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The COMPASS User`s Manual “COMPASS-Calcs”

1. Figure 5 8 You will need to first select the Source Type with which you wish to work Then you may add a new Profile ID or select an existing ID to modify current data Enter the Profile Description in the field directly under the ID field The user includes the instruction of whether or not to use the vapor phase composition for speciation by making the appropriate entry on the screen If this question is answered no then the composition that was entered in the Stream Property will be used without conversion to the vapor phase i e liquid phase weight percent will be used for speciation If for example a user wishes to perform calculations for wastewater discharges along with air emissions then a Profile can be included with this question answered no for the wastewater calculations When you click on the arrow for Estimation method a drop down list appears where you can choose from Emission Factors Site specific Emission Factors General or Manually Entered Emissions ACM Calcs Manual Chapter 5 Page 29 After choosing one a dialog box appears with Factors or Compounds relevant to that Profile record Select the Factors needed for the data you are working with See Figure 5 9 General Emission Factors Select All Clear All OK Cancel Compound Ef code Ef description 1 DICHLOROETHAME efcamb 1 00 TEST 1 2 2 TETRACHLOROETHANE FCOMB 02C TEST ACETALDEHYDE OXIME FCOMB 26 Fuel gas RENE FCOMB 27 Fuel
2. 3 5 Import Function A third option is also available on most versions of Calcs which is called Import The drop down arrow to the right of the Sources makes this choice available This function enables export and import of the Sources data from an external file format such as an Excel file While many file formats are available for users to export process data from Calcs only the tab delimited text file format may be used to load data from an external file into Calcs ACM Calcs Manual Chapter 4 Page 16 CHAPTER 4 SOURCE TYPES 4 1 The Importance of Source Types Source types are the determining factor in many different areas of Calcs Thus it is important that you fully understand each Source Type and its use The Source Type does not need to be the same as in the EI module Source Types define the equipment at the facility that generates emissions All data entry screens that require source types to be entered as data fields have a drop down list with all the available source types Select the one that fits with the data you are working with Other data fields will appear in the same form depending on the Source Type you select The following specific Source Type descriptions will give you an idea what data fields to expect upon that Source Type selection Estimation Dates Days On line and Operating Hours are available fields for all Source Types 4 2 Specific Source Types 4 2 1 Air Strippers Air Strippers are devices used
3. E E b E E E Fadly Unke Compounds Stream Prop Unit Streame Sources Formula Prefilss Cale Cont Inventory Exit zZz a 8 amp 8 amp Swe Cloce SweAc Calculate BatchCount Print Batch Calculations MEE Femy coders Te eupmort Jie onto veo e TE meee Fotino Sumemie Description fest Unit 112001 f r Volume 1200 gals Machine PKS T EXPLORER Step Parameters Charge Reaction Process Control Calculations aa codes 88901 test B A test test apor Press Phase Moles Liq Mapor Frac feaLe LbHr 2 PC Eff Potential Lb Hr H Step1 5 i CALC Lbistep f Override Potential Lb Step Step2 G na E 0 0000 Fiquia 0 0000 0 0009 aooogf 0000d Step 4 pm MN NE _ Step5 TOTALS 0 0000 0 0000 0 0000 0 0009 OE Cam 4 Step a Step 8 Step3 amp Step 10 Step 11 Step 12 fH EJ wemi test Figure 6 20 During the calculation process if any missing parameters such as molecular weights densities Antoine coefficients etc are detected by the program it notifies the user through a list of QA codes See Figure 6 21 The QA codes will also trap value overruns for instance vapor fractions greater than 1 0 If a user inadvertently inputs more material than the reactor can hold the system assigns QA code 12 Such user notifications can be very helpful to identify problems and ensure correct emission calculations ACM Calcs Manua
4. Page 23 The reason for the Unit Stream selection is to identify all of the Stream Properties that will be used in each process Unit in the plant The stream properties are entered separately as discussed in the next section There are two reasons for separating the streams from stream compositions in Padded streams Cleanup Streams Search for Stream name ji Stream name Stream id Unit Stream Compositi p faor STR LANNATE v 4401 STRM STREAM FOR FI ACHT STREAM VOC ACHT STRM LANNATE v ACHT STM ACHT TANK STRE ACD GAS STREAM BTRM 7 ACID UNIT v ACID GASSES ACID GASSES ADN 2M3 STORAGE PMaSTG ADN UNIT w 1030 2M3 STG DN 2M3BN M3BN ADN UNIT w 1030 2M3 STG ADN 2M3BN SIDEDRAW 2M3BN SIDED ADN UNIT v 1038 2M3BN SIDEDRAVW ADN BENZENE STORAGE TANK BZ ST TK ADN UNIT v 1056 BENZENE STORAGE T DN CAT BLEND AT BLEND ADN UNIT 11037 CAT BLEND ADN CAT PURGE paT PURGE ADN UNIT vw 11034 CAT PURGE DN COOLING TOWER OCLT 040 ADN UNIT vw 10CLT040 COOLING TOWER ADN CRUDE 2PN RUDE 2PN ADN UNIT v 1050 MULTIPUR 2PN ADN CRUDE CRESOL TK RUDE CRESOL ADN UNIT v 10584 CRUDE CRESOL TK S DN CRUDE DN TK RUDE DNTK ADN UNIT y 1057 CRUDE PN ADN CRUDE MGN RUDE MGN ADN UNIT w 1058 CRUDE MGN ADN CRUDE PN RUDE PN ADN UNIT v 1029 CRUDE PN p Figure 5 3 the system 1 In short the Stream and Stream Property concepts in Calcs is one example of using the power of a relational database much like the Formula
5. User s Manual Compliance Assurance System Emission Calculation and Process History Module COMPASS Calcs Process Data Control Corporation Copyright PDC Corp All Rights Reserved TABLE OF CONTENTS CHAPTER PAGE 1 INTRODUCTION seesccscnccsscncsnetisccacsisncbatecssvedesnedessacessanidbantessntoesaccianetiessses I AN 201 Cales ERE EE 1 1 2 Manual Procedures Affected by Calcs rrnrnnnnnnnnnnrrnnnnnrnrrnnnnsnnsrsenne l 1 3 System Requirements je een 2 1 4 Installation IA UELONS ankesak eastern 2 PO USME Help ER TT 2 1 6 Technical Support of Cales svavrvem vaere 3 1 7 Getting Started with Calcs s seseseesseesseesseesseessesssessressresereseresersseressre 3 LS L ser onto Cales Lake 3 VF 4 1 10 Conventions Used in This Documentation roronnrrnvrnnrnvnrrrrvnvrennnnse AE 216 OE EE ouavuaauduiabunvbecuss 6 EG REE OR NR 6 23 COMMON OS RENE EEE DE E REE 6 2 4 Streams and Stream Properll suLuananasersamsemne inuieee 6 PREETI 5 EAN AEEA RS AN 7 2 6 Emission Faen aranuseannets 7 PATE A KOI Gl lc een ene ee E ENE E E DRENERE 7 2 8 General Equipment Information 9 53sceesxesncseoudeasnnsdevsupbectonteransanecumavisepness 7 2 9 Menu Structure scnnsscsspicunssntnnwsiedadnapeovebneonaiesbneiesmemnsmiebiioneslabepaediennlonesiemes 7 2 9 1 File ee i 7 2 9 2 Process MEDU rererere e E aE EAE 7 2 9 3 Reference MENU ccccccccscccccsecccsecccssecccesececsssceceessssnesssesesesens 8 2 9 4 Emissions mM
6. Figure 6 16 TT Assochned with other saure Machine lzi The second tab displays material input output information See Figure 6 17 The user selects an input grade or raw material from a predefined set of materials stored in the database These materials and their chemical compositions are user maintained When a user selects an input grade the corresponding chemical composition is displayed under grade composition The number of pounds of each chemical fed to the reactor is calculated from the grade material composition neesi Suptaanmer Chepe Pesci Prozess cena Crzusan as czs Croic Campaskion Crimp Hema Figure 6 17 Da O maf m gie tha The bottom section of the Charge tab displays the material balance for the current step The emissions are calculated based on the moles of vapor displaced during the current step The volatility of various chemical species at the given temperature and pressure and the volume of ACM Calcs Manual Chapter 6 Page 44 material charged affect the number of moles displaced Heating de pressurization and material charging all lead to vapor displacement from the reactor The vapor pressures of various chemical species determine how much each will contribute to the total emissions resulting from vapor displacement Chemicals charged into the vessel can participate in one or more reactions See Figure 6 18 The software identifies the limiting reactant based on the quantiti
7. click on the Print icon This will send the Process Units report to your printer The Units screen includes a column called Scaling Factor This factor may be used in conjunction with another feature to copy all of the process history data for all sources from one year to a future or current year That feature is accessed by clicking on the Process menu and then clicking on the menu item called Copy Data To Another Year See Figure 3 4 SACM Calcs Emission Calculations Program File Process Reference Emissions Options Emission Sources Stream Properties and Compositions Emission Source Profiles Copy Data To Another Year Figure 3 4 ACM Calcs Manual Chapter 4 Page 13 If the Scaling Factor for say Unit 1 is 1 or is not filled in and the Copy Data To Another Year feature is selected then all process history records will be duplicated for the selected target year If there are twelve process history records in the base year one for each month for a storage tank for example then twelve records will be created in the target year with exactly the same throughput If the Scaling Factor for say Unit 2 is 0 5 and the Copy Data To Another Year feature is selected then all process history records will be duplicated for the selected target year but the throughput for all tanks and loading racks that are located in Unit 2 will be changed to a value that is one half as large as the v
8. e Eaipmentin 2 7 Delete Yeon 000 Jiz Delete Roling Sum mise Description fest unit 1201 z Yolume f 1200 gals Machine PKS GRADE EXPLORER Grade Detail Emissions 81865 test H A 88108 test ER a E 88901 test PIMS Batch Count Upload test th x ee je t amp This operation will upload the number of batches for each grade produced on the Machine 7 wemit test iD ID mapped to this Source The current number in the Actual Number of Batches field will be overwritten Are pou sure you want ta proceed Wait Time 12 hrs Secondary Group Actual Batches Yr 5 0000 man Btchessir 28 Tender Grom Calculated Quarternary Group Figure 6 14 A Batch icon appears on the main screen of CALCS as shown in Figure 6 15 which may be used to access all batch related functions SACH Calcs Emission Calculations Program File Process Reference Emissions Options Maintenance Window Help 2 b sr b 2 GB Bb E HE F Facility Unite Compounds Stream Prop Unitfftreame Sources Batch Formulaz Profiles Cale Cont Inventory Exit Figure 6 15 Using this set of features users can simulate a multi step batch process with charge drain and clean out operations Each set of batch emission calculations is associated with a product grade being manufactured One reactor vessel can be in service for manufacturing multiple product grades The emissions from each batch are then extrapolated to an annual
9. the contractor will need to supply you with two files a Leakers file and a Totals file The leakers file is a listing of all the leaking components and their ppm leak rates during the estimation period Note that we are considering leaking components as any component leaking above background zero not the regulatory 10 000 ppm definition The totals ACM Calcs Manual Chapter 8 Page 57 file is a listing of the total number of components by stream in the plant during that estimation period The information in each file should be the most recent available For instance if a certain unit is not monitored during the time period of interest then information for that unit should be obtained from the most recent past data If the past data indicates that a particular component was screened at 1000 ppmv then it should continue to be recorded in these monthly tables as being screened at 1000 ppmv until it is monitored differently in the future All components in the plant should be accounted for in these tables each month regardless of how many are monitored each month The Unit and Stream Information has a primary and secondary priority to it The Unit ID and Stream ID should always be filled in If the only data available is the Unit name or Stream name then this data should be placed in the Unit Stream ID column with the Unit Stream Name column blank If this is the case the format restricts the number of characters to the specified format T
10. 11 Comments on Data Items You may enter comments in the database about various entities and other elements of Calcs wherever there is a Comments icon Click on the Comments icon to open up a free form text box that will allow you to enter pertinent information that may not be contained within a field listing or it will allow you to make notes to yourself or other Calcs users on the network Once finished entering the notes and or text desired click on the OK button To clear previous notes click on the Clear Text button To delete the entire comment entry click on the Delete button To undo without saving what you are presently doing click on the Cancel button COMPASS Calcs Manual Chapter 2 Page 10 2 12 Steps in Entering Data into Calcs In order for Calcs to work correctly and generate the emissions data you need for inventory purposes it is important that you follow these steps closely in entering and modifying data in Calcs In general use the buttons from left to right Also ID number fields recognize spaces and are case sensitive PDC recommends entering ID s using all CAPs and no spaces unless it is necessary to duplicate a FIN This practice will reduce the possibility of errors that are difficult to trace Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Locate an existing Facility or create a new one Identify Units by either establishing new Units o
11. add to a new formula Click OK after your selection See Figure 6 4 gt Formula Picklist x Formula ID Description OFL44NOX AMMONIA TANK FLARE OFLSACO PYROLYZER DIAMINE FL CO OFLSAHCN PYROLYZER DIAMINE FL HCN OFLSANH3 PYROLYZER DIAMINE FL NH3 OFLSANOX DIAM FL NITR CON NOX 014RXMEOH O014RX FACTOR FOR METHANO Figure 6 4 To exit out of the Emission Factors window select the Close icon This will take you back to the main Calcs screen 6 2 Estimating Emissions The Estimate Emissions windows allow you to build the reports with which to view an estimated Emissions list To enter the Estimated Emissions window click on the Emissions menu and then select Estimate Emissions Alternatively click on the Calculate button See Figure 6 5 ACM Calcs Manual Chapter 6 Page 35 Estimate Emissions SELECT FACILITY ID V Begin date CG0010G PDC Corp 0101 2003 4 50010605 BLANK JV End date X0010G05 TEXARKANA MILL vi 1231 2003 JV Source Type I Process Units I Equipment Id CALCULATION CRITERIA Select All Select All Select All r Calc Mo valt AIR STRIPPERS a Use profile matching CATALYST HANDLIN selected time period COMBUSTION SOURC IV Cale emission results COOLING TOWER 50 de berro RAD DRAINS SUMPS AHL EQUIPMENT LEAKS FCC SOURCES FLARES LOADING RACK L User Defined Report Heading Use existing results Compound List Es Figure 6 5 You must select Sou
12. and Profile concepts discussed later in this manual First when process history is entered for a Source as described in Section 3 4 of this manual users are asked to identify the Stream s that are consumed in stored in or used by the Source during the process history time period Sources are related to specific Units just as the Streams are thus the system can provide a drop down list of Streams for this selection that is limited to the Streams associated with the Unit in which the Source is located If there were no relationship of streams to units in the system then the drop down list could contain several hundred streams or more for a large plant Therefore the Unit Stream feature makes future use of the system more convenient and greatly reduces the potential for error e g selecting the wrong stream for a Source It also allows for calculation of emissions by unit Second by separating stream compositions from streams the user has more flexibility in using Streams in emission calculations For example several Streams can and often do reference the same composition thus if the composition changes in some but not all units the user can add one or more new compositions and relate them to the Streams that have modified compositions only Also if several Streams reference the same composition and the composition changes for all streams the user needs only make the change in one place at one time thereby reducing maintena
13. are entered Step 2 Define all the chemicals and compounds that will be needed for speciation of the stream data Step 3 Define all your streams and enter the stream compositions in this window Step 4 Link the streams to each process unit in this window by inputting the first four columns Also the Leak contractor Stream ID and the Equipment leak stream category columns are necessary when importing data If you will be speciating your VOC the TVP and Deg F columns also need to be entered The columns for Stream phase VOC service and TVP 68F are optional Step 5 To access these screens from the main window choose Reference Equipment Leak Reference Data Before continuing on to the Source window make sure you fill in the Leak Ranges Leak Component Types Leak Monitoring Programs and Stream Categories Calcs uses the Leak Ranges and Leak Component Types information in Sources to construct the Leak Count table for Equipment Leaks so it is important that you consider what leak ranges you will need and the components to be monitored before proceeding Step 6 Consider each process unit as an Emission Source for fugitives List the streams within each process unit that are monitored for fugitive emissions The estimation dates should correspond to the frequency of the contractor data If the contractor supplies data for each month which is probably the most common each Source should have 12 sets of records with different Estimation
14. confirmation box This will take you out of Calcs ACM Calcs Manual Chapter 7 Page 53 CHAPTER 8 EQUIPMENT LEAKS 8 1 Calculating Equipment Leaks Equipment Leak or Fugitive emissions data is usually supplied by a contractor The user is responsible for creating the links between certain fields in both Calcs and the corresponding fields in the Source data files The system has capabilities to import the data provided by the contractor as long as the format that is used for this import procedure matches the format for which this feature was written call PDC for details There are several files needed for import The first set of files imported will be the leakers files that Calcs uses to enter in the component counts The next set of files is the Totals file that Calcs uses to keep track of the total number of components in the facility The total number of components and the number of zero leakers are determined by Calcs after processing this file Once the data is imported you set up equations in Calcs and calculate emissions If you used correlation equations Calcs will need to import the leakers file again to input the specific leak rates into the equations 8 2 Setting Up the Data Before importing contractor data you must first set up Calcs to accept the data for import You will need to perform the following steps before attempting to import equipment leak contractor data Step 1 Make sure all the process units
15. delete Facility information To select an existing Facility to modify click on the drop down list on the Facility Code field You will be given your choice of current Facilities resident in the system Clicking on the desired Facility will fill out the data entry boxes with the currently installed data items for that particular facility Notice the vertical scroll bars on the right side of your screen that will allow you to view Edit Facility Information New Facility code J X Date of Federal Operating Permit 00700700 Figure 3 1 the rest of the data Once an existing Facility is selected you may make modifications to the data that is present Once you have made any modifications to the data select the Save icon This will update the database Note that clicking on the Save icon first will result in a dialog error box appearing Name Company Name number of Employees a Plant Site Name Agency ID No Valid TNRCC Number Yes Plant Add Lines Addline2 gt Physical Location ny Nearest City City act State Zip CT County Plant Telephone C tS Business Type UTM Zone UTME Meter UTMN Meter Plant Latitude deg min sec Plant Longitude deg min sec es e fee st reel SIC Code SIC Code asking you to make a Facility selection first See Figure 3 2 You must enter a Facility Code to proceed gt ACM Calcs Manual Ch
16. from the list Step 3 Select the piece of equipment you created earlier under Equipment ID Step 4 Click on the Profile drop down list Select the profile you just created Step 5 Click on the Save icon Step 6 Click on the Close icon 7 4 10 Estimating Emissions After establishing Sources Formulas and Profiles you are ready to calculate emissions You are provided with different search criteria for calculating emissions You may choose from one to many source types process units pieces of equipment specific chemicals and estimation periods 1 Click on the Calculate icon 2 Click on the checkbox to activate the listbox for Source Types and then select Combustion Sources 3 Check the Equipment ID check box and select the Source you created Note In a large plant equipment can be filtered by clicking on Process Units check box first selecting a Unit then clicking on the Equipment ID box to list the equipment associated with the selected Unit ACM Calcs Manual Chapter 7 For Estimation method select Emission Factors General A popup window with a list of Page 52 4 The Begin date and End date are required fields You must enter the dates exactly as you did on the piece of equipment OR enter dates that include the date range for the piece of equipment Click the RUN green flag icon The results of your calculation will appear in the default or selected report format as discussed below Icons are pr
17. gas FCOMB 18 Fuel gas Cromium CHROMIUM COMPOUNDS FCOMB 28 Fuel gas ko ko COFAC CI ko Fo FACTOR FOR C3 0 FCOMB 01 Gas Fired lt 10 CO al Figure 5 9 Another dialog box also appears when you click on the Speciation drop down field list When you select one of the entries from the list a window entitled Multiple Species Compounds appears See Figure 5 10 Select a multiple species compound CADMIUM COMPOUNDS CATALYST ALL TYPES CHROMIUM COMPOUNDS COBALT COMPOUNDS LEAD COMPOUNDS MANGANESE Figure 5 10 You may click on the desired item Compositions may be entered directly from a pre defined Stream Composition by selecting Using Stream Comp from the Speciation drop down list To save the existing Profile record click on the Save icon If you made changes to existing records you may also click on the Save icon to update that particular record or you may save those changes to another unique record by choosing the Save As icon and naming the new record ACM Calcs Manual Chapter 5 Page 30 If you are making changes to the compound listing under the Profile record and you wish to delete a compound entry select the desired compound and click on the Erase icon This will delete that specific compound from the Profile ID Remember that clicking on the Delete icon will delete the entire Profile ID record so use that icon only when needed To print the Profile report click on the Print icon This
18. in the remaining process data including the time frame this data is valid for These dates will be used as criteria for estimating emissions Click on the Save icon Click on the Close icon 7 4 7 Creating an Emissions Factor An emission factor is a formula for calculating emissions for a particular compound You build this equation by selecting variables from the Columns list 1 2 3 4 90i ly ON 9 Click on the Formulas icon Click on the drop down list to Select Source Type Choose Combustion Sources To enter a new emission factor Enter Factor ID Enter a specific description for your emission factor Indicate whether this formula will calculate a Maximum also called Potential to Emit emission rate or an Actual e g annual tons year emission rate by selecting the appropriate Emission Type radio button Also indicate whether this formula uses a General or a Site specific calculation approach by selecting the appropriate Type of Factor radio button Formulas based on U S EPA AP 42 or American Gas Association factors would be examples of General formulas Select Process Heater as the general description for this combustion source Select VOC as the compound Enter the Emission Factor as 5 5 and the EF units as lb mmscf In the Columns listbox double click the column name COMBS cvt_fuelusage You should see the formula change to reflect ef cvt_fuelusage Now click on the 7 division symbol button a
19. open up a window asking you to name the new ID Remember that all fields of data from the previous ID that have not been modified will appear in the new ID Stack test data can be included in a calculation formula as discussed later in this manual ACM Calcs Manual Chapter 5 Page 28 To print the Stack Testing Report select the Print icon To exit out of the Stack Testing area click on the Close icon If any unsaved data remains on the entry form you will be asked whether you wish to update those records to the database 5 6 Emission Source Profiles Emission source Profiles identify the compounds emitted from a certain type of emission source as well as the methods used to calculate those emissions Emission Factors are equations for each compound emitted during a process A Profile is a group of these factors used to calculate all emissions for a particular source type the profile can also include instructions for speciation of Total VOC into constituent compounds based on their weight percent in the vapor phase To enter the emission source Profile area of Calcs click on the Profiles icon This will open the Emission Source Profile window See Figure 5 8 3 Emission Source Profiles New Select source type COOLING TOWER SOURCES v Enter profile id hd Profile description Use vapor phase rs composition Estimation method hd Speciation p Compound Methodtype Methodcode Stack Test Multiple Species
20. toeren ieii eii eea 18 120 Hav rn 18 4 2 9 Loading TACK SOURCES cscsonsancosussaniansbeicannebpacnspiicepuanvantessmusdabinentions 18 4 2 10 PN 19 12 VESP eor e E E E 19 42 12 Storage tanks recontos ei eee REER 19 4 2 13 Sulfur recovery Sources eeseeeesseeeseseesseresseressseressreessreesssee 19 4 2 14 Wastewater treatment systems rrrrnnrorrnnrrnnnnrrnnrnnnnvnrennnnnnenee 20 4 2 15 User defined oe 20 5 1 Selecting the Operating Facility sjascassevsescassnevessenncnassanenvsersoneransnveveaneas 22 5 2 PO aree EEEE EEE E EAEE T EAEN RERE E 22 NN 23 5 4 Stream Properties and Composition eerennrnrennrnvnvnrrvnrenreneennrrssrrnnseenn 25 5 4 1 NY Stream Properties and Composition eeenvrnvonnrnvrvnrnvnvvenne 27 i 16 GU ENE E arene eres 28 5 6 Emission Source FO MGS eee 29 Calcs Manual 6 EMISSION CALCULATIONS cccsssssssssssscssssssssssssssssssssesssssesses II 6 1 Formulas sssrin saine NE NE 33 6 2 Estimating Emissions ssessesssessessesesereesssresseresssressereessrrssereesseesseseess 35 6 3 Emission Inventory Summary ss sseseseeeessseseseeeessrresereesseressseessseresssees 37 64 D ta Pipeline EEE RE 39 6 A NY Data Pipeline caan 40 KE EE EN EE 41 6 6 NY Emission Calculations for Batch Processes errravrrrrnrvnrennrnven 42 6 7NY Using the Tabs to Navigate Batch Calculations Screens 43 6 8 WY Rolling Sum of EMISSIONS iusistiacasenerioanitasanksielinarteomeass 47
21. will present the user with three choices for printing out the profile information a print the profile on the display screen only b print all profiles stored in the database c print all profiles listed by site To exit out of the emission source Profile area click on the Close icon If there is any unsaved data you will be asked whether you wish to update the database Profiles may be assigned to a Source in one of two ways as explained in the following paragraphs 1 While the Profiles detail screen is open users may click on the Link Sources icon or the Options menu located at the top of the screen and select Link Sources This will open a screen in which Profiles and Sources are displayed in separate windows and users may drag and drop the desired Profile to the appropriate window to save this link See Figure 5 11 Select Profile Linked Equipment Search Equip ID Equip Hame TOHTROS4 ADN PYROLYZER ontos PON O E EDN PYROLYZER FIRING HCN OG fi0HTROBAOtRDN PYROLY ZER FIRING OFF GAS Fi cOMBS FOBUSTIONPROFLE Pow PRO PROFLEFORDOWHEATER Eso BOLERBT Es kosma o Esp oF Fosen 2 Fe Equip Hame EEE NO 1 RECYCLE COMPRESSOR Fer AP 42 GENERAL HEATER PROFILE 10 Esa AP 42 GENERAL HEATER PROFILE 10 MO 2 RECYCLE COMPRESSOR Ess a 42 GENERAL HEATER PROFILE 0 3 NO 1 PURGE COMPRESSOR Fri fro 1 NO 2 PURGE COMPRESSOR Ese __ BP 42 General Low NOx Heaters gt 1001 NO 1 MAK
22. Compound records from each property It is important that you understand that the Delete icon is for this purpose while the Erase icon is for the purpose of deleting the entire Stream Property record When you are finished with modifications click on the Save icon If you wish to create another unique property from the modifications you have just made click on the Save As icon This will allow you to keep intact the existing record s You will be asked to enter a new ID code to update the database Once this code is entered and the database is updated there will be a unique property record similar to the one you used to create the new one with the new data resident Liquid and Vapor Molecular Weight MW may be calculated on the Add Edit Stream Properties and Compositions window provided that the data needed to execute the required computations have been entered by the user e g Reference Temperature for the Vapor MW computation Simply click the Calc button by either the liquid or vapor MW field Message boxes will prompt the user for missing data as required for the calculations Alternatively users can enter the Liquid or Vapor MW instead of calculating the value Stream Properties are not related to any specific operating Facility nor to any Unit The relationship of a Stream Property to a Unit is established when the user includes the composition in a Unit Stream Because the physical chemical data that comprises Stream Properties often
23. Dates i e 01 01 2007 01 31 2007 02 01 2007 02 28 2007 03 01 2007 ACM Calcs Manual Chapter 8 Page 54 03 31 2007 and so on When you access the Leak Counts table Calcs constructs a table that includes all the information identifying the components in each stream The Leak Counts column will be blank When you import the data the Leak Counts column will be filled in for you TIP If you choose to have multiple estimation dates i e monthly then only set up one estimation period i e one month and import the first month s contractor files If errors are found then you can correct the errors in that month s record Once you have imported the files for one month go ahead and save the emission source for the remaining 11 months This way each file will have the corrections already saved This will save you a large amount of time if errors are found Step 7 From the main window choose Reference Equipment Leak Contractor Data These windows must be filled out so that the imported data will correspond correctly to the data in Calcs Step 8 Create an emission factor or correlation equation for each range group monitoring program component type and stream category A correlation equation calculates emissions by considering the actual ppm leak rate concentration of each component An emission factor estimates emissions by considering the number of components Both methods may be used Be sure to select the radio button on the uppe
24. EUP COMPRESSOR PRo c1 E1 PROFILE WITH COMBINED COMPOUN REECO INCINERATOR Hote Double click or Drag an equipment row to move it from Unlinked to Linked lists or viceversa eg oe jm Figure 5 11 This screen also enables users to view the currently assigned Profile for all Sources A Profiles report is also available under the Options menu selection to enable a detailed review of Profile links to Sources ACM Calcs Manual Chapter 5 Page 31 2 While the Sources Detail screen is open on the first tab users may click on the Profile data entry item and select from all Profiles that have been created for the selected Source Type to link the Source to a Profile See Section 3 4 ACM Calcs Manual Chapter 5 Page 32 CHAPTER 6 EMISSION CALCULATIONS 6 1 Formulas Formulas are the building blocks of the Emission Source Profiles in Calcs To create a formula you manipulate the objects you have at your disposal including data elements values and mathematical routines Once these formulas are created they may be used in multiple instances i e profiles to calculate emissions Should it become necessary to modify the formula it can be changed in one place at one time and all profiles that reference the formula will instantly be updated To enter the formula area of Calcs click on the Formulas icon This will open the Add Edit Emission Factors and Formulas window See Figure 6 1 1 Add Edit Emission Factors and Formu
25. TA What You WV UD reel 48 T 2 What You Wil Learn EE NE 48 NNN 48 7 4 Proceeding with the Tutorial vuesuaennemmersndnmgi e hist 49 7 4 1 Log into the Catalase araseeaN ene 49 FAZ Cr ate NE 49 7 4 3 Creating a process stream ssesseeesseseessesesseressrresssresserressseesse 49 7 4 4 Creating a stream composition eeeenvrnronnrrvrrernrnvrennrneennrneesennne 50 7 4 5 Editing compound i ial txejecnuivansnveeioastvaavenvennantdcavaatinpeancanaenian 50 7 4 6 Creating an emissions SOuUrCe ssssessesessesesseresseressseeesseresssressee 51 7 4 7 Creating an emissions factor ssesessesessseseseseesserssseresseresseressse 51 7 4 8 Creating an emissions proves iccassiscaisaseceocansesdannceosantesguvacdiazenes 52 7 4 9 Linking the profile to an emission source rernrrvrrennrrvrnnrrvneennne 52 7 4 10 Estimating emissions ssseesessessesesseresseresssresseresssstessereessressee 52 7 4 11 Displaying and printing reportS eerrrrronnrrvrrerrrnnrennrrernrrrnsrennne 53 8 EQUIPMENT LEAKS ssssscssussesasensscactsnassnaneiennssenssacnsscuossansavatsansensasavoacen D 8 1 Calculating Equipment UCAS 52 ccjscdinsssnencanesopdnhoinesawdestonneseotanindinaietenne 54 8 2 Sete p the Die 54 8 3 Importing Contractor Data ca sccessessecncses doesansaseavenen savaceeiave adm 55 SEE E E EE EN 56 8 3 2 TOtAlS ANd ZCTOS EET EE aLa E aE 56 8 4 Calculating Emissions seseesessessseeeessesesssressseeesseresseresssresseresssressese
26. Toolbar configuration window See Figure 2 7 blions Maintenance Window Help E 3 Tile bp Unit Streams Sou Cascade Layer Arrange Icons Toolbar Figure 2 7 COMPASS Calcs Manual Chapter 2 Page 9 2 9 8 Help Menu The Help menu in Calcs gives you access to the on line Help system and other information relating to Calcs and COMPASS See Figure 2 8 Window Help Contents Ctl F1 About Figure 2 8 2 10 Toolbar Configuration Calcs has toolbars that are the quickest navigational route to different windows and areas of the program The Calcs FrameBar is the main toolbar that allows access to the various Windows The FrameBar is by default positioned at the top of the screen The Calcs SheetBar is a secondary toolbar that appears when each section window sheet is open The SheetBar icons allow you to add modify delete records update your editing changes to the database and exit the window You may customize the toolbars by choosing the Toolbar selection from the Window menu This will open the Toolbar dialog box where you may select the position of the toolbar relative to the screen and whether or not to show the text displayed with the icon See Figure 2 9 Toolbar EI Hove Hide C Left Select the options you need for the Right Done Framebar and Sheetbar then click on Top Done Bottom Floating M Show Text f Frame Toolbar Figure 2 9 2
27. alues in the base year In fact all Sources located in Unit 2 will have their process or activity rate e g fuel usage for combustion flare gas burned for flares etc changed per the scaling factor Note that this feature does not scale emissions directly only process rates Therefore the effect on emission estimation is as defined in the estimation formulas If process rate is an important calculation variable e g storage tanks then the scaling of process rates will have a significant effect If the process rate is a minor variable or if it is missing altogether from the formula e g fugitive emissions then the scaling of process rates will have little or no effect on emission rates Click on the Close icon when finished editing the Process Units data to return to the main Calcs screen 3 3 Emission Sources Quick Edit Screen Users will note that there is a drop down arrow located just to the right of the Sources icon When this arrow is clicked the Quick Edit icon can be selected which enables multiple sources to be edited on a single screen See Figure 3 5 Source Quick Edit Facility vC0008G Type COMBUSTION SOURCES ej Unit aL Year 1936 F OHTROG4H1 6 1205196 on 15721 pass 332031 mmscti vern honena tamme OOD en Tenoa Figure 3 5 3 4 Emission Sources Emission Sources or the producers of emissions can be edited under the Sources section of Calcs To enter the Sources section click on the Sou
28. apter 4 No Select the Facility ID Number from the drop down list then fill out the data form Missing facility code R i Please enter a facility code Figure 3 2 Page 12 You may print the Facility information by clicking on the Print icon Once you are finished editing data in the Facility section of Calcs click on the Close icon This will return you to the main screen Be sure that you have saved changes to the database by clicking the Save icon before closing 3 2 Units To enter a Unit click on the Units icon This will open the Add Edit Process Units window To enter a new Process Unit click on the Insert icon This will open up a data box directly under the last existing Unit and place the cursor in that box You may enter the data as needed selecting the Save icon when finished See Figure 3 3 Add Edit Process Units Search for Unit name Process Unit Name ACID UNIT ADN UNIT ALL UNITS AMINE UNIT BUTANE BUTENE FEED SYSTEM UELS BLENDING UNIT EATING OIL UNIT LET UNIT ANNATE 10 1 CRUDE UNIT RUCK LOADING PROCESS UNIT Clicking on the Insert SheetBar icon inserts a row at the bottom of the form Figure 3 3 You may delete an existing Process Unit by selecting the unit record you wish to delete Click on the Delete SheetBar icon and you will be asked to verify the deletion so choose Yes To print the listing of Process Units
29. ata Pipeline The data Pipeline is a feature designed to copy calculated emissions from the Calcs module to WinCeis 1 e the Emission Inventory module It is accessed by selecting the Pipeline icon from the COMPASS folder on the Start menu As shown in Figure 6 9 the main tool bar enables choices to be made as to whether to pipeline equipment parameters or emissions as well as whether to run maintenance functions such as for equipment relationships or contaminants Most users will use this feature to copy emissions data only CALC to EI Pipeline File Actions Window Help 2 2 2 E Parameter Emissions Contam Equip Rename Figure 6 9 The procedure to copy emissions is to first select the Emissions icon from the Pipeline tool bar and enter the pertinent information on the retrieval screen to show the emissions that will be pipelined and then click on the List icon to retrieve the list See Figure 6 10 Highlight the emissions that you want to be copied to WinCeis S H BE Print Err Reports List Pipe Ricbuild INMY Close Emission Pipeline Select Parameters For Building Ex Year 1996 ility M f Prorate Emissions f Apply Control Efficiencies Apply Ozone Emissions Zero Out Emission Inventory Source ID Point ID fiocrtoao fiocrt 040 NONMETHANE WOCU vor foctioso focur040 fammona forsssa7 frorLro04a florLro04a HYDROGEN CYANIDE GA 00074903 frorLron4a fiorLrovsa AMMONIA 07664417
30. ation the emission calculation results and all aspects of the methodology such as formulas factors and stream compositions In addition this report always provides an accurate summary of the methods and data that were employed in the calculation of emissions for which questions have been raised so there is no chance of erroneously explaining them to the TCEQ 1 3 System Requirements The following platform is strongly recommended to operate the Calcs application Pentium II PC running at 250 MHz with 64 megabytes of RAM and 50 megabytes of free disk space The following platform is the minimum required to operate the EI application Pentium I PC running at 90 MHz with 25 megabytes of free disk space and 32 megabytes of RAM to obtain reasonable performance The following operating systems are supported Microsoft Windows 95 Windows 98 Windows ME Windows XP or Windows NT Operating Environment all Trademarks acknowledged The following Database Management System DBMS software is supported for the Data Repository ORACLE 7 3 and higher Sybase SQL Anywhere 5 5 and higher 1 4 Installation Instructions Directions for the installation are furnished in a separate document entitled Installation Instructions which is provided with this operations manual Calcs should always be loaded onto a local or network hard disk under the directory structure lt drive gt PDC ACM CALCS The installation program creates this structur
31. can easily be added together after calculations are done to estimate emissions for the entire Loading Rack ACM Calcs Manual Chapter 4 Page 21 CHAPTER 5 CALCS OPERATIONS 5 1 Selecting the Operating Facility To select the desired operating or default Facility choose the Setup selection from the Options menu You will be presented a list to choose the desired Facility in which to work See Figure 5 1 This Facility selection will carry the desired Facility across Process Units and other entities Select a Default Facility EI Select Facility PDC AG CHEMICAL PLANT POC SPECISLTY CHEMICALS Click on the desired facility and choose Figure 5 1 5 2 Compounds A listing of Compounds and their related data can be edited by clicking on the Compounds icon This will open the Add Edit Compounds window See Figure 5 2 You may add edit delete or print resident compounds ACM Calcs Manual Chapter 5 Page 22 Add Edit Compounds Search for Compound v Multiple Single Molecular Compound CAS number Species Weight Density gm cc Ar 1 1 TRICHLOROETHANE METHYL CHLOR 00071 55 6 Single 133 00 1 2 2 TETRACHLOROETHANE 00079 34 5 Single 0 00 E 1 2 TRICHLOROETHANE 00079 005 Single OE 1 DICHLOROETHANE 00075 34 3 Single Of 1 DIMETHYLHYDRAZINE Ooos7147 Sine om gt 2 3 TRIMETHYLBENZENE 00526 73 8 Single 12000 2 4 TRICHLOROBENZENE 00120 8624 Single Of 2 4 TRIMETHYLBENZENE PSEUDOCUMEN 00095 63 6 Sin
32. cause the User defined Source data table is actually a generic spreadsheet type table in which the user defines the labels for data elements The General Description field is used as a Source Type subcategory for User defined Sources When the user selects the User defined Source Type in the Add Edit Emission Factors and Formulas window and then selects a General Description from the drop down list the windows on the screen appear slightly different but work the same way as for other Source Types The Column Labels window on the right side of the screen displays the user specified data element labels while the Columns window on the left side of the screen displays the actual column numbers i e from the data table The user double clicks on the column numbers in the Columns window on the left side of the screen to add a variable to the formula See Figure 6 3 ACM Calcs Manual Chapter 6 Page 34 Add Edit Emission Factors and Formulas New Select source type USER DEFINED vi Enter factor id Specific Description OTE Type of factor General description General Site Specific Compound Emission factor Emission Type Actual Data source C Maximum Stream Data Stack Test i moroa e ene Asa Formula for estimating E br Embed Formula sem include Figure 6 3 By clicking on the Embed Formula button a Formula Picklist is accessed showing previously defined formulas that can be
33. ces as a source type are as follows Product Type Percent Control Efficiency Throughput Saturation Factor Throughput Units Max Temp ACM Calcs Manual Chapter 4 Page 18 Average Temp Max Vapor Press Average Vapor Press Pumping Rate 4 2 10 Oil Water Separation Oil Water separators receive the wastewater flow from process drains and junction boxes and remove the oil from the wastewater The fields that are present with the selection of Oil Water Separation as a source type are as follows Stream Processed Separator Type Flow Rate 4 2 11 Spills Some spills of VOCs result in emissions The fields that are present with the selection of Spills as a source type are as follows Stream Spilled Spill Units Spill Amount Percent Vaporized 4 2 12 Storage Tanks Storage tanks have emissions as the result of vapor displaced during transporting of volatile liquids The fields that are present with the selection of Storage Tanks as a source type include but are not limited to the following Product Insolation Factor State Wind Speed City Pumping Rate Min Avg amp Max Vapor Pressure Constant Level Tank Y N Max Ambient Temp Tax Constant Temperature Tank Min Ambient Temp Tan The fields on the Tank Data tab such as diameter height or length and other variables change depending on tank type Floating roof tanks have an additional Tank Fittings tab for entering the number of columns hatches etc 4 2 13 Su
34. challenges to making alterations or updates because calculation methodologies are not explicitly defined but rather exist in hidden areas that would be familiar only to the workbook author such as cell formulas pivot tables and macro code Because Calcs contains explicit and readily observable methods for calculating emissions and speciating chemical specific emissions from Total VOC users generally find that calculating emissions in Calcs offers a superior work process than XLS based approaches Calcs Manual Chapter I Page I Responding to Emission Calculation Questions from the TCEQ the manual procedure for responding to TCEQ questions about how emissions were calculated usually involves a cut and paste of data from one or more worksheets The process of extracting portions of the data contained in spreadsheets that contain macros and formulas can itself be very challenging but the major drawback for manually preparing responses to TCEQ questions is the fact that the excerpted data rarely explains how calculations were done Thus CPC staff must describe their calculation methods in e mails or letters which introduces the possibility of inadvertently making an incorrect statement in such documents Calcs provides a special Emission Calculation Parameters report that can be produced for any Source or group of Sources with little time or effort That report presents the values of relevant process information used in the calcul
35. date range The Emission Calculation Parameters report will show the methodology information including formula value of variables used when calculations were done and the calculated emission values See Figure 6 6 ACM Calcs Manual Chapter 6 Page 36 TI Estimate Emissions Process Data Control Corp COMBUSTION SOURCES EMISSIONS CALCULATION PARAMETERS AND RE SOURCE ID 10HTRO64HC ADH PYDROLYZER WHCH ESTIMATION DATES 14196 12 31 96 ENNSSION SOURCE DATA UNIT ADM UNIT FUEL USAGE 140 86 mmscfiest LIQUID FUEL USED NULL FUEL TYPE COMBUSTED ADN HCN OG FIRING RATE 4 80 mmBTUhr POTENTIAL HORSEPOWER DESIGN RATE 0 00 mmBTUihr LOAD REDUCTION FACTOR 0 00 UTILIZED HORSEPOWER STREAM AND STREAM COMPOSITION DATA LIQUID MOLECULAR WEIGHT NULL HIGH HEAT VALUE 287 30 HHV Btuisct TRUE YAPOR PRESSURE WAPOR MOLECULAR WEIGHT NULL LOW HEAT VALUE NULL STANDARD TEMP NULL DENSITY NULL RYP NULL COMPOUND ESTIMATION EMISSIONS EMISSIONS EMISSIONS EMISSIONS METHOD Ibs hr tons yr Ibs est tons est NOX 2 5422 11 5727 22 257 6276 11 1288 VOC 0 0278 0 1220 234 7168 0 1174 ACETONITRILE 6 04 AT of VOC 0 0019 0 0083 16 0546 0 0080 PAGE 1 OF 3 Figure 6 6 6 3 Emission Inventory Summary The Emission Inventory Summary is a data table that contains all of the emissions for all sources and date ranges that have been calculated by the user along with critical explanatory information Click on the Inventory icon to bri
36. e below the target installation folder chosen by the user The installation routine creates a COMPASS folder under the programs group on the Start menu with the Calcs icon in place Double click on the Calcs icon to enter Calcs A login screen will appear asking for your User I D and Password 1 5 Using Help Help is provided on line with Calcs and is as extensive as the printed documentation The on line Help allows you to search by topic or keyword for the area in which you need help and categorizes and defines words and phrases giving you a clear picture as to what you are doing Calcs Manual Chapter I Page 2 When you click on the Help menu item a dialog box will appear with selections for using the help features of the system Users can search for a specific topic of interest using the Index or by reviewing subject areas Users may also review the version number of Calcs by clicking on the submenu item About 1 6 Technical Support of Calcs Technical Support of the system is provided by PDC Corp Please be aware that support technicians will be handling many users so you can help them by doing the following Careful reading of printed and on line documentation of the System Please carefully read this documentation to be sure that your question or problem has not been addressed Make sure that the Data Sources section in your control panel is configured properly to run the Calcs database which is called ACM db If you are not u
37. e of a specific user defined subcategory is created the user creates data element labels that will be used for all future sources of the same type and populates the data values at the same time on the Source Detail screen For example to add a new source called Reactor 101 to the system the user clicks on the Sources icon to add the new source and enters the Equipment ID as REACTOR101 no spaces The Specific Description might be entered as Reactor for Product XYZ The General Description which will serve as the source type subcategory might be entered as ReactorX YZ Then in the lower portion of the screen the user might identify label the first data element as Reaction Time with a unit of measure of Minutes The second data element might be labeled Chlorine Used with a unit of measure of Pounds The third data element might be labeled Temperature with a unit of measure of Degrees F Note that some data elements such as Potential Throughput and Operating Hours are pre defined Therefore they do not require adding a label to identify the data that is entered for these items The user could enter the values for these data elements at the same time that the labels are defined but this is not necessary All fields need not be used When the Detail screen is saved the user defined source type subcategory called ReactorXYZ will be stored in the system much like a source type
38. e units are other than wt they will be converted for you when you save the composition Click on the Save icon Click on the Close icon to exit out of this window 7 4 5 Editing Compound Data Compound properties are important for converting units of measure to a standard unit and they are also used in converting liquid compositions to vapor Be sure to complete these parameters before calculating emissions Otherwise the emissions cannot be estimated 1 2 Click on the Compounds icon Make sure the compounds you selected for your stream composition have molecular weights and vapor pressures data such as Antoine Constants 2 Parameter data or 5 point data If you made changes click on the Save icon which will update the database Click on the Close icon to leave this window ACM Calcs Manual Chapter 7 Page 50 7 4 6 Creating an Emissions Source An emission source is a piece of equipment inside of a process unit that performs a task that generates releases to the air There are several different types of emission sources They all have different operating parameters that are used to estimate their emissions Fugitive equipment leaks are the most complicated 1 moe ari She Io Click on the Sources icon Click on the drop down list to select a source type Choose Combustion Sources To enter a new combustion source type in an Equipment ID for the source Select the Unit and the Stream you created earlier Fill
39. ee Figure 6 19 Profiles Cale Cont Inventory Exit Batch Calculations Bee Footy Code sese Faupmentws z2 Je beite vers Jie Delete Roing Sum Emiss Description fest Unit 712001 x Volume 800 gals Machine PKS Step Parameters Charge Reaction Process Controt Calculations GA codes 88301 test E test test Step 1 Control Type Step 2 Step3 I Total Reflux Step 4 jeg 5 Nitrogen Sweep 2 0000 sefm Condensor Press mm Hg Condensor Temp dege Approach Temp mm degC Step Start Pressure ba E wemit test Step End Pressure 78 Figure 6 19 ACM Calcs Manual Chapter 6 Page 45 This control device is not a regulatory abatement device but a process control device such as a condenser or a scrubber The software performs a vapor liquid equilibrium calculation using the Newton Raphson computation method This calculation provides the final emissions after condensation scrubbing The resulting condensate can also be recycled to the system by selecting the Total Reflux checkbox The calculations yield percent control efficiency for each chemical This process results in generated emissions from a given step The Calculations tab displays vapor pressures vapor fractions moles of liquid and percent control efficiency achieved from the process control step See Figure 6 20 If there is no process control then the potential and calculated emissions are the same
40. emission based on the number of batches produced in a given year The software estimates the potential to emit PTE total uncontrolled emissions for a given source and the ERP maximum uncontrolled emissions 6 7 NY Using the Tabs to Navigate Batch Calculations Screens The user can enter any number of steps to simulate a manufacturing process Each step can be associated with heating pressurization and material charging activities The grade explorer on the left side of the screen keeps track of the various production batches being run Each grade product represents a batch from a production standpoint and it is associated with one or more steps involved in the manufacturing process The user specifies the operating parameters for each ACM Calcs Manual Chapter 6 Page 43 step for example the temperatures pressures etc See Figure 6 16 The user also chooses a flow condition which points to a control device network configuration utilized for emissions abatement mf E win a yeh SRE Halti Sum bere CTT step erations fee kanten Kees Sati nd rate NA r Tier sep ID FT I Vacuum Charge Ireni bees 1 bsp ames ina Hitrnginn Sa map GEK wim Slats wel 3 mente Niper 05 men lig Aug ices SIR nen Ra Yal Charged IA p Natal Wal Yke tl nl Linu tanrihnre nroe maau E oae Tar Tampe i dr Awy hip L deg i wanneTampe gt amt ful Lay Murex tt Moles spiret sess ee os
41. enu cmiacvrcieicdisdesuectoassysctoacessuniatnndeiedseacbessliennoekoundvcdetbs 8 2 9 5 Options MEN co a eis cu sr seas t tse paw eco so vad ea EEES ESE gos een sere 9 2 9 6 Maintenance menu cceeccceececcesceccesccccccecensccccaacccceueccccaecenee 9 2 9 7 Window Men aceinicicarscnacscccensndessaccossacecinededealonabansisindieacendbedaceceoxs 9 2 9 8 Help MENU EEE EE 10 2 10 Toolbar Configuration s seesesseesseeeesserssseeesserssssresseresssresseresssresseres 10 2 11 Comments on Data Items eoorroovornvvrnnvrnnevnnevrnnvrnnevenevenneernneenneeeneeeee 10 2 12 Steps in Entering Data into Cals c cccccsrecsccessesssvanesteeccasssetcennnsee 11 Calcs Manual Ore Facilite Ssss esiaren u E Rn TE R 12 EE EEE 13 3 3 Emission Sources Quick Edit Screen rvrvrvrvrnnvvvnvnvnnnvnvnnnvnvnnnnnenenes 14 TESSA SOUTC S Ge iaia ine E AEE E eden 14 3 5 port Functio siseses e E R AE Mann Rpaa intone 16 4 1 The Importance of Source Types sessssesravasvesensanessasnnsnekenpnsennnesdennnnnnr 17 4 2 Specific Source TT Pee 17 271 STEE D E E 17 4 2 2 Catalyst handling SOURCES ss casncsdessvsondsdennesarenncevstecadeveneonsmnages 17 223 Comb stion SOURCES sessirnir 17 4 2 4 Cooling TOWER SOuUrCesS sseseseseessereseseesseresssereesseeessseesseeresssees 17 4 2 5 Drains sumps and junction boxes rrrrrarnrrverennrnvrnnrrvsernneeenn 18 4 2 6 Equipment leaks 55 as sas ges saen ge cna yane ceeeh ee 18 42d FOC SOME senesenca
42. es of the reactants present during a given step and the reaction stoichiometry The limiting reactant is the chemical species that will be completely consumed during a given chemical reaction and the reactor will still be left with other reactants to spare Hence the reaction can only proceed when all of the limiting reactants are available The program also accounts for the percent completion of a reaction The maximum amount of limiting reactant that can participate in a given reaction will be dictated by the percent completion of the reaction t b S e e b A C D Facility Units Compounds Stream Prop Unit Stresmz Sources Batch Formus Profiles Cale Cont Inventory Exit e a 8 E sw SaveAs Calculate BatchCount Print Close Batch Calculations jD gt Facility Code Equipment ID Detete vear Delete Rolling Sum Emiss Description fest Unit T12001 2 Volume 600 gals Machine PS Step Parameters carse Reaction Process Control Calculations aA Codes J E 88901 test EET test test Complete Cas Num Rxn Side Moles Phase Weight RXH ID G 5tep1 fico 999 97 3 Reactant fv 1 9300 Liquid 310 7300 Step2 or 46 0 xd Product sj 1 9000 Liquid 308 5410 Step 3 664 41 7 zi Product yi 1 9377 Liquid 32 9999 Step4 Step5 EE wemh fest Figure 6 18 Each step can optionally be linked to a control device that is integral to the process S
43. ess 56 8 5 FT 57 8 6 Resolving Unprocessed Data s esesseeeseesesseresssresseresssresseresssreresesees 58 8 7 Common Errors That May Cause Data Not To Be Processed 58 Calcs Manual CHAPTER 1 INTRODUCTION TO CALCS 1 1 About Calcs The COMPASS Emission Calculation and Process History COMPASS Calcs or Calcs module facilitates the collection storage and reporting of Air Emissions data including emissions inventory and calculations and Title V permitting Other modules of PDC s COMpliance ASsurance System COMPASS handle MSDS management and other environmental health and safety compliance needs Calcs incorporates data from such items as stream composition and process rate and computes overall emission calculations needed for reporting purposes Once the data is calculated it can be automatically updated in the EI Emission Inventory section of COMPASS 1 2 Manual Procedures Affected by Calcs Maintaining Process Data from plant operations manual procedures that have been used to record process data from plant operations that are pertinent to emission calculations such as fuel usage run times and throughputs would likely be discontinued in favor of using the Calcs module for the following reasons a Although process data can be manually inputted into Calcs many users find it more convenient to export spreadsheets containing the previous year s process data for Sources of a particular
44. f for some reason the contractor has monitored components or streams that you do not need to report or calculate emissions from then simply ignore this highlighted row The data will not be imported After troubleshooting is complete you will need to reprocess the data from the Import window by selecting Process If rows are still incompatible the rows will be highlighted in blue Repeat this troubleshooting procedure until all the errors are found Remember if you find that you only need to make a change to a few items it may be quicker to manually input the leak count Do this by going to the Leak Count tab in Sources entering the leak count and saving ACM Calcs Manual Chapter 8 Page 59
45. feature that links to the MSDS database shown in Figure 5 6 SACH Calcs Emission Calculations Program le Data Window Help F bb P amp E F o a mm amp F ae Ag Erase Inzert Delete MEDE Print Close E E b Compounds Stream Prop Unit Streams Sources Batch Formulas Profiles Calc Cont Inventory Exit FM Add Edit Stream Properties and Compositions New Figure 5 6 The Stream Properties icon is also used to display add change or delete materials that are used by continuous Sources such as fuels loading materials and tank materials ACM Calcs Manual Chapter 5 Page 27 5 5 Stack Testing Stack Testing provides storage of data derived from laboratory analysis of streams as well as pertinent operating conditions data To enter the Stack Testing portion of Calcs click on the Maintenance menu and select Stack Test from the list This will open the Add Edit Stack Testing Information window See Figure 5 7 Add Edit Stack Testing Information New Enter Facility code CG0010G Standard Conditions are 68 F 20 C and 29 92 in Hg Enter source type v 1atm Enter test id 3 Test description Equipment id 3 Method FT Stack temp in F Datasource or Lab EEE MW of fluegas He Date sampled a Stack gas velocity brybasis flowrate sefm ft sec Actual flowrate acfm Wet basis flowrate pane scfm Feedrate to the unit E Feedrate comments Compound DL BDL Concentrat
46. foFLROodA foFLRODAA NOx foFLRooda florLRooss Fo Fontross ffOHTR 064 NONMETHANE YOC U 215 otal Rows 4 PE Figure 6 10 ACM Calcs Manual Chapter 6 Page 39 In addition to copying emissions the Pipeline feature also applies control efficiencies for all connected control devices and prorates emissions to connected emission points Selections are available to turn these special processing functions on or off The Zero Out option will change all actual emission rate values to 0 before the pipeline is done including emissions that are not affected directly by the Pipeline Otherwise if this checkbox is left blank emissions that are not affected by the pipeline will retain their current emission rate value 6 4 1 NY Pipeline dl The data Pipeline is accessed by clicking on the Pipeline icon in the COMPASS folder As shown in Figure 6 11 the main toolbar has two reference lists to assist the user to synchronize data between CALCS and WinCeis for the export of emissions They are Equip which displays equipment relationships and Contam which displays a list of chemicals with the WinCeis assigned contaminant code and CALCS assigned CAS Number In order for chemical specific emissions to transfer from CALCS to WinCeis it is necessary for the correct CALCS assigned CAS Number to be correlated with the related WinCeis Contaminant Code CALC to EI Pipeline File Actions Window Help AE DE SEE Parameter Emissions Expo
47. for Batch Processes The Batch Calculation feature and related features such as automatic updates from production and materials databases are custom features that were added to the CALCS module especially for New York Program functions related to creating Formulas and Profiles for continuous Sources calculating emissions summing secondary and primary Sources and other features are explained in the standard CALCS user s manual Batch calculations require extensive setup data to be entered into the system to identify how the batch processes operate Once created the Batch Source information may be updated with a more streamlined set of information to calculate emissions for future time periods The Number of Batches field an important data element that drives significant portions of the emission calculations can be updated automatically from the PIMS database through a feature that is explained in the next section See Figure 6 14 This section concentrates on manual data entry by engineers or technicians who understand batch processes and are familiar with the type of information that will be required by the system to calculate emissions ACM Calcs Manual Chapter 6 Page 42 Cloze a amp 4 Kr 2 U D EB 0 Facility Units Compounds Stream Prop Unit Streams Sources Batch Formulas Profiles Cale Cont Inventory Exit 20 z a amp F Save Swaas Caleulste Bateh Count Print Batch Calculations ioj xj Facility Code E SL
48. gle 120 20 E 2 DIBROMO 3 CHLOROPROPANE 00096 12 8 Single 0 00 2 DIBROMOETHANE ETHYLENE DIBROMI 00106 93 4 Single 0 00 E 2 DICHLOROBENZENE 00095 50 1 Single 147 01 i 2 DICHLOROETHANE ETHYLENE DICHLO 00107 06 2 Single 0 00 2 DICHLOROETHYLENE 00540 59 0 Single 0 00 E 2 DICHLOROPROPANE 00078 87 5 Single 0 00 m 2 DIPHENYL HYDRAZINE HYDRAZOBENZ 00122 56 7 Single 0 00 RE 4 Figure 5 2 To add a new Compound click on the Insert icon This will bring a blank field listing at the bottom of the existing lists of compounds Simply enter the data using the tab key to move to the next field When you have added the new compound click on the Save icon This will update the database Compounds are not related to any operating Facility the same compound list is used or can be used for all plants To delete an existing compound click on the Delete icon Be careful when you are deleting compound records as there is no confirmation window in this section To print a listing of compounds click on the Print icon 5 3 Streams To work with Stream data click on the Unit Stream icon Note that this icon is different from the Stream Properties icon This will open up the Add Edit Streams window See Figure 5 3 It is assumed that the Stream Property i e composition for any stream that will be added in this part of the program already exists See Section 5 4 for adding Stream properties ACM Calcs Manual Chapter 5
49. he columns so they never leave the screen by clicking on the small black bar at the left of the horizontal scroll bar and dragging the black bar to where you wish to split the screen Once that is done there will be two horizontal scroll bars at the bottom of your screen Leave the Stream Composition field blank since we have not yet created the composition Click on the Save icon to update the database Click on the Close icon to leave this window 7 4 4 Creating a Stream Composition A Stream has several physical properties and is a mixture of several different compounds When this mixture is processed it emits these compounds into the air Estimated multiple species compounds are speciated based on the weight percent of the compound in the stream Stream properties are important for converting units of measure to a standard unit and they are also used in converting liquid compositions to vapor Be sure to complete these parameters before calculating emissions Otherwise emissions cannot be estimated 1 2 ON a a Click on the Stream Properties icon To create a new composition Enter Lab Sample ID and press the tab key to move to the next field Enter the Sample Description for the composition Fill the remaining fields in the top portion of the window Click on the drop down list box under Compound to select Benzene Type in 7500 as the concentration of the compound you have added and select ppmw as the unit of measure If th
50. he reason why the blank column exists in the Totals file is that the two files need to have the same number of columns so that Calcs can import the files correctly The contractor format will read 01 01 2007 01 31 2007 NSPS ASPHALT and so on Note the 2 commas that indicate a blank column 8 6 Resolving Unprocessed Data After you have imported contractor equipment leak data and have run the Process data step you may find that a number of records could not be processed This is because something in Calcs is not linking correctly with the contractor data You may have left a necessary piece of information out of a record the contractor may have added streams that you don t have input in your records and so on The rows that could not be processed are highlighted in blue on the Import and Process screen You may view these rows by scrolling down the file line by line Note the first highlighted row Without closing this screen click on the following items to determine what the problem may be Do not close the import screen or you will have to repeat the entire process of importing and processing the data You may have many windows open at one time and an easy way to switch between open windows is the select Window from the menu bar and the correct window to view 8 7 Common Errors That May Cause Data Not To Be Processed If you find that you only need to make a change to a few items it may be quicker to manually input the leak co
51. ications are done to your satisfaction click on the Save icon This will update the database with your edits To print the current streams click on the Print icon 5 4 Stream Properties and Composition You may work with Stream Properties and compositions by clicking on the Stream Prop icon This will open up the Add Edit Stream Properties and Compositions window See Figure 5 4 AM Add Edit Stream Properties and Compositions 1032 Enter lab sample id fi 032 v Sample description Lo BOIL WASTE TK There could be High heat value meer Low heat value many compounds HHV Btu sef LHV Btuiscf for each MW liquid phase 580 CALC MW vapor phase 9 87 CALC Stream Property record z perty RVP psia Composition phase Vapor z red cig iy P33 Sulfur content in ppmw 2 00 MW Reference F jsn Temperature Sample date EST Data source or Lab pu PONT Compound Concentration Units Cut concentration Cut units 2M38N v if 0 6785 v i 0 6785 pi BENZENE v p7 1808 v B7 1808 ht pan v p 8022 E 8022 priae MON yp 0626 gt p 0626 fvt T2M28N v 2759 v pz 2759 p Total Concentration in WT 100 0000 100 000 Figure 5 4 ACM Calcs Manual Chapter 5 Page 25 When adding a new Stream Property you may enter all of the compounds that are present in the composition Composition data is required for streams that will be speciated based on the weight percent of components in the vapor phase in which case the composition data may be e
52. ion Units Emissions Ib hr 5 Figure 5 7 The Stack Testing data entry window allows you to enter information after selecting the Facility and Source Type via drop down lists Enter the new Test ID and the rest of the relevant data values Near the bottom of the form is the Compound entry where you may enter as many compound values for that test as needed Once you have entered the new test data click on the Save icon This will update the database with the new test information Minimum data requirements for a new stack test include Test ID Test Description Equipment source ID and at least one compound To make modifications to an existing test select the Test ID from the drop down list after selecting the relevant Facility and Source Type The previously entered data will appear along with the list of compounds If you only need to make modifications and not delete any portion of the compound record simply make the necessary edits and click on the Save icon You may cancel certain compound entries by selecting the particular compound record and clicking on the Erase icon It is important to note that Erase clears the compound record while the Delete icon clears the entire Test ID record Use the Delete icon only when you need to delete the entire portion of data appearing on your screen You may also use an existing Test ID to create another similar ID by making necessary edits and clicking on the Save As icon This will
53. ion about that emission source Create an emission profile Create and use a compound list Estimate air emissions for an emission source Access print the different types of emission reports 7 3 Step Overview The following steps are what you will be doing in the tutorial You will create a process heater and estimate the VOC emissions and speciate the benzene emissions Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Creating a unit Calcs is designed to estimate emissions for sources included in a unit Creating a process stream process unit has several incoming and outgoing streams to perform its ultimate process This is where you define those streams and link them to the process unit Creating a stream composition A stream has several physical properties and is a mixture of several different compounds When this mixture is processed it emits these compounds into the air Editing compound data Compound properties are important for converting units of measure to a standard unit and are used in converting liquid compositions to vapor Creating an emission source An emission source is a piece of equipment inside of a process unit that performs a task that releases contaminants to the air Creating an emission factor An emission factor is actually a formula for calculating emissions for a particular compound You build this equation by selecting parameters for the source you are building the equat
54. ion for Creating an emission profile An emission profile is a group of emission factors and compounds to be speciated After you build a profile once you can link it to several pieces of equipment for that source type ACM Calcs Manual Chapter 7 Page 48 Step 8 Linking the profile to the emission source A profile has to be associated with a piece of equipment before you can estimate emissions Otherwise the system would not know how to estimate emissions Step 9 Estimating emissions This window provides you with different search criteria for calculating emissions Step 10 Viewing printing the different reports Now that you have calculated emissions you are ready to see the results There are several different report options 7 4 Proceeding With the Tutorial 7 4 1 Log Into the Database Before you start the tutorial you will need to log into the database Follow the directions in Logging onto Calcs in Section 1 7 7 4 2 Create a Unit Calcs is designed to estimate emissions for sources included in process units Therefore the first step in estimating emissions is defining one or more units such as a powerplant or a sulfur recovery complex 1 Click on the Process Unit icon 2 A window with a list of resident process units appears Click on the Insert icon 3 Enter a name for the process unit you are creating e g Process Unit SRU 4 In the Process Unit Number column type an ID number that corresponds w
55. is communicated to the user from a sample analysis the Add Edit Stream Properties and Compositions window includes data elements such as Laboratory Name and Sample Date which enable users to store the source of the analytical data as well as the composition ACM Calcs Manual Chapter 5 Page 26 5 4 1 NY Stream Properties and Composition dl The CALCS module depends on Stream Properties information to determine emission rates of the specific chemical constituents that make up a material Each material may be defined in the program by clicking on the Stream Properties icon on the main toolbar as shown in Figure 5 5 8 EE BE A GC nh E HE amp Facility Units Compounds Stream Prop Unit Streamz Sources Batch Formulaz Profiles Cale Cont Inventory Exit Save Save As Erase Insert Delete MSDS Print Close ja 23 Ze hme Figure 5 5 A material composition is referred to as a Lab Sample Id In the standard version of the CALCS module a drop down list of Lab Sample Id s is displayed from which the user selects one item to edit or delete In the New York version due to the large number of potential materials gt 200 000 items users enter the Lab Sample Id that they wish to view change or delete next to the phrase Enter Lab Sample Id If the material was previously entered it will be found and displayed Otherwise the program will assume the material will be added to the list Compositions may be updated automatically by using a
56. is labeled Rename to FIN on the Rename screen as shown in Figure 6 13 The Err Reports icon enables users to review reports that can explain why a calculated emission rate is not transferring from CALCS to WinCeis There are three possible reasons 1 The Source Id s don t match 2 The equipment relationship has not been defined or critical data showing the percent of flow from Sources to Control Device s and or Emission Point s is missing or 3 The CAS Number for the chemical that is being emitted as shown in CALCS has not been associated with a valid WinCeis contaminant More than one of these three conditions could exist at the same time If one or more conditions do apply and are interfering with the Pipeline users can easily correct the missing or incorrect data related to Source Id s flow routing or contaminant code CAS Number assignment and re try the Pipeline when corrections are finished ACM Calcs Manual Chapter 6 Page 41 kj CALC to EI Pipeline File Actions Window Help SB amp fe p T Parameter Emissions Export Contam Equip Rename Exit amp F Print Close 6J Align CALCS Sources to EI FINS Faciny Account VC0008Q Jenta a Description a p41 WN INTER TK FARM SU OFLR 005 SS eS eee horos y pren PIAMNEFLARE YRO COND fortrosa OTHER OPIAMINEFLAREQNTREE WA forros TI C fane free CONOCOC a Figure 6 13 6 6 NY Emission Calculations
57. it limit and reference data into rows of the Emissions Inventory Summary window These items are located on the right side of the window and must be accessed by moving the horizontal scroll bar to the right Users may sum up emissions from Secondary Sources into Primary Sources by clicking Data and Sum Emissions while viewing emissions in the Emissions Inventory Summary window All Primary Sources are listed at the top of the Sum Emissions To Primary Sources window When a Primary Source is highlighted by a single mouse click in this window all emissions from related Secondary Sources appear in the bottom portion of the screen See Figure 6 8 M E amp F k 2 n E E Faziity Wsie Componde irean Prep bntkame Soursce Fonds Profe Cikuhta Irvsmtorg Exh Mr Irise Srerch Crizeriz Cleo Sum kEmitsione 10 Premary Source PRIMARY EMISSIONS BY COMPOUND 7 Remove Zero Emiesiene Select AN Pi imay Sources IEE FER Deselect All Primary Sources Sum and delete amiesione Sum and restore emissions Primary Equipment ID General Desci iption ATHER 121196 AYDROGEM CYANIDE OFLROOSA OTHER 1251 96 SMMONA OFLROOSA OTER 120196 X OFLROOSA OTHER 120106 NC AFI RASAI OCHFR 13RA SEFFAF OFLROSAI OVER 1201 30 MEROSON CANIDE Figure 6 8 Several command buttons enable the user to sum up the Secondary Source emissions into the Primary Source and to delete them or not delete them depending on the button that is pu
58. ith the name you gave the process unit e g PU1 5 Use the tab key to move into the other columns to enter the necessary data 6 Click on the Save icon to record your process unit to the database 7 Click on the Close icon to exit this window 7 4 3 Creating a Process Stream process unit has several incoming and outgoing streams to perform its ultimate process This is where you define those streams and link them to the process unit Like the process unit itself streams are generic in nature Thus the same process stream e g Natural Gas may be used in more than one Facility There are several stream parameters that are needed when estimating emissions in the vapor phase using a liquid composition Be sure to complete these parameters before calculating emissions otherwise emissions cannot be estimated 1 Click on the Unit Streams icon 2 A window appears with the resident process streams Click on the Insert icon which will insert a new blank row 3 Enter a name for the Stream Name e g Process Stream 1 4 Use the tab key to move forward to the Stream ID column where you will assign the new process stream an ID number e g PS1 ACM Calcs Manual Chapter 7 Page 49 T 8 9 Tab to the Unit column and click on the drop down list to display the list of units and select the process unit you created in the previous step As you move through the columns the stream name scrolls off the screen You can fix t
59. l Chapter 6 Page 46 l a amp pg Formule Profiles CokCont Inventory Exit Batch Calculations ol x FectityCoae ce st Equipmentwn 23 x Delete vear i935 J Delete Rolling Sum miss Description fest unit T12001 Volume 1200 gals Machine PKS Step Parameters Charge Reaction Process control Calculations QA Codes E 88901 test test test Step 1 vessel volume is missing or Step 1 does not contain any charging Ether density or MW data is missing for one or more compounds Ine or more operational parameter for Step 1 is missing or is not correct Step2 Step3 Step 4 6 Forthis step the end pressure may not be correct B or this step the start temperature may not be correct j or this step the end ternperature may not be correct f or this step the vp override temperature may not be between the start and end temperature iii g SEHRE z T M i led BARE i or this step the nitrogen sweep rate may not be correct or this step the time may not be correct For this step the volume of the material in the vessel exceeds the volume of the vessel itself HEJ wermi test Figure 6 21 6 8 NY Rolling Sum of Emissions WinCeis data is used to produce a report that shows the Rolling Sum of emissions from Batch Sources This feature is run from the Batch Sources screen in the CALCS module as shown in Figure 6 22 When run for a specific Source this fea
60. l emissions from the reactor vessel i e all steps All Sources are automatically deemed to be Primary unless indicated otherwise in the Equipment Maintenance window This window is accessed by clicking on Options menu while the Sources screen is open Only the Account needs to be selected in the Add Edit Sources window prior to retrieving the Equipment Maintenance Each row in the Equipment Maintenance window represents one Source as identified in the first column of the screen display The column located along the right margin is used to indicate if the Source is secondary to a Primary Source To indicate this users click in this column and select the Primary Source from the drop down list of all sources The Primary Source for which Secondary Sources have been identified is also highlighted but the same Source ID is selected from the drop down list for the Primary Source i e it is a primary source related to itself as a primary source The actual summing of emissions from Secondary Sources into Primary Sources is done from the Inventory window by clicking on the Data menu item and then on Sum Emissions The Equipment Maintenance window is also used to correct or change a Source Type for a Source This is accomplished by clicking on the second column entitled Source Type and selecting the correct Source Type from the drop down list Specific and general descriptions for Sources may also be edited in the Equipment Maintenance window
61. las New Select source type STORAGE TANKS Enter factor id Specific Description Type of factor General description yv S Gene You may use these buttons Compound ake Specii like you would on a calculator p Emission Type Emission factor EF units v Actual Data source C Maximum Columns Column labels Columns to include STREAM_MASTER tempf_std in F atmospheric_press_pa Stream Data STREAM MASTER tup std in psia avg clingage fac c Stack Test TANKS atmospheric press p in psia brtr vent pr setrange BREATH TANKS avg_clingage_fac_c in column diameter fc COLUMI xY 1E TANKS brtr_vent_pr_setrange in TANKS column diameter fe in gt TANEC annet lanal tl far in Formula for estimatina E Ib hr ef Figure 6 1 To add or modify formulas you must first select the Source Type for the formula If you are adding a new Factor or formula enter the new formula name in the Factor ID field If you are modifying an existing Factor ID select that ID from the drop down list box Once the Source Type and Factor ID to be modified are selected the form accepts data in all other data fields See Figure 6 2 ACM Calcs Manual Chapter 6 Page 33 Add Edit Emission Factors and Formulas PRSH WT Select source type STORAGETANKS tsi Enter factor id fra o i Specific Description FIMEDROOFFACFORWIT Type of factor The resulting fo
62. lfur Recovery Sources The fields that are present with the selection of Sulfur Recovery Sources as a source type are as follows Sulfur Recovery Efficiency Percent Emitted Units Sulfur Produced CEM Type Produced Unit CEM Concentration Tail Gas Emitted Type of Exit Flue Gas ACM Calcs Manual Chapter 4 Page 19 4 2 14 Wastewater Treatment Systems Wastewater treatment system filters process wastewater from plant water runoff including equalization tanks aeration tanks clarifiers dissolved air flotation units lagoons etc The fields that are present with the selection of Wastewater Treatment Systems as a source type are as follows Stream Processed Flow Rate Flow Rate Units 4 2 15 User Defined Sources Enter the Source Type User Defined if none of the other Source Types fit the description for your specific equipment or if the calculations for a particular source will be facilitated or simplified by using the User Defined category When a user makes a new source and identifies its source type as User Defined the General Description that is entered for that source will be used by the system as a source type subcategory Examples of such subcategories include Blowdown Losses Reactor and Process Vent For each user defined subcategory the user can customize the data element labels that will be used by the system on the Detail screen for all sources that have the same General Description Thus when the first sourc
63. nce of the system ACM Calcs Manual Chapter 5 Page 24 The extra time that is spent in set up for streams and compositions is more than offset by the increased convenience and more powerful maintenance capabilities that result from this aspect of the system Streams as well as Stream Properties and many other system entities are not related to any specific operating Facility Even though streams are related to Units the Units themselves can be generic if the user wishes to set up the database in this manner For example if a company has several gas processing plants that have Amine Units the Unit called Amine Unit can be entered only once and an associated stream such as Amine Gas can also be entered only once This stream can be associated with Sources located in several different operating Facilities To add new streams to the database click on the Insert icon This will open a field box at the bottom of the current field listing where you may enter data Much of the data to be entered in the Streams window consists of drop down list boxes Simply click on the drop down portion of the box and scroll down until you find the desired entry The Stream Composition is one such drop down list You may also modify existing stream data by clicking on the field of the stream record you wish to modify Simply overwrite existing data or make another selection with the drop down field listing After stream additions and modif
64. nd double click on COMBS Operating_hours The final formula should read ef cvt_fuelusage operating hours Spaces are allowed for readability and ignored in the calculations Click on the Save icon 10 Click on the Close icon ACM Calcs Manual Chapter 7 Page 51 7 4 8 Creating an Emissions Profile An emission Profile is a group of Formulas and Compounds for speciation After you build a Profile once you may link it to several pieces of equipment for that source type 1 Click on the Profiles icon Click on the drop down list to Select Source Type Select Combustion Sources Enter Profile ID for the new profile Type in a Profile Description Select No for Use vapor phase composition Dur GID general emission factors for combustion sources appears 7 Scroll to the VOC emission factors and click on the EF Code or formula you created Click on the OK button 8 Now choose Compositional Analysis Manual for the Speciation method A popup window with a list of multiple species compounds appears Select VOC and press OK 9 Click inside the blank Compound field 10 Press B and choose Benzene from the list 11 Click on the Save icon 12 Click on the Close icon 7 4 9 Linking the Profile to an Emission Source Another method for linking profiles to source is described in the following six steps Step 1 Click on the Sources icon Step 2 Click on the drop down list to select a Source Type Choose Combustion Sources
65. ng up an Emission Inventory Search Criteria screen that enables users to specify the scope of the emissions data that will be reviewed After the Facility ID time frame and other filter criteria have been entered in the criteria screen the user clicks on the Retrieve command button to access the Emission Inventory Summary window See Figure 6 7 Emissions Inventory Summary Iof x Source id Start date End date Compound E Ibperhr E tonsiest Max Ibperhr Max Tons est Meth 1OHTROB4HC 01011996 12 31996 ACETONITRILE 0 0019 0 0080 DUPONT TOHTROBSHC 0101995 12 31996 ACRYLONITRILE 0 0001 0 0004 DUPONT TOHTROB4HC 01014995 12 31998 CH4 0 0233 0 0982 DUPONT 1OHTROS4HC 01014996 121311995 CO 01009 0 4249 PYROCO vomasa fOMTRUGAREONNASS f2mvsM HYOROGENCYANDE owas ooe pwo WCO00BQ 1OHTROB4HCO1M1N998 12 31996 NOX 26422 111288 PYRONO WCO008Q 4OHTROB4HC 01014996 12 31 1996 PROPIONITRILE 0 0000 0 0002 DUPONT VCO00BQ 10HTROB4HC 08011996 12314996 VOC 0 0279 0 1174 PYROLVI Figure 6 7 You may delete rows from the Emission Inventory Summary window by selecting the row and clicking on the Delete icon Multiple rows may be deleted by selecting one row and then selecting another row while holding down the lt Shift gt key This will highlight all rows between the 2 rows selected with the mouse Click on the Delete icon to delete any highlighted rows ACM Calcs Manual Chapter 6 Page 37 You may also enter Perm
66. nit to work with in Calcs and you may modify existing Units The same Unit may be used in multiple Facilities because it is a unit rather than a physical area in a specific plant Units are associated with process streams and emission sources in Calcs 2 3 Compounds You will need to define all chemical Compounds for emission calculation purposes Compounds are unique to Calcs because there is no corresponding entity linking the compounds to another module of COMPASS Compounds are either single or multiple species compounds identified by a unique CAS Number which may be a real or dummy CAS Number Most of the columns that are presented to the user on the Compounds Detail screen contain physical chemical data such as molecular weight TVP and the coefficients to be used for vapor phase speciation i e 3 parameter equation coefficients 2 parameter coefficients or vapor pressure temperature data points for five different temperatures Columns are also provided for SARA and HAP chemical identification these flags are used under the Compound List icon to make compound lists that contain only SARA or HAP chemicals A Category column is also provided so that users can produce criteria pollutant summary reports as available under the Process Unit Reports on the Calculations window 2 4 Streams and Stream Properties Streams and Stream Properties are unique to Calcs as you may add modify and delete existing Properties Stream Pr
67. ns menu within Calcs allows you to select a default Facility to work within Once the Facility is selected you may only do data modification on equipment or sources within that facility until you select another default facility See Figure 2 5 Emission Calculations Program Reference Emissions Options Mainta Setup Figure 25 Select the riafanlt Canil 2 9 6 Maintenance Menu The Maintenance menu Figure 2 6 has five options and is viewable only when all screens are closed Stack Tests has fields for entry of stack test results to be used later as a basis for emission rates Compound Lists are lists made by the user for emission calculation of only certain compounds Source Type Display allows rearrangement of the order of Source Types in pick lists Disable Formula Edit allows locking and unlocking of general formulas such as those from AP 42 Cleanup Database is generally used after calculating emissions to remove streams not used in the database stream compositions not linked to a unit stream records showing zero emissions and emissions not linked to current accounts or sources Options Maintenance Window Help B Stack Tests op Unit stre Compound Lists Source Type Display Disable Formula Edit Cleanup Database Profiles Figure 2 6 2 9 7 Window Menu The Window menu allows you to manipulate the Data Windows into the structure you wish to operate in Calcs The Window menu also allows you to bring up the
68. ntered for the liquid or vapor phase of the stream For streams that will not be speciated such as a fuel for a boiler composition data is not necessary but BTU value probably will be needed for a calculation which is also entered on the same window To enter compounds for the composition simply make the selection from the drop down listing under the Compound section of the screen When you are finished adding the data click on the Save icon This will update the database The accuracy of certain calculations such as Stream TVP will depend to a great extent on the completeness of the composition analysis that is entered into the Stream Property Hence a running tally of the percentage of total stream composition is displayed in weight percent at the bottom of the screen while users input composition data Note that a wide range of units of measure may be used to enter compounds in the composition e g weight percent weight fraction ppm etc When the Save icon is clicked by the user all composition amounts that are entered in units other than weight percent are automatically converted into weight percent To modify existing properties select the property you wish to modify from the drop down listing at the Enter Lab Sample ID field box Selecting one property from the list will fill out the form with the data that has been previously entered Simply make needed changes and click on the Save icon You may also add or delete existing
69. ompt the user to Select the files for use in the correlation equation Choose the Leakers file that corresponds to the correct estimation period and Calcs will read the actual leak rate values from the Leakers file and input them into the correlation equation This will take several minutes because Calcs will have to import the file again Repeat this process for each estimation period When all the emissions have been calculated once you may select an estimation period that spans all the estimation dates to sum up these emissions if you mark the box Use Existing Results before selecting Run For instance if you chose to set up monthly estimation dates for the year 2007 you may choose 1 1 2007 12 31 2007 in this window to calculate the emissions for the entire year If no correlation equations were used to estimate emissions only emission factors used you may choose 1 1 2007 12 31 2007 whether or not you had calculated emissions once before This is possible because Calcs does not have to pull in any import files for emission factors You may also calculate multiple date ranges simultaneously for any other Source Type in Calcs You may display the results in several different report formats if you choose Options and the desired report under General Reports or Process Unit Reports Select Use Existing Results and then Run The Source Detail report will give you the most detailed information including a listing of the leak counts This repo
70. operties define each stream which are contained under one or more Process Units Stream properties may be used in emission calculations Streams are generic liquid or gaseous fuels materials or emission streams A single stream may be used in multiple Facilities Only the data that will be used in a calculation formula is required to be filled in For example BTU value of a stream is important for fuel streams and it may be left blank in a tank or loading stream COMPASS Calcs Manual Chapter 2 Page 6 2 5 Sources Sources are the sources of the emissions you will be calculating Sources include boilers engines flares manufacturing process units and other equipment as well as area sources that generate air emissions Unlike units and streams sources are Facility specific 2 6 Emission Factors You will need to define both the Emission Factors or Formulas and the corresponding equations for the emission sources contained within each Facility Only when these factors are defined will you be able to calculate emissions 2 7 Profiles Emission Profiles are groupings of factors and formulas that are used to calculate a range of contaminant emissions for a source 2 8 General Equipment Information You will need to associate Sources with emission Profiles prior to calculating emissions This task is accomplished under the General equipment information tab Additional equipment information and emission point parameters may also be sto
71. ovided to go to the next or previous page of the report print the report or Zoom back to the calculate window Print Preview feature is available under the File menu 7 4 11 Displaying and Printing Reports Once Emissions are calculated you may view the results There are several different report options as discussed below 1 Select the desired report format from the Options menu There are two types of reports General and Process Unit A total of eleven different formats are provided in these two categories Under General Reports all reports that have the word Summary in the report name will sum up emissions for the time period that was selected on the calculation screen and they will only display the total emission rate All other reports will present emissions separately for each time period for which process history data has been entered To continue this lesson select the Source Specific report under the General Reports category Click the Use Existing Results checkbox in the Calculation Criteria This will unclick the calculate button Click on the green Run flag to view the report Repeat this process for all the reports To view a summary report change the begin date to at least two years before the end date so that it will pick up the previous results Click the Save icon Select the Close icon To exit Calcs select Exit from the File menu or the X in the upper right corner of the screen then Yes in the
72. put to the screen 4 Select Process on the toolbar This function inserts the total counts in the appropriate row in the leak counts tables in Sources Next it will calculate the zero leakers by subtracting the number of leaking components from the number of total components Some of the rows may get highlighted in blue This means that the data does not match with the information in Calcs When processing is complete a status box will appear saying either that the process was successful or that the contractor supplied data could not be processed Click OK 5 If certain rows could not be processed see Section 8 7 on how to resolve data that could not be processed Correct the data and repeat Step 4 6 Close out of this window and select Sources Select an Equipment Leak emission source and proceed to the Leak Count tab Check to see that the process worked 7 Repeat all importing steps for the remaining estimation periods 8 4 Calculating Emissions After importing the Contractor Data you are ready to calculate emissions Go to the Calculate window and calculate emissions for the Equipment Leak sources as you would for any other source ACM Calcs Manual Chapter 8 Page 56 If correlation equations are used to estimate emissions the user must enter estimation dates that correspond to the estimation periods used when setting up the emission sources and do a calculation for each estimation period i e 1 1 2007 1 31 2007 Calcs will pr
73. r by using the previously created ones Enter and modify Compound data that will be needed for emission calculations Assign Stream Properties and create stream compositions from Compounds previously entered Calcs will automatically convert entered stream data into proper standard units of measure and it will notate the stream type Alternatively use an existing stream type Associate process streams and Units in the Unit Streams screen Create or modify emission Sources and define all types of equipment that create emissions Link the source to Units and Streams Enter stack test data from the Maintenance menu if such data will be used in emission calculations Create or edit an emission factor or Formula for each contaminant that will be emitted Create a Compound List if desired Create an emission Profile which is a list of Formulas or Stream Compositions Alternatively use profiles that already exist in the system Link the Profile to an emission Source Estimate emissions with the Calculate screen view and print reports COMPASS Calcs Manual Chapter 2 Page 11 CHAPTER 3 CALCS ENTITIES 3 1 Operating Facilities You may view and modify Facilities that exist in Calcs Provided Facilities are resident in COMPASS they will also be present in Calcs To enter the Facility section of Calcs select the Facility icon This will bring up the Facility Information window See Figure 3 1 where you may add modify or
74. r right corner of the screen that corresponds to either Emission Factor or Correlation Equation For the monitoring program you may select ALL if the factor correlation equation works for all the programs entered in Reference Equipment Leak Reference Data Monitoring Programs For the equation if you want to raise a number to a power select the button on the square button to the left of the equation box When is selected the formula f_exp x y will appear which represents xy You need to replace the x and p with the actual values For instance 5 would be f exp 5 3 and leak_ o would be f_exp leak_rate 0 82 Step 9 Set up an Profile for calculating Equipment Leak emissions based on the factors set up in Formulas When selecting estimation methods you may choose both correlation equations and emission factors which you may have set up for different leak ranges in Step 8 Step 10 Link each Source to the Profile You may do this faster for multiple sources in the Profiles window by selecting Options Link Equipment 8 3 Importing Contractor Data The second file is a listing of the total number of components by stream in the plant during that estimation period The information must be in a specific format From the main window select Reference Equipment Leak Contractor Data Import and Process Leak Counts This will bring up the Import window ACM Calcs Manual Chapter 8 Page 55 8 3 1 Leakers Always en
75. rce Type Equipment ID s and the Begin End date range to establish the necessary parameters for emission estimation Source data such as fuel usage pertinent to this date range will be utilized in the emission calculation procedure You may click on the Up Down arrows that appear on the right side of the date entry windows to change the Year Day and Month after clicking in the appropriate area of the Begin End data for the change The begin date will automatically default to January I of the preceding year while the end date will default to December 31 of the same year You may specify a Begin End date range that is longer in duration than the date ranges used for source data For example if monthly fuel schedules have been entered for January February and March of 2007 and the total fuel burned for the same source was entered for the period June I through December 31 of 2007 then an emission calculation may be run for all of 2007 for the first quarter of 2007 or for the month of March or any month mentioned However an emission calculation could not be performed for the month of July or for the third quarter because source process data does not exist for such time periods After emissions have been calculated for the desired sources click on the Use Existing Results check box and select a new report format from the Options menu For example a Source Summary report will sum emissions for all embedded date ranges within the Begin End
76. rce type are as follows Stream Processed Number of Controlled Sources Number of Uncontrolled Sources 4 2 6 Equipment Leaks Equipment Leaks represent fugitive emissions These emissions come from equipment like pumps compressors flanges and valves Before you may add data under this source type you must have already set up the Leaks data in order for the stream name to appear in the drop down list For the information needed on Equipment Leaks see Chapter 8 Equipment Leaks The fields that are present with the selection of Equipment Leaks as a source type are as follows Monitoring Program Stream Name VOC Percentage 4 2 7 FCC Sources FCC Sources are Fluid Catalytic Cracking Units that have various emissions The fields that are present with the selection of FCC Sources as a source type are as follows Type of Flue Gas Wt Sulfur in Feed Fresh Feed Amount Flue Gas Coke Ratio Coke Production Electric Precipitator amp CO boiler Wt Sulfur in Coke 4 2 8 Flares Flares burn gaseous waste products from refineries The fields that are present with the selection of Flares as a source type are as follows Type of Gas Flared Quantity Flared Flare Efficiency Flared Units Crude Processed Processed Units 4 2 9 Loading Rack Sources Loading Rack sources represent emissions due to loading losses from tanks truck railcar or marine vessels The fields that are present with the selection of Loading Rack Sour
77. rces icon This will open the Add Edit Sources window See Figure 3 6 ACM Calcs Manual Chapter 4 Page 14 Add Edit Sources Facmty Code vco0sa zi Soucete i OA Equipment itl TE Estimation Dates v Figure 3 6 You must select the Source type to work with any Source on this screen Selecting a Source Type and Equipment ID will open up data entry fields See Figure 3 7 and Figure 3 8 Add Edit Sources T IHTROG4HC Facility Code v lt 00080 vi Source type COMBUSTION SOURCES Equipmentid OHTROS4HC Delete Estimation Dates 01 01 1996 12 3141996 x Delete EE General Detail General description Specific description unit pwm O Profile 10HTROG4HC M Figure 3 7 H Add Edit Sources 10HTROG4HC Facility Code C0008 i Source type COMBUSTION SOURCES Equipmentid 10HTROB4HC Delete Estimation Dates 01011995 12311996 Delete HB General Kh Detail Manually Enter Emissions Comment esign rate mooo mmBTUhr Potential horsepower booe fr tized horsepower Cut fuel usage fi40 86mmsctiest Liquid fuel used a gals mass ms Potentiat operating hours Fa Utilized operating hours Bag NOx load reduction factor po Figure 3 8 An emission source needs to be linked to a Profile that contains one or more emission calculation formulas These formulas are engaged during the calculation process ACM Calcs Manual Chapter 4 Page 15 Sources may be
78. red under General equipment information 2 9 Menu Structure 2 9 1 File Menu The File menu of Calcs only allows one selection if no screens are open which is to Exit the Calcs program See Figure 2 1 Use this selection when you are finished working in Calcs After opening a screen other options appear such as New Run Close Save Save As Erase Print Preview Print and Print Setup depending on the screen 2 m P A Calcs Emission Figure 2 1 2 9 2 Process Menu The Process menu in Calcs gives you direct access to the Emission Sources Stream Properties and Compositions and Emission Source Profiles See Figure 2 2 This menu also provides access to a feature Copy Data To Another Year This feature duplicates all process history records for a user selected base year to a target year If for example there are twelve process history records in the base year one for each month for a storage tank then twelve records will be created in the target year for that tank If desired a Scaling Factor may be entered in the Units COMPASS Calcs Manual Chapter 2 Page 1 window before using this feature If the user enters a scaling factor of 0 5 for say Unit 2 and the Copy Data To Another Year feature is selected then all process history records will be duplicated for the selected target year but the process rate for all Sources that are located in Unit 2 will be changed to a value that is one half as large as the
79. rmula General description ferticalFixedRoof i General text appears in this box ANER C Site Specific which you may edit Emission factor 000024 EF units omr v pape Type rm Columns Column labels r Columns to include STREAM MASTER tempf stdin F atmospheric press p ATMOSI Stream Data V STREAM MASTER tup std in psia avg clingage fac c AVERAGC Stack Test STRMCOMP cut Conc in WT STRMPROP density in Lbs gal STRMPROP heat content in HHV BTU scf brtr went pr setrange BREATH column diameter fe coLum _ te 2 z STRMPROP Iow heat content in LHV BTU CTDHMDDAD ma in gt pi a a n n Formula for estimatina E Ib hr ef mw vup_pr_dly avlq sftmp throughput_q turn_over_factor_kn work_loss_prd_fac_kp 0 0226 f_exp vp_pr_dly_avlq_sftmp atmospheric press p up_pr_dly_avlq_sftmp 0 68 f_exp diameter_d 1 73 f_exp vp_sp_outage_hvo 0 51 f_exp dl Figure 6 2 The Columns box provides the variable building blocks for your formula To enter one of those variables you will need to double click that variable to add it to the formula The mathematical tools to the left are there for you to manipulate the variables into the formula you need Simply click on the calculation function you need for that particular variable Some formulas are quite complex and may involve many variables e g storage tank variables The Source Type called User defined is a special case for developing Formulas That is be
80. rt Contam Equip Batch Pipe Fiename Exit Figure 6 11 The Batch Pipe icon provides a list screen to select batch Sources for transferring emissions from CALCS to WinCeis as shown in Figure 6 12 The Emissions icon provides a list screen to select non batch Sources for transferring emissions from CALCS to WinCeis as explained in Section 6 4 ACM Calcs Manual Chapter 6 Page 40 SEE amp H Print Err Ficports List Pipe Close lbj Batch Emissions Pipeline Select Parameters For Building Emissions List Year 1998 Ea Facility GE SIL General Electric Silicone Proc Source m z Batch Emissions List For Facility GE_SIL Source 123 and Year 1998 Batch Emissions List Ready For Pipeline Account GE SIL Source 123 Year 1998 Emission Uncontrolled Uncontrolled Emissions Maximum Max Point Tons Yr Lbr Tons Yr Lbsitir ERP Tons A Jie Jos IL 1 10 sel recat Jos kos 1 10 10 23 b99 97 3 p730 E7003 lI I I 0 0000 4 Figure 6 12 6 5 Renames A special Rename icon is provided on the Pipeline toolbar Users can use the screen that appears when this icon is clicked on to rename CALCS Sources that do not have the same Source Id as was used in WinCeis This feature may not be used to add new Sources in either module nor to change Source Id s in WinCeis Note to change a Source Id in WinCeis simply edit it in the Detail screen The renamed Source Id data entry column
81. rt is good for QA QC of the data The Source and Stream Summary report sums up emissions by source and stream The General Description Summary report totals all the fugitive emissions on one page 8 5 Format of Contractor Data The imported files must be in a specific format and your contractor should be able to supply you with the data in the correct format at minimal cost Usually the contractor charges a one time fee for the initial programming to get the data in this format but should not charge any more to continue supplying the data in this format First decide how frequent you would like to obtain fugitive data Some plants desire the ability to quantify each month s emissions and others only require quarterly emissions reports Still others may only need an annual report Note that monthly emissions gives you the most flexibility You can easily sum the emissions for each year if needed On the other hand a yearly report cannot be broken down by emissions occurring in each month Consider this step carefully before proceeding Next ask the contractor to supply you with data It must be ASCII text files in comma delimited format with the specified character format for each estimation period An example of comma delimited format is 01 01 2007 01 31 2007 01234 NSPS ASPHALT If you choose monthly emissions you will get 12 sets of files one set for each month in a reporting year 2 files per set For each estimation period
82. shed Command buttons also enable users to select all Primary Sources for summing with a single click If the user has not taken the time to set up Secondary Sources and their relationship to Primary Sources in advance but still wishes to sum emissions a feature is available for meeting this objective By double clicking on any row in the Emissions Inventory Summary window a window with four different options is presented to the user to assist him in finding the emissions that will be summed Regardless of the summing technique any summed emission records in the Emissions Inventory Summary window are automatically displayed with a gray highlight and a Summed note is entered into the comment column of the Inventory data table Both a Print icon and File menu Print function are available to the user to prepare hard copy reports from the data presented in the Emissions Inventory Summary window Users can re calculate historical emissions using the Profile that was linked to the Source in a previous time period if they wish If the historical data exists in the Inventory data table and the ACM Calcs Manual Chapter 6 Page 38 user has checked the check box on the Estimate Emissions screen labeled Use Profile Matching Selected Time Period then the calculations will be performed in accordance with the information contained in the previously linked Profile instead of the currently linked Profile assuming that it still exists in the system 6 4 D
83. sing Oracle then the drivers for ODBC will also need to be loaded for proper program operations If you are running on a Network check with your system administrator to make sure your workstation is configured correctly to run the program and connect to the database and check that you have the rights to modify a file in the drive and directory where Calcs is loaded namely the database file ACM db If your issue is not addressed in the documentation and you are satisfied that your system configuration is fine feel free to call PDC Corp Please have information about your system including Windows version and type of network 1 7 Getting Started with Calcs The installation routine will automatically create ODBC connection profiles path adjustments and a COMPASS folder on the Start menu with an icon for the Calcs login screen Click on the Calcs icon to directly access the Calcs main screen 1 8 Logging onto Calcs When you click on the Calcs icon in the COMPASS folder a login window entitled Calcs Emission Calculations Program will appear If you are using an Oracle database enter your User I D and Password and select Oracle from the selection list and then click OK Otherwise you may leave the default entries alone and select SQLAnywhere from the selection list and then click OK See Figure 1 1 Calcs Manual Chapter I Page 3 CALCS Login ACM SQL Anywhere Figure 1 1 1 9 Exiting Calcs To exi
84. such as Storage Tanks is stored The next time a source is added if the user selects ReactorXYZ from the drop down list of General Descriptions on the Detail screen three data elements will automatically be presented to the user for data entry Reaction Time Chlorine Used and Temperature Also when a new Formula is added on the Formula screen if the user selects ReactorX YZ from the drop down list of General Descriptions three data elements will automatically be presented to the user for use in the calculation formula labeled Reaction Time Chlorine Used and Temperature Because of the capability to scale throughputs of sources in future years from a base year throughput and user entered Scaling Factor as explained in Section 3 2 it is advisable to use the ACM Calcs Manual Chapter 4 Page 20 throughput data element that is provided by the system instead of creating a new label for throughput However if the scaling factor will never be used in connection with a User Defined Source there is no reason to use the throughput data element instead of a data element labeled Throughput that is created by the user In some cases such as in Loading Racks a conventional AP 42 calculation formula might be used for the working losses during loading and a User Defined Secondary Source as discussed later in this manual might be used with its own user specified formula to account for Blowdown losses The working and blowdown losses
85. t out of Calcs back to the desktop simply select the Exit icon or choose the Exit selection from the File menu You will be presented with a confirmation of your choice so select Yes 1 10 Conventions Used in This Documentation The Frame window is the main window in CALCS with a Frame toolbar FrameBar at the top and an empty workspace See Figure 1 2 A user can open one or more windows in the Frame workspace These windows are called sheets IACM Calcs Emission Calculations Program Figure 1 2 Calcs Manual Chapter I Page 4 Each sheet is provided with a Sheet toolbar SheetBar at the top and the workspace displays the corresponding data See Figure 1 3 ACM Calcs Emission Calculations Program Options Figure 1 3 Calcs Manual Chapter I Page 5 CHAPTER 2 CALCS OVERVIEW 2 1 Facilities The Facility section of Calcs is the same as Facilities set up in the TaskTrakker module of COMPASS A Facility in this case is the site It often uses the Account Number as the ID You may upon entering Calcs select a default Facility site to work with and define emissions within that Facility You may of course choose any Facility already set up in TaskTrakker to work with but you may not modify certain Facility data such as account number once the Facility is updated in the Database 2 2 Units Units are generic process unit types such as sulfur recovery units tank farms and powerhouse complexes You may select the U
86. ter the Leakers file first 1 Enter the leak time period covered by the file to be imported Note only one file can be imported at a time 2 Select the leakers file by choosing Browse 3 Make sure the Leakers box is X d 4 Select Import to begin importing the leaker data When the import is complete the data will be output to the screen 5 Next select Process on the toolbar This function places the leak counts into the Leak Counts column within the Source table Some of the rows may get highlighted in blue This means that the data does not match with the information in Calcs When processing is complete a status box will appear saying either that the process was successful or that the contractor supplied data could not be processed Click OK and a reminder will appear saying to Process Totals now to calculate zeros 6 If certain rows could not be processed see Common Errors That May Cause Data Not To Be Processed in Section 8 7 on how to resolve data that could not be processed Correct the data and repeat Step 5 8 3 2 Totals and Zeros If you have not processed the Leakers file do so before proceeding 1 Select the Totals file by choosing Browse 2 Make sure the Totals and Zeros box is X d 3 Select Import on the toolbar to begin importing the Totals data This may take several minutes to complete because Calcs is reading and inserting each row into the database When the import is complete the data will be out
87. to reduce the VOC concentration in a process stream The data fields that are present with the selection of Air Strippers as a source type are as follows Stream Processed Sand Filter Effluent VOC Concentration Flow Rate Outlet VOC Concentration Inlet VOC Concentration 4 2 2 Catalyst Handling Sources Catalyst Handling Sources create emissions as a result of handling catalyst The fields that are present with the selection of Catalyst Handling as a source type are as follows Catalyst Type Unloaded Units Unloaded Amount Percent Lost 4 2 3 Combustion Sources Combustion sources are calculated emissions from heaters engines and boilers The fields that are present with the selection of Combustion Sources as a source type are as follows Design Rate Fuel Usage Fuel Type Combusted Fuel Usage Units NOx Load Reduction Factor Horsepower Liquid Fuel Used gallons 4 2 4 Cooling Tower Sources Cooling Tower sources measure the emissions from cooling towers due to system leaks or chemical additives to the cooling tower water The fields that are present with the selection of Cooling Tower Sources as a source type are as follows ACM Calcs Manual Chapter 4 Page 17 Stream Processed Flow Rate Plant Feed Amount M bbls 4 2 5 Drains Sumps and Junction Boxes Emissions from Drains Sumps and Junction Boxes are determined by emission factors The fields that are present with the selection of Drains Sumps and JB as a sou
88. ture searches all records in the PIMS i e Production database to obtain a total number of Batches produced in each month during the prior twelve months Emissions data in WinCeis is used to correlate the emission amounts with the number of batches so it is important for users to have calculated emissions and to have used the data Pipeline to update WinCeis for any time period in which a Rolling Sum report is produced MACM Calcs Emission Calculations Program amp oF BRB GH amp E F Facility Units Compounds Stream Prop Unit Streams Sources Batch Formulas Profiles Cole Cont Inventory Exit Batch Calculations Ox Facility Code GE SIL Equipmentib 123 7 Derete vear f2000 Delete Rolling Sum Emiss Description fest Unit T12001 l Volume 1200 gals Machine Prs Figure 6 22 ACM Calcs Manual Chapter 6 Page 47 CHAPTER 7 CALCS TUTORIAL 7 1 What You Will Do The tutorial is a series of lessons in which you will estimate air emissions for an emission source in the refinery using the Calcs module You will begin by creating a unit a stream a composition for the stream a source a formula and a profile for the source You will then link the estimation profile back to the emission source calculate estimated emissions and print a report 7 2 What You Will Learn After finishing the tutorial you should know how to do the following Create an emission source Create all pieces of informat
89. type e g Tanks and then ask process engineers or supervisors to provide the current year s data These updated spreadsheets can be imported into Calcs using standard program features b Process data that has been updated in Calcs can immediately be used to calculate and characterize air emissions because the set up information for each Source s calculation regime such as formulas factors and stream compositions are usually defined in the system and require no updates c Calcs maintains process data in its database for every year that it was used and enables users to retrieve the data and the emissions that were calculated based on the data with minimal effort In addition users can re calculate emissions for prior years by changing the process data for that year applying at their option either currently assigned formulas and factors or the ones assigned in the previous year unless they were deleted or modified Calculating Emissions the manual procedure for calculating emissions in CPC facilities as in most other plant where programs such as Calcs are not used involves inputting process data into MS Excel workbooks where the formulas factors and streams have been provided to enable a calculation of air emissions These workbooks tend to be calendar year specific complex and extremely large factors that create special challenges for users in organizing archiving and using them They also present significant
90. unt Do this by going to the Leak Count window in the Sources screen entering the leak count and saving 1 From the Import window select Reference Process Units Check to see that the correct Process unit ID is entered If not add it from this screen 2 From the Import window select Reference Component Types Check to see that the abbreviations used by the contractor correspond to the existing abbreviations in this window If the abbreviation does not exist add it to this window ACM Calcs Manual Chapter 8 Page 58 3 Click on Sources on the toolbar Check to see that the stream has been added to the correct emission source record If not add the stream and save If you add a stream in emission sources check to see that the Leak Contractor Stream ID has been listed in Unit Streams 4 Also in Sources check to see that you have the correct estimation dates If not create a record with the correct estimation dates and save 5 Click on Unit Streams on the toolbar Check to see that the correct ID for the stream is listed in the Leak Contractor Stream ID column If the contractor has a different stream ID either a add another stream with the same information except the new stream ID i e if stream is fuel gas rename fuel gas 2 or b change the stream ID as long as the contractor did not use the existing stream ID for any of the imported streams If a is done add this new stream to the emission source record I
91. values in the base year Manually entered emissions may also be copied to a new year if this feature is selected by the radio button shown near the bottom of the screen ACM Calcs Emission Calculations Program File Process Reference Emissions Options Maintenance Emission Sources Sources Quick Edit Import Stream Properties and Compositions Emission Source Profiles Copy Data To Another Year You may use these menu items instead of FrameBar icons Figure 2 2 2 9 3 Reference Menu The Reference menu allows you to go directly to the various windows to set up Facility Data Compounds Streams and other data See Figure 2 3 The Reference menu is also where the Contractor Leak data can be imported ACM Calcs Emission Calculations Program File Process Reference Emissions Options Mainta Facility Information Compounds Units Streams gt Emission Factors IVP and WTZ Vapor Values Equipment Leak Contractor Data gt Equipment Leak Reference Data gt Facility You may use these menu items instead of Framebar icons Figure 2 3 2 9 4 Emissions Menu The Emissions menu allows you to Estimate Emissions from the data entered and View those Emission Results See Figure 2 4 Emission Calculations Program Reference Emissions Options Mainten Estimate Emissions Goa View Emission Results Figure 2 4 COMPASS Calcs Manual Chapter 2 Page 8 2 9 5 Options Menu The Optio
92. viewed or edited one at a time on the Sources screen or in a group for a specified time period and Unit in the Quick Edit screen Not all process variables are displayed on the Quick Edit screen In general only the variable s that are likely to change from one year to the next such as throughput or fuel usage are shown in the Quick Edit screen You may print the Source listing by clicking on the Print icon This will send the Source report to your printer By clicking on the Comment button on the detail screen you may make further informational entries into the comment box See Section 2 11 Comments on Data Items Chapter 4 Source Types deals specifically with Source Types and explains each available Source type and its corresponding data entry fields that become available upon selection Sources can be broken down into Secondary Sources if desired This would be done for any source for which the emissions must be calculated using more than one formula An example might be a Loading Rack that has both working losses and blowdown losses two types of emissions that are calculated in entirely different ways Reactor vessels used in batch processes are often broken down into steps and the emissions for each step are likely to be calculated in different ways e g temperature increase loading of catalyst mixing etc These steps can be identified as Secondary Sources which can then be summed to the Primary Source that represents the tota

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