ANNUAL COMPLIANCE CERTIFICATION—An annual compliance certification report is required to be submitted to DAQ and EPA postmarked by no later than March 1 each year,noting any deviations from permit conditions. APPEARS IN COMPLIANCE—The last ACC report was received at FRO on 02/11/19 and appeared complete. vi. PERMIT GENERAL CONDITION 3.X-ANNUAL EMISSION INVNETORY REQUIREMENTS—An annual emission inventory is required to be submitted no later than June 30 of each year. APPEARS IN COMPLIANCE—The last annual emission inventory for the facility was received at FRO on 06/07/18 and appeared complete. vii. PERMIT GENERAL CONDITION 3.DD-CLEAN AIR ACT, SECTION 112(r) REQUIREMENTS APPEARS IN COMPLIANCE—The facility does not store any of the listed 112(r)chemicals in amounts that exceed the threshold quantities. Therefore,the facility is not required to maintain a written Risk Management Plan(RMP). 7. COMPLIANCE HISTORY: There have been no negative compliance instances since the permit was initially issued in 2011. 8. FACILITY PINK SHEET REVIEW: There were no pink sheet items to be included in the facility inspection. 9. CONCLUSIONS/RECOMMENDATIONS: The facility appeared to be IN COMPLIANCE during the inspection on 05/29/2019.