COMPRESSION SYSTEMS

Introduction to Engine Testing

Gas Machinery Research Council
Engine Emissions Stack Testing

and Analyzer Workshop

Bruce Chrisman
Ajax
October 30, 2012

RAISING PERFORMANCE. TOGETHERTM

COMPRESSION SYSTEMS

GMRC Engine Emissions Stack Testing and Analyzer Workshop

Introduction to Engine Testing
1. Pollutants and Test Methods
1.1 Description of pollutants and approved test methods
1.2 Analyzers and sample handling
1.3 Calculation of exhaust emissions rate
1.4 Determining the exhaust flow rate
2. Exhaust Emissions Control Methods
2.1 Emissions controls used by various engine manufacturers
2.2 Prechambered engines
2.3 Fuel rich engines
2.4 Catalytic converters
3. Determining the Conditions of the Engine and Compressor
3.1 Factors which affect exhaust emissions
3.2 Cylinder balance and combustion stability
3.3 Analysis of power cylinder cards
3.4 Power cylinder health report
4. Determining the Power Output
4.1 Performance prediction and compressor loading curves
4.2 Compressor cylinder health report
4.3 Analysis of compressor cylinder cards
5. Effects of Operating Conditions
5.1 Effects of torque and speed on emissions
5.2 Effects of site elevation, ambient temperature, and speed on emissions
6. Evaluation and Reporting of Test Results
6.1 Examples of well documented reports
6.2 Wyoming format for reporting test results
6.3 Documentation of test variables
7. Ajax Engine Information
7.1 Design features of Ajax engines
7.2 Two stroke, loop scavenged power cylinder
7.3 Air fuel control system

10/30/2012

Introduction to Engine Testing

Pollutants and Test Methods

Pollutants and Test Methods

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

7e, 20
CTM-022, -030, -034
CO
10
CTM-030, -034
THC
25a
NMHC
18
O2
3a
CTM-030, -034
Exhaust Flow Rate
2
19

Analyzer
Chemiluminescent
Electrochemical Cell
NDIR
Electrochemical Cell
FID
Chromatograph
Paramagnetic Cell
Electrochemical Cell
Pitot Tube
Calculated from fuel flow, gas comp. and O2

Hazardous Air Pollutants

CH2O
CH2O

301
323

FTIR
Acetyl Acetone

Exhaust Emissions Regulations Affecting Stationary Gas Fueled Engines

8/20/2010 BC

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

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

Effective 2011: NOX < 1.0

CO < 2.0
VOC < 0.7

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

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

Emissions Analyzers and Sample Handling Systems

Stack/
Source

Calculation of Exhaust Emissions Rate

Mp= (Cp) (Qe) (r p)
BSE= Mp/BHP
Where:

Mp= Mass flow rate of pollutant

Cp= Volume concentration of pollutant
Qe= Volume flow rate of exhaust
r p= Density of pollutant
BSE= Brake specific emissions rate
BHP= Engine brake HP

Calculations of Exhaust Emissions Rate

Methods for Determining Exhaust Flow
Air Nozzle for intake + fuel flow
Pitot tube for exhaust flow (2)

Carbon Balance:
Balance carbon content of fuel with carbon
content of exhaust
F factor (19):
Calculate exhaust flow from fuel flow, gas
composition and O2 in exhaust

Summary of Emissions Test Data

ENGINE FUEL DATA:
Fuel Consumption Rate`
(BTU/BHP/HR-LHV)
Fuel Consumption Rate
SCFH

7837

2610

STACK FLOW DATA:

(EPA Method 19):

(EPA Method 2)

Stack Flow (DSCFM)

1246

1331

Stack Flow (DSCFH)

74776

79832

O2 F-Factor (DSCF/MMTBTU

8659

EMISSIONS CONCENTRATIONS
(Volume Dry Base Corrected):
NOx (PPMV)

39

CO (PPMV)

159

O2 %

13.99

THC (PPMV)

599

H2O %

6.80

EPA Method 19 O2 F Factor Dry Basis Calculations

Per Fuel Gas Analysis
O2Fd = O2 F factor (dry) SCF/million BTU
K

= Conversion Factor (1,000,000 BTU)

Khd

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

Kc

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

Ks

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

Kn

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

Ko

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

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

GCV = 23047.1
% of fuel gas which is made up of the following elements:
H = 23.42518 %

C = 74.66305 %

S=0%

N = 1.556136 %

O = 0.355788 %

O2Fd = [(Khd x H) + (Kc x C) + (Ks x S) + (Kn x N) (Ko x O2)] x 1000000

GCV
O2Fd = [(3.64 x 23.42518) + (1.53 x 74.66305) + (0.57 x 0) + (0.14 x 1.556136)
(0.46 x 0.355788)] x 1000000 / 23047.1

O2Fd = 8659

Summary of Emissions Test Data

Mass Emissions Rates
EPA Method 19
Calculations:

EPA Method 2
Calculations:

NO x (lbs/hr)
NA
Permit Limit

0.351

0.374

NO x (tons/yr)
NA
Permit Limit

1.536

1.639

NO x (g/BHP-hr)
NA
Permit Limit

0.483

0.516

CO (lbs/hr)
NA
Permit Limit

0.865

0.923

CO (tons/yr)
NA
Permit Limit

3.789

4.043

CO (g/BHP-hr)
NA
Permit Limit

1.193

1.274

Introduction to Engine Testing

Exhaust Emissions Control Methods

Introduction to Engine Testing

Determining the Conditions of the Engine
and Compressor
Mechanical Condition
Operating Parameters
Cylinder Balance

Factors Which Affect Exhaust Emissions

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

Introduction to Engine Testing

Determining the Power Output
Compressor Loading Curves
Use of Engine/ Compressor Analyzer

Model:
Cylinders:

2802LE
YK11MA 2300 1 Poppet Valves
YK11F 1300 1 Poppet Valves
Elevation (ft)
4900
Ambient Temperature (deg F) 35
Gas Gravity
.5835
Super Compressibility Used
YES
BHPAvailable for Compression 323.0
Barometric Pressure (psia)
12.28
Gas to be Compressed
NATURAL
Ratio of Specific Heats
1.2891
RPM
440
Non-lube Factor
1.00
Condition

49.

49.

Stage

1.

Active Head Ends

Active Crank Ends

Standard Conditions 14.65 psia & 60 deg F.

Suction and Discharge Pressures are at the Skid Edge

Z Suction

0.997

0.993

2.

Z Discharge

0.997

0.993

1.

1.

HE Vol. Eff (%)

62.3

87.2

1.

1.

CE Vol. Eff (%)

84.1

88.0

Bore (in)

23.00

13.00

PS (psig)

7.0

38.4

Stroke (in)

11.00

11.00

PD (psig)

41.0

90.0

Rod Load-C (lb)

14140.

7575.

TS (deg F)

66.0

65.0

Rod Load-T (lb)

13905.

6924.

TD (deg F)

200.5

159.9

65.0

55.0

Rod Dia. (in)

2.50

2.50

Cooler TD (deg F)

HE Normal Clr (%)

10.80

12.60

Compression Ratio

HE Set Clr (%)

28.94

12.60

BHP Utilized/Stage

188.2

134.8

Pocket Setting

6.24

.00

BHP Utilized/Unit

323.0

.0

CE Clearance (%)

10.80

11.60

BHP/MMSCFD

59.23

42.42

FC Clearance (%)

19.92

12.11

MMSCFD

2.76

3.178

2.10

3.178

Compressor Capacity and Power Curve

1400

Constant Discharge Pressure 1000.0 PSIG Capacities at 900

RPM

1200
1000

Variable Volume Pocket Setting - Inches

Brake Horsepower

Four 6.500 Double Acting Compressor Cylinders

800
600
400

MMSCFD at 14.700 PSIA &

60.0 DEG F

200
60.0
50.0
40.0
30.0
20.0
20.0
10.0
0.0
200

300

400

500

600

Suction Pressure - PSIG

700

800

Compressor Cylinder
ID

Theo Dis Temp

1> Comp 1 H Pressure

191.0

2> Comp 1 C Pressure

(F)

(delta)

Clearances (percent)

Compressibility

Suc

Dis

Z dis

Z suc

Z std

4.0

52.25

47.38

0.997

0.998

0.999

1.294

192.5

2.5

10.85

9.02

0.997

0.998

0.999

1.294

3> Comp 2 H Pressure

148.2

61.8

23.89

23.82

0.996

0.994

0.999

1.299

4> Comp 2 C Pressure

154.2

55.8

11.20

12.14

0.995

0.994

0.999

1.299

N Ratio
Load Step

Exp/Comp

Theoretical

Capacity

EFF

HP

STG

Suc

Dis

1> Comp 1 H Pressure

0.69

82.0

45.0

1.00

1.07

2> Comp 1 C Pressure

0.97

86.8

100.3

2.22

2.11

3> Comp 2 H Pressure

0.96

81.4

50.5

1.58

1.40

4> Comp 2 C Pressure

1.03

87.1

56.7

1.67

1.48

Stage 1 Capacity 3.1992 (MMSCFD)

Stage 2 Capacity 3.0662 (MMSCFD)

Total IHP

297.5 @ 438.3 average RPM

Total BHP

313.1 @ 95% efficiency with 0.0Hp auxiliary load

Current Load =

98.2%

Rated BHP

320.0 @ 440.0 RPM

Introduction to Engine Testing

Effects of Operating Conditions

Introduction to Engine Testing

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

Summary of Emission Test Data

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

Test Run No.

Time Start:
Time End:

1
02:57 PM
03:16 PM

Ambient Conditions:
Temperature Wet Bulb (F)

87

Temperature Dry Bulb (F)

94

Relative Humidity (%)

74%

Barometric Press. ("Hg)

26.25

Elevation (Ft.)

4450

Engine Operational Data:

Speed (RPM)

440

Spark Setting (BTDC)

Manifold Press

NA

Intake Manifold Temp. (F)

102

Fuel Header Pressure (PSIG)

NA

Engine Horsepower (BHP)

329

Compressor Operational Data:

Suction Pressure (PSIG)

225

Final Discharge Press. (PSIG)

1130

Compressor Volume (MMCF/D)

3.29

Compressor Horsepower (BHP)

323

STATE OF WYOMING

Department of Environmental Quality Air Quality Division

Reciprocating Engine Form

Form D-1

Reciprocating Engine Test Results

Source Tested:
Date:
Source Manufacturer/Model #:
Site Rated Horsepower:
Source Serial #:
Analyzer Manufacturer/Model #:
Suction/
Discharge
Pressures
3.5/82

Engine
RPM

439

Engine
Gas
Throughput

Unit 4
07/31/01
Ajax 2802-LE
316
84632
Enerac 3000
Operating Conditions
Engine
Fuel Heat
Fuel
Content
Consumption
Btu/cf
70

Engine
Engine
Specific
Tested
Fuel
Horsepower
Consumption
(Btu/hp-hr)
947.54
9,400
316

NOx (NO + NO2)

Average NOcorrected Average NO2corrected NOXcorrected NOX
Tested NOX
Tested
ppm
Tested
ppm
ppm
Tested
lb/hr
Allowable
NO ppm
NO2 ppm
gm/hp-hr
gm/hp-hr
3.31
3.29
28.68
16.07
19.36
0.27
0.19
1

O2
Average O2corrected Average CO corrected CO
Tested CO
Tested
%
Tested
ppm
Tested
lb/hr
Allowable
O2 %
CO ppm
gm/hp-hr
gm/hp-hr
14.34
14.34
113.97
113.35
0.97
0.68
2

Ajax 2802LE Performance for Site Elevation = 5000 ft.

Introduction to Engine Testing

Ajax Engine Information
General Description
Design Features

Two-Stroke, Loop Scavenged Power Cylinder

Intake Air Valve

Gas
Injection
Valve

Prechamber
Exhaust Port