SRI/USEPA-GHG-QAP-43
April 2007
Test and Quality Assurance
Plan
Electric Power and Heat Production Using
Renewable Biogas at Patterson Farms
Prepared by:
Greenhouse Gas Technology Center
Operated by
S°?TREUS^ERCH Southern Research Institute
Affiliated with Vie
University of Alabama at Birmingham
Under a Cooperative Agreement With
U.S. Environmental Protection Agency
and
Under Agreement With
\YSERDA New York State Energy Research and Development Authority
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EPA REVIEW NOTICE
This report has been peer and administratively reviewed by the U.S. Environmental Protection Agency, and
approved for publication. Mention of trade names or commercial products does not constitute endorsement or
recommendation for use.
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SRI/USEPA-GHG-QAP-43
April 2007
Greenhouse Gas Technology Center
A U.S. EPA Sponsored Environmental Technology Verification ( EXr ) Organization
Test and Quality Assurance Plan
Electric Power and Heat Production Using Renewable Biogas
at Patterson Farms
Prepared by:
Greenhouse Gas Technology Center
Southern Research Institute
PO Box 13825
Research Triangle Park, NC 27709 USA
Telephone: 919/806-3456
Reviewed by:
New York State Energy Research and Development Authority
The Patterson Farm
U.S. EPA Office of Research and Development QA Team
indicates comments are integrated into TQAP
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(this page intentionally left blank)
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Greenhouse Gas Technology Center
A U.S. EPA Sponsored Environmental Technology Verification ( ETr ) Organization
Electric Power and Heat Production Using Renewable Biogas
at Patterson Farms
This Test and Quality Assurance Plan has been reviewed and approved by the Greenhouse Gas
Technology Center Project Manager and Center Director, the U.S. EPA APPCD Project Officer, and the
U.S. EPA APPCD Quality Assurance Manager.
Signed by Richard Adamson
Richard Adamson
Director
Greenhouse Gas Technology Center
Southern Research Institute
11/07
Date
Signed by David Kirchgessner
David Kirchgessner
APPCD Project Officer
U.S. EPA
11/20/07
Date
Signed by William Chatterton
William Chatterton
Project Manager
Greenhouse Gas Technology Center
Southern Research Institute
11/07
Date
Ringler
Quality Assurance Manager
Greenhouse Gas Technology Center
Southern Research Institute
04/07
Date
Signed by Robert Wright
Robert Wright
APPCD Quality Assurance Manager
U.S. EPA
11/20/07
Date
TQAP Final: April 2007
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TABLE OF CONTENTS
Page
APPENDICES ii
LIST OF FIGURES ii
LIST OF TABLES ii
DISTRIBUTION LIST iii
1.0 INTRODUCTION 1-1
1.1 BACKGROUND 1-1
1.2 PATTERSON FARMS DG/CHP SYSTEM DESCRIPTION 1-2
1.3 ORGANIZATION AND RESPONSIBILITIES 1-3
1.4 SCHEDULE 1-5
2.0 VERIFICATION APPROACH 2-1
2.1 SYSTEM BOUNDARY 2-1
2.2 VERIFICATION PARAMETERS 2-2
2.2.1 Electrical Performance (GVP §2.0) 2-3
2.2.2 Electrical Efficiency (GVP §3.0) 2-3
2.2.3 CHP Thermal Performance (GVP §4.0) 2-4
2.2.4 Emissions Performance (GVP §5.0) 2-4
2.2.5 Field Test Procedures and Site Specific Instrumentation 2-5
2.2.6 Estimated NOX and CO2 Emission Offsets 2-8
3.0 DATA QUALITY OBJECTIVES 3-9
4.0 DATA ACQUISITION, VALIDATION, AND REPORTING 4-1
4.1 DATA ACQUISITION AND DOCUMENTATION 4-1
4.1.1 Corrective Action and Assessment Reports 4-1
4.2 DATA REVIEW, VALIDATION, AND VERIFICATION 4-2
4.3 INSPECTION/ACCEPTANCE OF SUPPLIES, CONSUMABLES, AND
SERVICES 4-2
4.4 DATA QUALITY OBJECTIVES RECONCILIATION 4-3
4.5 ASSESSMENTS AND RESPONSE ACTIONS 4-3
4.5.1 Project Reviews 4-3
4.5.2 Test/QA Plan Implementation Assessment 4-4
4.5.3 Audit of Data Quality 4-4
4.6 VERIFICATION REPORT AND STATEMENT 4-4
4.7 TRAINING AND QUALIFICATIONS 4-5
4.8 HEALTH AND SAFETY REQUIREMENTS 4-5
5.0 REFERENCES 5-1
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APPENDICES
Page
APPENDIX A Electric Power System Emissions Reduction Estimates A-l
LIST OF FIGURES
Figure 1-1. Patterson Farms in Auburn, New York 1-3
Figure 1-2. Project Organization 1-4
Figure 2-1. The Patterson Farm DG/CHP System Boundary Diagram 2-2
Figure 2-2. Position of Test Instrumentation for SUT Electrical System 2-7
Figure 2-3. Location of Test Instrumentation for SUT Thermal System 2-7
Figure B-l. Example Aggregated Emissions Introductory Screen B-2
Figure B-2. Example EPS Emission Rates for 2000 B-2
Figure B-3. Nationwide Emission Rates B-3
LIST OF TABLES
Table 2-1. Site Specific Instrumentation for Patterson Farms DG/CHP System Verification 2-6
Table B-l. Example Fuel Cell Emissions Offsets Estimates B-3
Table B-2. Example CHP Emissions Offsets Estimates B-4
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DISTRIBUTION LIST
New York State Energy Research and Development Authority
Richard Drake
James Foster
Ed Kear
Patterson Farms
Connie Patterson
John Patterson
U.S. EPA - Office of Research and Development
David Kirchgessner
Robert Wright
Southern Research Institute (GHG Center)
Richard Adamson
William Chatterton
Eric Ringler
in
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1.0 INTRODUCTION
1.1 BACKGROUND
The U.S. Environmental Protection Agency's Office of Research and Development (EPA-ORD) operates
the Environmental Technology Verification (ETV) program to facilitate the deployment of innovative
technologies through performance verification and information dissemination. The goal of the ETV
program is to further environmental protection by substantially accelerating the acceptance and use of
improved and innovative environmental technologies. Congress funds ETV in response to the belief that
there are many viable environmental technologies that are not being used for the lack of credible third-
party performance data. With performance data developed under this program, technology buyers,
financiers, and permitters in the United States and abroad will be better equipped to make informed
decisions regarding environmental technology purchase and use.
The Greenhouse Gas Technology Center (GHG Center) is one of six verification organizations operating
under the ETV program. The GHG Center is managed by EPA's partner verification organization,
Southern Research Institute (Southern), which conducts verification testing of promising GHG mitigation
and monitoring technologies. The GHG Center's verification process consists of developing verification
protocols, conducting field tests, collecting and interpreting field and other data, obtaining independent
peer-review input, and reporting findings. Performance evaluations are conducted according to externally
reviewed verification Test and Quality Assurance Plans (TQAPs) and established protocols for quality
assurance (QA).
The GHG Center is guided by volunteer groups of stakeholders. The GHG Center's Executive
Stakeholder Group consists of national and international experts in the areas of climate science and
environmental policy, technology, and regulation. It also includes industry trade organizations,
environmental technology finance groups, governmental organizations, and other interested groups. The
GHG Center's activities are also guided by industry specific stakeholders who provide guidance on the
verification testing strategy related to their area of expertise and peer-review key documents prepared by
the GHG Center.
In recent years, a primary area of interest to GHG Center stakeholders has been distributed electrical
power generation systems. Distributed generation (DG) refers to equipment, typically ranging from 5 to
1,000 kilowatts (kW) that provide electric power at a site closer to customers than central station
generation. A DG unit can be connected directly to the customer or to a utility's transmission and
distribution system. Examples of technologies available for DG includes internal combustion engine
generators, photovoltaics, wind turbines, fuel cells, and microturbines. DG technologies provide
customers one or more of the following main services: standby generation, peak shaving generation,
baseload generation, or cogeneration. DG systems that utilize renewable energy sources can provide even
greater environmental and economic benefits.
Since 2002, the GHG Center and the New York State Energy Research and Development Authority
(NYSERDA) have collaborated and shared the cost of verifying several new DG technologies throughout
the state of New York under NYSERDA-sponsored programs. The verification described in this
document will evaluate the performance of one such DG system: a Caterpillar Model G379 internal
combustion engine and generator - combined heat and power (CHP) system manufactured by Martin
Machinery and fueled with biogas generated at a dairy farm. The system is owned and operated by
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Patterson Farms near Auburn, New York. The GHG Center will be evaluating the performance of this
system in collaboration with NYSERDA.
In September 2005 the GHG Center published the Generic Verification Protocol (GVP) for Distributed
Generation and Combined Heat and Power Field Testing [1]. The GVP is designed specifically for
microturbine and 1C engine based CHP systems. This document is the site specific TQAP for this
performance verification. This TQAP does not repeat the rationale for the selection of verification
parameters, the verification approach, data quality objectives (DQOs), and Quality Assurance/Quality
Control (QA/QC) procedures specified in the GVP. Instead, this plan includes descriptions of the
Patterson Farms DG/CHP system, its integration at the farm, site specific measurements and
instrumentation, and site specific exceptions to the GVP. This performance verification will include
evaluation of the following parameters:
- electrical performance
- electrical efficiency
- CHP performance
- atmospheric emissions
NOX and CO2 emission offsets
This TQAP has been reviewed by NYSERDA, Patterson Farms representatives, and the EPA QA team.
As evidenced by the signature sheet at the front of this document, it meets the requirements of the GHG
Center's Quality Management Plan (QMP) and thereby satisfies the ETV QMP requirements for
environmental testing. This TQAP has been prepared to guide implementation of the test and to
document planned test operations. Once testing is completed, the GHG Center will prepare a Technology
Verification Report and Verification Statement, which will first be reviewed by NYSERDA and Patterson
Farms. Once all comments are addressed, the report will be reviewed by the EPA QA team. Once
completed, the GHG Center Director and the EPA Laboratory Director will sign the Verification
Statement, and the final Report will be posted on the Web sites maintained by the GHG Center (www.sri-
rtp.com) and ETV program (www.epa.gov/etv).
1.2 PATTERSON FARMS DG/CHP SYSTEM DESCRIPTION
The Patterson Farm, shown in Figure 1-1, is a dairy farm in upstate New York housing approximately
1,725 cows and heifers. Farm operations generate approximately 50,000 gallons per day of manure and
process water. This waste is collected and pumped to a solids removal system where solids are separated
and composted. Composted solids are later used as animal bedding, and separated liquids are pumped to
a complete mix anaerobic digester designed by RCM Digesters of Berkeley, California. The digester's
dimensions are approximately 135 by 125 by 16 feet deep with a total waste capacity of approximately
270,000 cubic feet.
In addition to farm waste, operators also feed cheese whey waste generated off-site into the digester. The
anaerobic digestion system produces biogas that is typically about 60 percent methane and has an average
lower heating value (LHV) of approximately 600 Btu/cf Approximately 4,800 cfh of the biogas is used
to fuel an on-site DG/CHP system, and the remainder is flared.
The DG/CHP system consists of a Caterpillar Model 379, 200 kW engine-generator set with integrated
heat recovery capability.
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Figure 1-1. Patterson Farms in Auburn, New York
Prior to being used as fuel, the wet biogas is passed through two Filtration Systems, Inc. Model G82308
water filtration units arranged in series to remove moisture from the gas. Dry biogas is then metered and
delivered to the engine. During normal farm operations, the engine generates nominal 187 kW power at
an electrical efficiency of approximately 22 percent. The facility is equipped with net power metering so
that excess power generated on-site can be exported to the grid and credited. The engine is equipped with
a heat recovery system that recovers approximately 800 to 1,400 thousand Btu per hour (MBtu/hr) during
full load operations and also cools the engine. Water with trace amounts of rust inhibitor is used as the
heat transfer fluid. Of the heat recovered, approximately 200 to 500 MBtu/hr is used to warm the digester
during summer months and approximately 400 to 800 MBtu/hr during colder months. The remaining
excess heat is dissipated through a radiator. The farm has plans to expanded engine heat use by supplying
hot water to the milking parlor in the future.
1.3 ORGANIZATION AND RESPONSIBILITIES
Figure 1-2 presents the project organization chart. The following section discusses functions,
responsibilities, and lines of communications for the verification test participants.
Southern's GHG Center has overall responsibility for planning and ensuring the successful
implementation of this verification test. The GHG Center will ensure that effective coordination occurs,
schedules are developed and adhered to, effective planning occurs, and high-quality independent testing
and reporting occur.
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Richard Adamson
GHG Center Director
I
Robert Wright
US EPA APPCD
QA Manager
David
Kirschgessner
US EPA APPCD
Project Officer
Bill Chatterton
GHG Center
Project Manager
Staci Haggis
GHG Center
Field Team Leader
Eric Ringler
GHG Center QA
Manager
Ed Kear
NYSERDA
Project Manager
Connie Patterson
Patterson Farms
Owner / Operator
Empact Analytical
Gas Analyses
Figure 1-2. Project Organization
Richard Adamson is the GHG Center Director. He will ensure the staff and resources are available to
complete this verification as defined in this TQAP. He will review the TQAP and Report to ensure they
are consistent with ETV operating principles. He will oversee the activities of the GHG Center staff, and
provide management support where needed. Mr. Adamson will sign the Verification Statement, along
with the EPA-ORD Laboratory Director.
Bill Chatterton will serve as the Project Manager for the GHG Center. His responsibilities include:
drafting the TQAP and verification report;
overseeing the field team leader's data collection activities, and
ensuring that data quality objectives are met prior to completion of testing.
The project manager will have full authority to suspend testing should a situation arise that could affect
the health or safety of any personnel. He will also have the authority to suspend testing if the data quality
indicator goals are not being met. He may resume testing when problems are resolved in both cases. He
will be responsible for maintaining communication with Patterson Farms, NYSERDA, and EPA. He also
oversees and manages subcontractor activities and submittals.
Staci Haggis will serve as the Field Team Leader. Ms. Haggis will provide field support for activities
related to all measurements and data collected. She will install and operate the measurement instruments,
supervise and document activities conducted by the emissions testing contractor, collect gas samples and
coordinate sample analysis with the laboratory, and ensure that QA/QC procedures outlined in this TQAP
are followed, including QA requirements for subcontractors (in this case, the analytical laboratory). She
will submit all results to the Project Manager, such that it can be determined that the DQOs are met.
Southern's QA Manager, Eric Ringler, is responsible for ensuring that all verification tests are performed
in compliance with the QA requirements of the GHG Center QMP, the GVP, and this TQAP. He has
reviewed and is familiar with each of these documents. He will also review the verification test results
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and ensure that applicable internal assessments are conducted as described in these documents. He will
reconcile the DQOs at the conclusion of testing and will conduct or supervise an audit of data quality. He
is also responsible for review and validation of subcontractor activities, review of subcontractor generated
data, and confirmation that subcontractor QA/QC requirements are met. Mr. Ringler will report all
internal reviews, DQO reconciliation, the audit of data quality, and any corrective action results directly
to the GHG Center Director, who will provide copies to the project manager for corrective action as
applicable and citation in the final verification report. He will review and approve the final verification
report and statement. He is administratively independent from the GHG Center Director and maintains
stop work authority.
Connie Patterson of Patterson Farms and Ed Kear of NYSERDA will serve as the primary contact
persons for the verification team. They will provide technical assistance, assist in the installation of
measurement instruments, and coordinate operation of the cogeneration system at the test site. They will
ensure the units are available and accessible to the GHG Center for the duration of the test. They will
also review the TQAP and Reports and provide written comments.
EPA-ORD will provide oversight and QA support for this verification. The APPCD Project Officer, Dr.
David Kirchgessner, is responsible for obtaining final approval of the TQAP and Report. The APPCD
QA Manager reviews and approves the TQAP and the final Report to ensure they meet the GHG Center
QMP requirements and represent sound scientific practices.
1.4 SCHEDULE
The tentative schedule of activities for testing is:
Verification TQAP Development
GHG Center Internal Draft Development October, 2006
NYSERDA and Patterson Farms Review/Revision December, 2006
EPA Review/Revision January, 2007
Final TQAP Posted April, 2007
Verification Testing and Analysis
Measurement Instrument Installation/Shakedown May, 2007
Field Testing May, 2007
Data Validation and Analysis May, 2007
Verification Report Development
GHG Center Internal Draft Development June, 2007
NYSERDA and Patterson Farms Review/Revision July, 2007
EPA Review/Revision July, 2007
Final Report Posted August, 2007
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2.0 VERIFICATION APPROACH
This performance verification will be conducted following the guidelines and procedures specified in the
GVP. This TQAP includes site-specific information including the following:
Definition of the system under test (SUT) boundary for this verification - §2.1,
Summary of the Patterson Farms verification parameters and references to the applicable
measurements, procedures, and calculations from the GVP - §2.2, and
Site specific instrumentation - §2.3.
Following the GVP, the verification will include evaluation of the Patterson Farms system performance
over a series of controlled test periods. The GVP specifies controlled tests be conducted at three different
loads including 100, 75, and 50 percent of capacity. Following these specifications, the electrical load on
the generator will be modulated such that tests will be conducted at nominal power outputs of 200, 150,
and 100 kW. Procedures related to the load tests are summarized in §2.2.6 of this TQAP and detailed in
§7.1 through §7.4 of the GVP. In addition to the controlled test periods, the GHG Center will collect
sufficient data to characterize the system's performance over normal facility operations. This will include
up to 1 week of continuous monitoring of fuel consumption, power generation, power quality, and heat
recovery rates.
2.1 SYSTEM BOUNDARY
The Patterson Farms verification will be limited to the performance of the system under test (SUT) within
a defined system boundary. Figure 2-1 illustrates the SUT boundary for this verification.
The figure indicates two distinct boundaries. The device under test (DUT) or product boundary includes
the Caterpillar engine and generator set, and the heat recovery system and all of its internal components.
The SUT includes the DUT as well as parasitic loads present in this application: the water circulation
pump, the gas filtration system, and the radiator fan motor. Following the GVP, this verification will
incorporate the system boundary into the performance evaluation. The parasitic loads will be verified to
determine the overall system electrical and thermal efficiency for this installation.
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Hot Water Loop
Figure 2-1. The Patterson Farm DG/CHP System Boundary Diagram
2.2 VERIFICATION PARAMETERS
The defined SUT will be tested to determine performance for the following verification parameters:
Electrical Performance
Electrical Efficiency
CHP Thermal Performance
Emissions Performance
NOX and CO2 Emission Offsets
The test sequences and durations will follow the guidelines specified in GVP §1.3. There will be three
separate one-hour test runs conducted at each of the specified operating points. Permissible measurement
variability criteria for 1C engines presented in GVP §2.2.1 will apply to this testing. In addition to these
verification parameters, this verification will also include estimation of NOX and greenhouse gas (CO2)
emissions reductions realized through use of the digester and cogeneration system at this test location.
The approach and methodology for these estimations are provided in §2.2.4 and Appendix A of this test
plan.
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The following sections identify the sections of the protocol that are applicable to the verification
parameters for this test, identify site specific instrumentation for each (Table 2-1), and specify any
exceptions or deviations.
2.2.1 Electrical Performance (GVP §2.0)
Determination of electrical performance will be conducted following §2.0 and Appendix Dl.O of the
GVP. The following parameters will be measured:
Real power, kW
Apparent power, kVA
Reactive power, kVAR
Power factor, %
Voltage total harmonic distortion, %
Current total harmonic distortion, %
Frequency, Hz
Voltage, V
Current, A
The verification parameters will be measured with a digital power meter manufactured by Power
Measurements Ltd. (Model 7500 or 7600 ION). The meter scans all power parameters once per second
and computes and records one-minute averages. Test personnel will install the power meter on the
cogeneration unit. The meter will operate continuously, unattended, and will not require further
adjustments after installation. The rated accuracy of the power meter is ± 0.1 percent, and the rated
accuracy of the current transformers (CTs) needed to employ the meter at this site is ± 0.5 percent.
Overall power measurement error is then ± 0.5 percent.
2.2.2 Electrical Efficiency (GVP §3.0)
Determination of electrical efficiency will be conducted following §3.0 and Appendix D2.0 of the GVP.
The following parameters will be measured:
Real power production, kW
External parasitic load power consumption, kW
Ambient temperature, °F
Ambient barometric pressure, psia
Fuel LHV, Btu/scf
Fuel consumption, scfh
Real power production and external parasitic load consumption will be measured by the Power
Measurements Ltd. Digital power meter, as described in §2.2.1 above. Ambient temperature will be
recorded on the datalogger from a single Class A 4-wire RTD. The specified accuracy of the RTD will be
± 0.6 °F. Ambient barometric pressure will be measured by a Setra Model 280E ambient pressure sensor
with a full scale (FS) of 0 - 25 psia and an accuracy of ± 1% FS.
Gas flow will be measured by a Model 5M175 Series B3 Roots Meter manufactured by Dresser
Measurement with a specified accuracy of ± 1 %. Gas temperature will be measured by a Class A 4-wire
platinum resistance temperature detector (RTD). The specified accuracy of the RTD is ± 0.6 °F. Gas
pressure will be measured by an Omega Model PX205 Pressure Transducer. The specified accuracy of
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the pressure transducer is ± 0.25% of reading over a range of 0 - 30 psia. At least three gas samples will
be collected in 500 ml stainless steel canisters and shipped to subcontractor Empact Analytical of
Brighton, Colorado for LHV analysis according to ASTM Method 1945. The QA Manager will confirm
that the subcontractor satisfies the required QA elements of the method.
The external parasitic loads introduced by the heat transfer circulation pump, the gas filtration system,
and the radiator fan motor will be verified using a Fluke Model 336 clamp on power meter. The meter
has rated accuracies of 2 percent of reading for current and 1% of reading for voltage.
2.2.3 CHP Thermal Performance (GVP §4.0)
Determination of CHP thermal performance will be conducted following §4.0 and Appendix D3.0 of the
GVP. The following parameters will be quantified:
Thermal performance in heating service, Btu/h
Thermal efficiency in heating service, %
Actual SUT efficiency in heating service as the sum of electrical and thermal efficiencies, %
To quantify these parameters, heat recovery rate from the DUT will be measured on the heat transfer loop
and defined as the heat delivered to the facility. This verification does not include quantification of the
heat recovered by the heat transfer fluid to hot water heat exchanger. This verification will employ a
Sparling Economag Model FM618 Electromagnetic Flowmeter with a nominal linear range of 0 to 40
gpm. Accuracy of this meter is ± 1.0 % of reading. Class A 4-wire platinum resistance temperature
detectors (RTDs) will be used to determine the transfer fluid supply and return temperatures. The
specified accuracy of the RTDs is ± 0.6 °F. Pretest calibrations will document the RTD performance.
Following Section 4.2 of the GVP, CHP performance determinations also require heat transfer fluid
density (p) and specific heat (cp). These values may be obtained from standard tables for water.
2.2.4 Emissions Performance (GVP §5.0)
Determination of emissions performance will be conducted following §5.0 and Appendix D4.0 of the
GVP. Consistent with all of the DG/CHP verifications conducted for NYSERDA, this verification will
include only emissions of NOX, CO, CO2, and THC. Emissions testing will be performed by GHG Center
Personnel using a portable emissions monitoring system (PEMS). The PEMS is an Horiba OBS-2200
system, which is essentially a miniaturized laboratory analyzer bench which has been optimized for
portable use. The instrument meets or exceeds Title 40 CFR 1065 requirements for in-use field testing of
engine emissions.
This PEMS is suitable for testing a wide variety of stationary sources as well as the mobile sources for
which it is intended. Accuracy for all analytes is better than ± 2.5 % full scale (FS), while linearity is
better than +1.0 % FS. Exhaust gas concentrations must be integrated with exhaust gas flow rates to yield
mass emission rates or brake-specific emissions. EPA Method 2 will be used to determine exhaust gas
volumetric flow rates.
Response times for all OBS-2200 analyzers are approximately 2 seconds alone and 5 seconds with the
heated umbilical in the sample line. Test personnel establish exact analyzer response times prior to
testing. Software algorithms then align analyzer data outputs with other sensor signals, such as exhaust
gas flow and engine control module data. Resolution depends on the analyzer range setting, but is
between 4 and 5 significant digits.
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The OBS-2200 measures CO and CO2 with non-dispersive infra-red (NDIR) detectors. The OBS-2200
does not require a separate moisture removal system for the CO and CO2 NDIR detectors. The NOX
analyzer section consists of a chemilumenescence detector with a NO2 / NO converter. This is the kind of
system specified in Title 40 CFR 60, Appendix A, Method 7E, "Determination of Nitrogen Oxides
Emissions from Stationary Sources", which is a reference method for NOX.
The OBS-2200 measures THC with a FID. This method corresponds to the system specified in Title 40
CFR 60 Appendix A, Method 25, "Determination of Total Gaseous Non-methane Organic Emissions as
Carbon", which is a reference method for THC.
The PEMS sample pump conveys all samples through a heated umbilical directly to heated analyzer
sections which eliminates the need to remove moisture and eliminates possible moisture scavenging.
Proposed calibration ranges for the gas analyzers are listed in Table 2-1. Results for each pollutant will
be reported in units of ppm, ppm corrected to 15% O2, Ib/h, and Ib/kWh.
2.2.5 Field Test Procedures and Site Specific Instrumentation
Field test procedures will follow the guidelines and procedures detailed in the following sections of the
GVP:
Electrical performance - §7.1
Electrical efficiency - §7.2
CHP thermal performance - §7.3
Emissions performance - §7.4
Load tests will be conducted as three one-hour test replicates at cogeneration power commands of
approximately 200, 150, and 100 kW. In addition to the controlled tests, system performance will be
monitored continuously for a period of approximately one month while the unit operates under normal
farm operations. Continuous measurements will be recorded during the entire period including:
Power output,
Power quality parameters,
Fuel consumption (gas flow, pressure, and temperature),
Heat recovery rate (transfer fluid flow, supply temperature, and return temperature),
Heat transfer fluid circulation pump power consumption, and
Ambient conditions (temperature and pressure).
Using these data, the GHG Center can evaluate DG/CHP system performance and usage rates for
Patterson Farms under typical facility operations.
Site specific measurement instrumentation is summarized in Table 2-1. The location of the
instrumentation relative to the SUT is illustrated in Figures 2-2 and 2-3. All measurement
instrumentation meets the GVP specifications.
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Table 2-1. Site Specific Instrumentation for Patterson Farms DG/CHP System Verification
Verification
Parameter
Electrical
Performance
Electrical
Efficiency
CHP Thermal
Performance
Emissions
Performance
Supporting Measurement
Real power
Power factor
Voltage THD
Current THD
Frequency
Voltage
Current
Ambient temperature
Barometric pressure
Parasitic loads
Gas flow
Gas pressure
Gas temperature
Heat tranfer loop flow
Heat tranfer supply temp.
Heat tranfer return temp.
NOX concentration
CO concentration
CO2 concentration
O2 concentration
THC concentration
Expected Range of
Measurement
0.0 - 200 kW
90-100%
0- 100%
0- 100%
58 -62 Hz
240V
300 -600 A
20 - 40 °F
14.5- 15.0 psia
1000 W
2400 - 4800 cm
5-20 in. w.c.
50 - 90 °F
10 - 20 gpm
180-200°F
170- 190 °F
100-300ppmv
100-300ppmv
5-10 %
8-15 %
100-300ppmv
Instrument
Power Measurements Ltd. ION
power meter (Model 7600 or
7500)
Omega Class A 4-wire RTD
Setra Model 280E
Fluke Model 336 portable power
meter
Model 5M175 Roots Meter
Omega PX205 Pressure
Transducer
Omega Class A 4-wire RTD
Sparling Economag Model
FM618
Omega Class A 4-wire RTD
Omega Class A 4-wire RTD
Chemilumine scence
(NDIR)-gas filter correlation
NDIR
Electrochemical cell
Flame ionization detector (FID)
Instrument
Range
0 - 260 kW
0 - 100 %
0 - 100 %
0 - 100 %
57 - 63 Hz
0 - 600 V
0 - 400 A
0 - 250 °F
0-25 psia
0 - 260 kW
0 - 5000 cfh
0-30 psia
0 - 250 °F
0-40 gpm
0 - 250 °F
0 - 250 °F
0- lOOOppmv
0- lOOOppmv
0-20 %
0-25 %
0- lOOOppmv
Instrument
Accuracy
±0.1% of reading
± 0.5% of reading
±1%FS
± 1%FS
±0.01% of reading
±0.11% of reading
±0.11% of reading
±0.6°F
±0.1%FS
± 2% of reading
±1% of reading
±0.25% of reading
±0.6°F
± 1.0% of reading
± 0.6 °F
±0.6°F
± 2% FS
± 2% FS
± 2% FS
± 2% FS
± 2% FS
2-6
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EPS
Facility Wiring
Ion Power
Meter
120/240v
Transformer
CAT 200kWGenset
Figure 2-2. Position of Test Instrumentation for SUT Electrical System
Power
Meter
To Atmosphere4
Exhaust Gas »
II
(J)TemPre,urr
* (
X^I^S F
ill Tsmp
^" Vx ~^
Fluid Flow Mete
To suitable
120V source
pipe
Engine
Heat
Exchanger
Figure 2-3. Location of Test Instrumentation for SUT Thermal System
From Digester
To Digester
2-7
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2.2.6 Estimated NOX and CO2 Emission Offsets
This verification parameter is not included in the GVP, so the approach and procedures to be used in this
verification are described here. Use of the DG/CHP cogeneration system at this facility will change the
NOX and CO2 emission rates associated with the operation of the Patterson Farms facility. Annual
emission offsets for these pollutants will be estimated and reported by subtracting emissions of the on-site
CHP unit from emissions associated with baseline electrical power generation technology. Appendix A
provides the procedure for estimating emission reductions resulting from electrical generation. The
procedure correlates the estimated annual electricity savings in MWh with New York and nationwide
electric power system emission rates in Ib/MWh. For this verification, analysts will assume that the
Patterson Farms DG/CHP system generates power at a rate similar to that recorded during the 1 week
verification monitoring period throughout the entire year.
Since the heat recovered is currently only used to warm the digester, there is no real baseline emissions
offset associated with heat production. Should the capacity to warm the milking parlor with CHP
recovered heat be added at a later date, then additional emissions offset are likely at this site due to the
reduction of utility provided energy in the parlor. Emission reductions associated with use of farm waste
as fuel will not be conducted, as this process requires baseline GHG emission assessments of standard
waste management practices. Due to the significant resources required to do this, this analysis is beyond
the scope of this project, and therefore this verification includes emission reductions from electricity
generation only.
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3.0 DATA QUALITY OBJECTIVES
Under the ETV program, the GHG Center specifies data quality objectives (DQOs) for each verification
parameter before testing commences as a statement of data quality. The DQOs for this verification were
developed based on past DG/CHP verifications conducted by the GHG Center, input from EPA's ETV
QA reviewers, and input from both the GHG Centers' executive stakeholders groups and industry
advisory committees. As such, test results meeting the DQOs will provide an acceptable level of data
quality for technology users and decision makers. The DQOs for electrical and CHP performances are
quantitative, as determined using a series of measurement quality objectives (MQOs) for each of the
measurements that contribute to the parameter determination:
Verification Parameter DQO (relative uncertainty)
Electrical Performance ±2.0 %
Electrical Efficiency ±3.0%
CHP Thermal Efficiency ±3.5 %
Each test measurement that contributes to the determination of a verification parameter has stated MQOs,
which, if met, ensure achievement of that parameter's DQO. This verification is based on the GVP which
contains MQOs including instrument calibrations, QA/QC specifications, and QC checks for each
measurement used to support the verification parameters being evaluated. Details regarding the
measurement MQOs are provided in the following sections of the GVP:
§7.1 Electrical Performance Data Validation
§ 7.2 Electrical Efficiency Data Validation
§ 7.3 CHP Performance Data Validation
The DQO for emissions is qualitative in that the verification will produce emission rate data that satisfies
the QC requirements contained in the EPA Reference Methods specified for each pollutant. The
verification report will provide sufficient documentation of the QA/QC checks to evaluate whether the
qualitative DQO was met. Details regarding the measurement MQOs for emissions are provided in the
following section of the GVP:
§7.4 Emissions Data Validation
Completeness goals for this verification is to obtain valid data for 90 percent of the test periods
(controlled test period and extended monitoring).
3-9
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4.0 DATA ACQUISITION, VALIDATION, AND REPORTING
4.1 DATA ACQUISITION AND DOCUMENTATION
Test personnel will acquire the following electronic data and generate the following documentation
during the verification:
Electronic Data
Electronic data will be monitored for the following measurements:
power output and power quality parameters
fuel flow, pressure, and temperature
transfer fluid flow, supply temperature, and return temperature
ambient temperature and barometric pressure
The ION power meter will poll their sensors once per second. They will then calculate and record one-
minute averages throughout all tests. The field team leader will download the one-minute data directly to
a laptop computer during the short-term tests. GHG Center personnel will download the data by
telephone during the long term monitoring period.
An Agilent / HP Model 34970A datalogger will record all of the temperature, pressure, and flow meter
data once every 5 seconds. The field team leader will download the data directly during short-term tests
while GHG Center will download the data by telephone during the long term monitoring period. Analysts
will use Excel spreadsheet routines to calculate one-minute averages from the 5-second snapshots.
The electronically-recorded one-minute averages (except for the manually-logged water system pressure
data) will be the source data for all calculated results.
Documentation
Printed or written documentation will be recorded on the log forms provided in Appendix B of the GVP
and will include:
Daily test log, including water system pressure data, starting and ending times for test
runs, notes, etc.
GVP Appendix A forms which show the results of QA / QC checks
Copies of calibrations and manufacturers' certificates
The GHG Center will archive all electronic data, paper files, analyses, and reports at their Research
Triangle Park, NC office in accordance with their quality management plan.
4.1.1 Corrective Action and Assessment Reports
A corrective action will occur if audits or QA / QC checks produce unsatisfactory results or upon major
deviations from this TQAP. Immediate corrective action will enable quick response to improper
procedures, malfunctioning equipment, or suspicious data. The corrective action process involves the
field team leader, project manager, and QA Manager. The GHG Center QMP requires that test personnel
submit a written corrective action request to document each corrective action.
4-1
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The field team leader will most frequently identify the need for corrective actions. In such cases, he or
she will immediately notify the project manager. The field team leader, project manager, QA Manager
and other project personnel, will collaborate to take and document the appropriate actions.
Note that the project manager is responsible for project activities. He is authorized to halt work upon
determining that a serious problem exists. The field team leader is responsible for implementing
corrective actions identified by the project manager and is authorized to implement any procedures to
prevent a problem's recurrence.
4.2 DATA REVIEW, VALIDATION, AND VERIFICATION
The project manager will initiate the data review, validation, and analysis process. At this stage, analysts
will classify all collected data as valid, suspect, or invalid. The GHG Center will employ the QA/QC
criteria specified in Section 3.0 and the associated tables. Source materials for data classification include
factory and on-site calibrations, maximum calibration and other errors, subcontractor deliverables, etc.
In general, valid data results from measurements which:
meet the specified QA/QC checks, including subcontractor requirements,
were collected when an instrument was verified as being properly calibrated, and
are consistent with reasonable expectations (e.g., manufacturers' specifications,
professional judgment).
The report will incorporate all valid data. Analysts may or may not consider suspect data, or it may
receive special treatment as will be specifically indicated. If the DQO cannot be met, the project manager
will decide to continue the test, collect additional data, or terminate the test and report the data obtained.
Data review and validation will primarily occur at the following stages:
on site ~ by the field team leader,
upon receiving subcontractor deliverables,
before writing the draft report ~ by the project manager, and
during draft report QA review and audits ~ by the GHG Center QA Manager.
The field team leader's primary on-site functions will be to install and operate the test equipment. He will
review, verify, and validate certain data (QA / QC check results, etc.) during testing. The log forms in
Appendix B of the GVP provide the detailed information he will gather.
The QA Manager will use this TQAP and documented test methods as references with which to review
and validate the data and the draft report. He will review and audit the data in accordance with the GHG
Center's quality management plan. For example, the QA Manager will randomly select raw data,
including data generated and submitted by subcontractors, and independently calculate the verification
parameters. The comparison of these calculations with the results presented in the draft report will yield
an assessment of the GHG Center's QA/QC procedures.
4.3 INSPECTION/ACCEPTANCE OF SUPPLIES, CONSUMABLES, AND SERVICES
The procurement of purchased items and services that directly affect the quality of environmental
programs defined by this TQAP will be planned and controlled to ensure that the quality of the items and
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services is known, documented, and meets the technical requirements and acceptance criteria herein. For
this verification, this includes services provided by Empact Analytical for fuel analyses and O'Brien &
Gere, Inc. for emissions testing services.
Procurement documents shall contain information clearly describing the item or service needed and the
associated technical and quality requirements. The procurement documents will specify the quality
system elements of the GVP for which the supplier is responsible and how the supplier's conformity to the
customer's requirements will be verified.
Procurement documents shall be reviewed for accuracy and completeness by the project manager and QA
manager as noted in Sections 1.4 and 4.2. Changes to procurement documents will receive the same level
of review and approval as the original documents. Appropriate measures will be established to ensure
that the procured items and services satisfy all stated requirements and specifications.
4.4 DATA QUALITY OBJECTIVES RECONCILIATION
A fundamental component of all verifications is the reconciliation of the collected data with its DQO. In
this case, the DQO assessment consists of evaluation of whether the stated methods were followed,
MQOs achieved, and overall accuracy is as specified in the GVP. The field team leader and project
manager will initially review the collected data to ensure that they are valid and are consistent with
expectations. They will assess the data's accuracy and completeness as they relate to the stated QA / QC
goals. If this review of the test data show that QA / QC goals were not met, then immediate corrective
action may be feasible, and will be considered by the project manager. DQOs will be reconciled after
completion of corrective actions. As part of the internal audit of data quality, the GHG Center QA
Manager will include an assessment of DQO attainment.
4.5 ASSESSMENTS AND RESPONSE ACTIONS
The field team leader, project manager, QA Manager, GHG Center Director, and technical peer-reviewers
will assess the project and the data's quality as the test campaign proceeds. The project manager and QA
Manager will independently oversee the project and assess its quality through project reviews, inspections
if needed, and an audit of data quality.
4.5.1 Project Reviews
The project manager will be responsible for conducting the first complete project review and assessment.
Although all project personnel are involved with ongoing data review, the project manager must ensure
that project activities meet measurement and DQO requirements. The project manager is also responsible
for maintaining document versions, managing the review process, and ensuring that updated versions are
provided to reviewers and tracked.
The GHG Center Director will perform the second project review. The director is responsible for
ensuring that the project's activities adhere to the ETV program requirements and stakeholder
expectations. The GHG Center Director will also ensure that the field team leader has the equipment,
personnel, and resources to complete the project and to deliver data of known and defensible quality.
The QA Manager will perform the third review. He is responsible for ensuring that the project's
management systems function as required by the quality management plan. The QA Manager is the GHG
Center's final reviewer, and he is responsible for ensuring the achievement of all QA requirements.
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ECOTS and NYSERDA personnel will then review the report. ECOTS will also have the opportunity to
insert supplemental unverified information or comments into a dedicated report section.
The GHG Center will submit the draft report to EPA QA personnel, and the project manager will address
their comments as needed. Following this review, the report will undergo EPA management reviews,
including the GHG Center Director, EPA ORD Laboratory Director, and EPA Technical Editor.
4.5.2 Test/QA Plan Implementation Assessment
The GHG Center has previously conducted numerous internal technical systems audits (TSAs) of the
methods and procedures proposed for this verification and will therefore not repeat a TSA for this test.
However, the GHG Center QA Manager or designee will conduct a readiness review and observe and
document a pre-test assessment and bench test of the measurements system including the following
systems:
flow meters, transmitter, and datalogger
temperature and pressure sensors and datalogger
power consumption meters
During the assessment, the QA Manager will verify that the equipment, procedures, and calibrations are
as specified in this TQAP. Should the QA Manager note any deficiencies in the implementation of the
TQAP, corrective actions will be immediately implemented by the project manager. The QA Manager
will document this assessment in a separate report to the GHG Center Director.
EPA QA management is planning to conduct an external TSA on this verification which will include on-
site assessment of the equipment, procedures, and calibrations.
4.5.3 Audit of Data Quality
The audit of data quality is an evaluation of the measurement, processing, and data analysis steps to
determine if systematic errors are present. The QA Manager, or designee, will randomly select
approximately 10 percent of the data. He will follow the selected data through analysis and data
processing. This audit is intended to verify that the data-handling system functions correctly and to assess
analysis quality. The QA Manager will also include an assessment of DQO attainment.
The QA Manager will route audit results to the project manager for review, comments, and possible
corrective actions. The ADQ will result in a memorandum summarizing the results of custody tracing, a
study of data transfer and intermediate calculations, and review of the QA/QC data. The ADQ report will
include conclusions about the quality of the data from the project and their fitness for the intended use.
The project manager will take any necessary corrective action needed and will respond by addressing the
QA Manager's comments in the verification report.
4.6 VERIFICATION REPORT AND STATEMENT
The project manager will coordinate report preparation. The report will summarize each verification
parameter's results as discussed in Section 2.0 but will not include the raw data or QA/QC checks that
support the findings. All raw and processed measurements data as well as calibration data and QA/QC
checks will be made available to EPA as a separate CD, and can be provided to other parties interested in
assessing data trends, completeness, and quality by request. The report will clearly characterize the
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verification parameters, their results, and supporting measurements as determined during the test
campaign. The report will also contain a Verification Statement, which is a 3 to 5 page document
summarizing the technology, the test strategy used, and the verification results obtained.
The project manager will submit the draft report and Verification Statement to the QA Manager and
GHG Center Director for review. A preliminary outline of the report is as follows:
Preliminary Outline
Patterson Farms DG/CHP Verification Report
Verification Statement
Section 1.0: Verification Test Design and Description
Description of the ETV program
Patterson Farms DG/CHP System Description
Overview of the Verification Parameters and Evaluation Strategies
Section 2.0: Results
Electrical performance
Electrical efficiency
CHP performance
Atmospheric emissions
NOX and CO2 emission offsets
Section 3.0: Data Quality
Section 4.0: Additional Technical and Performance Data Supplied by Patterson Farms (optional)
Section 5.0: References
Appendices: Raw Verification or Other Data
4.7 TRAINING AND QUALIFICATIONS
This test does not require specific training or certification beyond that required internally by the test
participants for their own activities. The GHG Center's project manager has approximately 20 years
experience in field testing of air emissions from many types of sources and will directly oversee field
activities. He is familiar with the test methods and standard requirements that will be used in the
verification test.
The field team leader has performed numerous field verifications under the ETV program, and is familiar
with EPA and GHG Center quality management plan requirements. The QA Manager is an
independently appointed individual whose responsibility is to ensure the GHG Center's conformance with
the EPA approved QMP.
4.8 HEALTH AND SAFETY REQUIREMENTS
This section applies to GHG Center personnel only. Other organizations involved in the project have
their own health and safety plans which are specific to their roles in the project.
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GHG Center staff will comply with all known host, state/local and Federal regulations relating to safety at
the test facility. This includes use of personal protective gear (such as safety glasses, hard hats, hearing
protection, safety toe shoes) as required by the host and completion of site safety orientation.
4-6
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5.0 REFERENCES
[1] Distributed Generation and Combined Heat and Power Field Testing Protocol, DG/CHP Version,
Association of State Energy Research and Technology Transfer Institutions, Madison, WI, October
2004.
[2] Inventory of U.S. Greenhouse Gas Emissions and Sinks: 1990 - 1999, Annex A: Methodology for
Estimating Emissions ofCO2from Fossil Fuel Combustion, U.S. Environmental Protection Agency,
EPA 23 6-R-01-001, Washington, DC, 2001.
[3] DAP-42, Compilation of Air Pollutant Emission Factors - Volume 1, Stationary Point and Area
Sources, Fifth Edition, U.S. Environmental Protection Agency, Office of Transportation and Air
Quality, Washington, DC, 1995.
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Appendix A
Electric Power System Emissions Reduction Estimates
The verification report will provide estimated emissions reductions (or increases) as compared to
aggregated electric power system (EPS) emission rates for the state in which the apparatus is located
(New York for this verification). The report will also include estimated reductions based on aggregated
nationwide emission rates. Analysts will employ the methods described in this Appendix.
A DG asset or power-saving device, when connected to the EPS, will change the overall EPS emissions
signature. As an example, a zero-emission generator, such as a hydroelectric power plant, will decrease
EPS CO2 emissions on a Ib/MWh basis. The potential emissions reduction (or increase) for DG is the
difference between the EPS and DG emission rates, multiplied by the expected power generation or
savings rate:
Reductiorii = (EREps,, - ERDG:i) *MWhDG:Ann Eqn. Al
Where:
Reduction! = annual reduction for pollutant i, pounds per year (Ib/y)
EREps,i = EPS emission rate for pollutant i (see below), pounds per megawatt-hour
(Ib/MWh)
ERDG,i = DG emissions rate for pollutant i, Ib/MWh
MWhDG Ann = annual estimated DG power production or device-based power savings,
megawatt-hours per year (MWh/y)
The potential emissions reduction for a power savings device is simply:
Reductionj = EREPSj *MWhDeviceiAnn Eqn. A2
Values for ERDGl are available from the performance verification results. Estimated MWhDGAnn or
MWhDevice Am should also be available from the verification results. This estimate depends on the specific
verification strategy and its derivation should be clearly described in the TQAP and verification results.
A simple example is the power production or power savings multiplied by the annual availability or
capacity factor. For example, a 200 kW fuel cell which operates at full capacity 75 percent of the time
can be expected to generate 1314 MWh annually.
EREPS; for specific pollutants can vary widely because the EPS may obtain its power from many different
generators. The generation mix can change dramatically from hour to hour, depending on market forces,
system operations, wheeling practices, emergencies, maintenance, and other factors. Many different
approaches have been suggested for estimating EREPS)1, but no consensus has been achieved.
The following estimation methodology is simple, it uses peer-reviewed carbon dioxide (CO2), nitrogen
oxide (NOX), mercury (Hg), and sulfur dioxide (SO2) data available from the US Environmental
Protection Agency's "EGRID" database, and it provides some analysis flexibility.
EGRID is available from www.epa.gov/cleanenergy/egrid/download.htm. At this writing, data is
available through 2000. The example presented here is for a generator located in Florida, but this
procedure can be used for any state. Data through 2003 will likely be available in late 2005. Figure A-l
shows the introductory screen prompts which provide year 2000 emission rates for Florida.
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* eGRID2002PC , Version 2.01 - Main Selection Screen f]T| fx]
File Search Filters Import/Export Interchange
"" Select One 01 Multiple Entities ""
. State Fille's
.- Electric Generating
Company (EGC)
r US Total
Grid Regions:
f~ NERC Region
1 eGRID Subregion Data Yeai
r Power Control Area [PCA] 1 2000 ^ I
Enter text to search for:
| Find | Reset jj| [ Display
Data
SEBV eGRID He.P|
ALABAMA (AL) A
ALASKA (AK)
ARIZONA (A2)
ARKANSAS (AR)
CALIFORNIA (CA)
COLORADO (CO)
CONNECTICUT (CT)
DELAWARE (DE)
DISTRICT OF mUJMBjAJDC)
GEORGIA (GA)
HAWAII (HI)
IDAHO (ID)
ILLINOIS (IL)
INDIANA (IN)
IOWA (IA)
KANSAS (KS)
KENTUCKY (KY)
LOUISIANA (LA)
MAINE (ME)
MARYLAND (MD)
MASSACHUSETTS (MA)
MICHIGAN (Ml)
MINNESOTA (MN)
MISSISSIPPI (MS)
MISSOURI (MO)
MONTANA (MT)
NEBRASKA (NE)
NEVADA (NV)
Figure A-l. Example Aggregated Emissions Introductory Screen
Double-clicking the state of interest brings up the emissions data, as shown in Figure A-2.
s eGRID2002PC , Version 2.01 - State Level Data ?X\
Slate: (FLORIDA
Capacity , Hf
(MW): ] 46,041.1
Emissions Profile
Help 1 Previous
(MMBlu): 1,616,637,109 (MWh): ! 191,906,639 m Data Year: |2QQQj-J
J
generation Resource Mix ^tate IrnporrVExport Data
[Display emission:
i rates for fossil, j
[ coal/oil/gas j
Display Ozone
Season NOX Data
Emissions (tons) Output Rate (Ibs/MWh) Input Rate (Ibs/MMBtu)
Annual CO 2
Annual 502
Annual NOX
136,29X930.61 1,420.42 168.61
579,623.25 | 6.04 | 0.72
322,813.74 | 3.36 | 0.40
Annual llg B | 2,499.63 | 0.0130 | 0.0016
tt Annual mercury (Hg) emissions are in Ibs; Hg emission rates are in Ibs/EWh and Ibs/BBtu.
Figure A-2. Example EPS Emission Rates for 2000
Figure A-3 provides the nationwide emission rates for 2000.
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Si eGRID2002PC
, Version 2.01 - United States Level Data
ILINITED STATES
Help | Pre
Capacity .
(MW): [864
Heal Input Generation , ? I
ious Next
905.7 (MMBtuj: I 28,221,854,877 (MWhj: I 3,810,305,466 ^ Data Year: 1 2000 j»J
. . T r- i- o M- U.S. Generation and Consumption!
Emissions Profile Generation Resource Mix pa(a
Display Ozon
Season NOX D
display emission
rates for fossil,
coal/oil/gas
e
ata
Emissions (tons) Output Rate (Ibs/MWh) Input Rate [Ibs/MMBtu)
Annual
Annual
Annual
CO 2 I 2,652,801,442.24 1,382.48 181
57
502 | 11,513,033.84 |~~ 6.04 \~ 0.78
NOX | 5,644,353.87 |~ 2-96 l~~ °'39
Annual Hg « | 103,554.66 j 0.0272 | 0.0035
tt Annual mercury (Hg) emissions are in Ibs; Hg emission rates are in Ibs/GWh and Ibs/BBtu.
Figure A-3. Nationwide Emission Rates
These results form the basis for comparison. Table A-l provides emissions offsets estimates for a
hypothetical 200 kW fuel cell located in Florida.
Table A-l. Example Fuel Cell Emissions Offsets Estimates
Pollutant
EREPS (from EGRID),
Ib/MWh
ERDG (from
verification tests),
Ib/MWh
EREPS - ERDG, Ib/MWh
DG capacity, kW
Estimated availability
or capacity factor
MWhDaAm
Emission offset, Ib/y
Florida
CO2
1420
1437
-IT
NOX
3.36
0.13
3.23
200
75%
1314
-22400
4250
Nationwide
CO2
1392
1437
.45°
NOX
2.96
0.13
2.83
200
75%
1314
-59130
3720
"Negative numbers represent an increase over the EPS emission rate
Note that this fuel cell increases the overall EPS CO2 emission rate if electricity generation alone is
considered. The increased CO2 emissions in this example would be balanced by the fuel cell's heat or
chilling power production if it is in combined chilling / heat and power (CHP) service. Each verification
TQAP must provide a specific accounting methodology for electricity production and CHP utilization
because it is impossible to consider all the permutations here. The simplest case, that the unit really
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operates at a constant power output, predictable availability (or capacity factor), and that all the heat
produced is actually used, is not necessarily true for every installation. Also, the CHP application may
displace units fired by various fuels (electricity, heating oil, natural gas, etc.) with their own efficiencies
and emission factors. Each verification strategy should explicitly discuss these considerations as part of
the specific emissions offset calculation.
It is useful, however, to continue this example. Assume that the fuel cell provides a constant 800,000
British thermal units per hour (Btu/h) to a domestic hot water system, thus displacing an electric-powered
boiler. This heat production is equivalent to 234 kW, which would require approximately 239 kW of
electricity from the EPS at 0.98 water heating efficiency (source: ASHRAE Standard 118.1-2003, § 9.1).
The fuel cell would therefore save approximately 15700 MWh annually at 75 percent capacity factor.
Table A-2 shows the resulting emissions offsets estimates.
Table A-2. Example CHP Emissions Offsets Estimates
Pollutant
EREPS (from EGRID),
Ib/MWh
ERDG (from
verification tests),
Ib/MWh
EREPS - ERDG, Ib/MWh
DG capacity, kW
Estimated availability
or capacity factor
MWhDaAm
Emission offset, Ib/y
Florida
CO2
1420
0"
1420
NOX
3.36
0"
3.36
239"
75%
15700
2.23 xlO7
(11 100 tons)
52800
(26.4 tons)
Nationwide
CO2
1392
0"
1392
NOX
2.96
0"
2.96
239"
75%
15700
2.19xl07
(10900 tons)
46500
(23.2 tons)
"Emissions are zero here because the electricity production offset estimate included them.
*Based on the power required to run an electric-fired boiler at 98 % water heating efficiency.
In this CHP application, the fuel cell represents a considerable net annual CO2 emissions reduction for
New York of 2.23 x 107 Ib/y.
This approach is generally conservative because it does not include transmission and distribution (T&D)
losses. T&D losses vary between approximately 3 to 8 percent depending on dispatch practices, the unit's
location with respect to the EPS generator actually being displaced, and other factors. This means that
100 kW of energy at the DG unit's terminals will actually displace between 103 and 109 kW (and the
associated emissions) at the EPS generator.
EGRID provides numerous other aggregation options, and the reader may wish to conduct other
comparisons, such as for a particular utility, North American Electric Reliability Council (NERC) region,
or control area.
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