RICE NESHAP for the Diesel Engine Owner or Operator
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The below specification information is to help guide the development of a quote specification for a reciprocating engine retrofit for RICE NESHAP, Subpart ZZZZ compliance. It is not meant to be an all inclusive document. The quote specification's completeness and accuracy is the responsibility of the engine owner. Click here for the below information in Word format.
Scope
Supplier is to have an understanding of EPA's 40 CFR Part 63 subpart ZZZZ. 1.2 Supplier is to have been in continuous operation for 5 years. 1.3 Supplier is to be incorporated in the United States of America. 1.4 Supplier is to have experience in reciprocating engine exhaust system operation and configuration; including exhaust flow path management, exhaust temperature management, sound reduction, emissions control and engine back pressure minimization. 1.6 Supplier is to have products specifically designed for RICE NESHAP Part 63 subpart ZZZZ compliance. 1.7 Supplier to provide a system that provides less than _____" H2O of backpressure. 1.8 Supplier to provide a system that has a dBA reduction of ______.
Compliance Products
- Diesel Oxidation Catalysts(select between serviceable or non-serviceable designs)
- Serviceable
- Catalyst coating is to be formulated specifically for 70% CO reduction for cost savings
- Catalyst coating is to be formulated to resist poisoning. 2.3 Catalyst to have a service lifetime of 8,000 hrs before cleaning.
- Catalyst will continue to be operational after 2 cleanings.
- Catalyst substrate is to consist of a robust metal foil design to maximize performance and longevity.
- Catalyst element is to have a heavy-duty flange to aid in proper sealing and therefore eliminate exhaust bypass of the catalyst.
- Catalyst to have a high temperature fiberglass gasket to eliminate exhaust bypass of the catalyst.
- Catalyst to have a handle to aid in the removal, replacement and handling.
- Catalyst to be able to withstand 1100°F exhaust gas temperatures.
- Non-serviceable
- Catalyst coating is to be formulated specifically for 70% CO reduction for cost savings
- Catalyst coating is to be formulated to resist poisoning.
- Catalyst to have a service lifetime of 8,000 hrs 2.4A Catalyst substrate is to consist of a robust metal foil design to maximize performance and longevity.
- Catalyst to be able to withstand 1100°F exhaust gas temperatures.
- Serviceable
- Catalyst Housing (select between serviceable and non-serviceable designs)
- Serviceable
- Catalyst housing to be constructed by an ISO 9001 certified manufacturer.
- Catalyst housing to be welded in accordance with AWSD1.1 or ASME section IX.
- Manufacturer to have AWS-CWI certified inspectors.
- Catalyst housing to be coated with high heat aluminum paint.
- Catalyst housing to have a pre-installed test port on both the upstream and downstream ends.
- Catalyst housing to have a flat access panel to eliminate exhaust gas escape. A concave access panel will not be accepted. 2.7B Catalyst housing to contain an axial catalyst capturing mechanism that forces the catalyst against the downstream end of the housing's interior. Capture mechanism to consist of a special alloy threaded sleeve that resists galling.
- Catalyst housing not to require any internal fasters or retaining bars to capture the catalyst.
- Catalyst housing to be of a dual catalyst design to allow for future emission control upgrades.
- Catalyst housing to be able to withstand 1100°F exhaust gas temperatures.
- An Installation and Operation Manual needs to be provided at or before delivery.
- Non-serviceable
- Catalyst housing to be constructed by an ISO 9001 certified manufacturer.
- Catalyst housing to be welded in accordance with AWSD1.1 or ASME section IX.
- Manufacturer to have AWS-CWI certified inspectors.
- Catalyst housing to be coated with high heat paint. 2.5B Catalyst housing to have a pre-installed test port on both the upstream and downstream ends.
- Catalyst housing to be able to withstand 1100°F exhaust gas temperatures.
- An Installation and Operation Manual needs to be provided at or before delivery.
- Serviceable
- Sound Requirements
Design incorporates an integrated silencer and emission control device consisting of a single unit to minimize system backpressure and costs. A silencer attached to a catalyst housing will not be accepted because it generally will exceed the engine restriction limits. 3.2 Silencer will provide ____ dB attenuation. 3.3 Manufacturer must have experience list of successful engine applications and be willing to warrant system performance.
- CPMS - Continuous Parametric Monitoring System
System will continuously log catalyst inlet temperature and intermittently log catalyst differential pressure. 4.2 Monitor to contain a Programmable Logic Controller (PLC) with integral Human Machine Interface (HMI). 4.3 Orange light to indicate temperature or pressure warning when system is approaching not meeting RICE NESHAP subpart ZZZZ catalyst operating requirements. 4.4 Red light to indicate temperature or pressure warning when system is not meeting RICE NESHAP subpart ZZZZ catalyst operating requirements. 4.5 Monitor enclosure to be NEMA 4 rated. 4.6 Catalyst inlet temperature and differential pressure are displayed textually on the monitor screen. 4.7 PLC to be protected from UV degradation. 4.8 Monitor must have the ability to mount remotely from engine. 4.8 System must provide and use a removable microSD card for easy access to data. 4.9 System must contain memory to log at least 105,000 hours of logged data. 4.10 System to operate on 100-240 Volt AC power supply. 4.11 System to incorporate a circuit breaker to protect it from power line variances. 4.12 An Installation and Operation Manual needs to be provided at or before delivery.
- Engine Crankcase Ventilation
An open or closed system will be accepted. 5.2 If open system, filter must remove oil mist, particulates and metals as defined by RICE NESHAP Subpart ZZZZ. 5.3 If system will face conditions that may freeze lines, the system must be insulated or provided with thermal heating. 5.4 An Installation and Operation Manual needs to be provided at delivery.
Structural Engineering/Design
Retrofitted exhaust System will be evaluated or designed by a qualified civil engineering firm. 6.2 Equipment manufacturer to provide weights and dimensions of required equipment to the engineering firm. 6.3 Civil engineering firm to ensure proper support structures are incorporated at time of installation to ensure exhaust system stability, foundation and facility structure stability, and employee safety. 6.4 Civil engineering firm to ensure that the system is in compliance with federal, state and local regulations as it pertains to safety and structure codes.
Installation
- Contractor is to be fully insured.
- Contractor to provide field labor and supervision, all equipment (from hand tools, portable to heavy, any lifting and crane rentals), consumables, project management, planning and scheduling, professional or subcontracted services and any expenses incurred for transportation, fuel, lodging, and logistics.
- All welding shall be performed by welders qualified in accordance with ASME Section IX utilizing welding procedures qualified to ASME Section IX requirements.
- Demolition or installation to begin approximately on ____ and be completed by ______.
- DOC System - Contractor responsible for selecting catalyst housing location to ensure operating temperature of 500°F and if serviceable housing design, safe and easy access to the catalyst and test ports.
- Contractor responsible for disconnection, removal, rerouting, disposal and installation of exhaust system components.
- Contractor responsible for constructing and installing supportive structures for the catalyst system.
- Contractor responsible for constructing and installing ladders and/or platforms in accordance to OSHA employee safety rules for access to catalyst and test ports, if applicable.
- Contractor to install DOC system in accordance to manufacturers Installation and Operation Manual. CPMS System - CPMS system to be installed by a qualified electrical contractor.
- Contractor responsible for mounting monitor to specified location, providing proper power connection, supplying and installing twisted pair from the monitor to the sensor box on the catalyst housing.
- Contractor responsible for verifying the proper operation of the monitor, including warning indicator lights operation and storage of temperature and differential pressure on the microSD card.
Compliance Testing
Supplier is to be an experienced provider of EPA testing standards. 8.2 Testing to be performed in accordance to ASTM D6522-00 and procedures outlined by RICE NESHAP Subpart ZZZZ. 8.3 Supplier to provide the report in a format that is acceptable by the EPA or local Department of Natural Resources.
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