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The COMPASS User`s Manual “COMPASS-CALCS”

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1. 52 4 8 3 2 8 Detail Tab FCC Unit Source Type eee 53 4 8 3 2 9 Detail Tab Flare Source Type csscccsssceeceeenes 54 4 8 3 2 10 Detail Tab Loading Rack Source Type 55 4 8 3 2 11 Detail Tab Oil Water Separator Source Type 57 4 8 3 2 12 Detail Tab Spills Source Type eens 58 4 8 3 2 13 Detail Tab Storage Tank Source Type 59 4 8 3 2 14 Detail Tab Sulfur Recovery Source Type 60 4 8 3 2 15 Detail Tab User Defined Source Type 61 4 8 3 2 16 Detail Tab Wastewater Source Type 000 62 ASO or Tank Data Tabuaeran EE eee 63 4 8 3 3 1 Tank Data Tab Horizontal Fixed Roof Tanks 63 4 8 3 3 2 Tank Data Tab Vertical Fixed Roof Tanks 65 4 8 3 3 3 Tank Data Tab Internal Floating Roof Tanks 66 4 8 3 3 4 Tank Data Tab External Floating Roof Tanks 67 4 8 3 3 5 Tank Data Tab Domed Ext Floating Roof Tks 68 4 8 3 4 Tank Fittings Tab ssesoeeesseeeeeeessesssssseessrresssresseresssresseens 68 4 8 3 4 1 Tank Fittings Tab Internal Floating Roof Tanks 68 4 8 3 4 2 Tank Fittings Tab External Floating Roof Tanks 69 4 8 3 4 3 Tank Fittings Tab Domed Ext Floating Roof Tks 70 4 8 3 5 Leak Counts Tab Equipment Leaks Source type 71 CALCS Manual 4 8 4 Primary and Secondary Sources ccccceceeseeceeeseeceeeteeeeeeneeees 72 4 8
2. Negative lbs yr and The difference between Set the breather pressure and tpy max and min vapor pressure vacuum settings so that the range in Source Detail screen is equals the vp range Any larger less than the breather vent setting is irrelevant because the setting range A term the vp never overcomes the vent Formula is max vp min settings vp setting range Negative number ina field Check all fields for negatives Formula screen has a Trace back from Formula screen Compound entered that is though Profile to Source to find not in the related Stream Stream Add Compound and or Properties or has no wt concentration in Stream Properties Source screen has an Correct the temperature erroneous Tank Avg Liq Surf Temp It should be in degrees R 460 F No VOC data Manually entered emissions List VOC in Stream Composition for VOC are applied to a Stream Composition without VOC specifically listed with no concentration number or Units entered Retry calculation The Leak Counts tab does not have that Stream Delete and re insert that Stream on details tab to create a corresponding Stream under Leak Counts tab No Wt data in Calculate Estimate Emissions screen The Profile referenced by the Source lists a Compound not in Stream Properties or its concentration is blank If Compound and wt is wanted trace links backward from Profile to Stream Properties and e
3. User s Manual Compliance Assurance System Emission Calculation and Pipeline Modules COMPASS CALCS amp COMPASS PIPELINE CALCS amp PIPELINE Version 5 01 November 2007 Manual Process Data Control Corporation Copyright PDC Corporation 2007 All Rights Reserved TABLE OF CONTENTS CHAPTER PAGE 1 INTRODUCTION sessdasstvcstacsenccshewsieississosdaeiuedinnidesssisssnasveneiauadeasssacseisvenss 1 1 1 About CALCS ooennsnooeenossssesnsssssreessssereessnsersessoseresssoeeessssoreessssereesse 1 1 2 System Requirements yeasts sicinaasaieondasininecteucdiereinasdedtonasesinaabhudetendes 1 1 3 Installation Instructions cccceeccesceseeseeesceseceeeeseeeeeeaeceseeeeeeeeeeeeaeenees 2 1 4 Usine TM acct cette shspidce tlenctaeedatuc eerie nan snciesit e ET eaaa eia eeaeee 2 1 5 Technical Support of CALCS csc uectanaecnrnrscoanuntmuarieeienendaebianens 2 1 6 Getting Started with CALCS oo cccccsscessseseceseceeeseeeeeseeeseeeeeeeeenees 3 1 7 About This Manual acsccducnunisartoratosavotuustencueces stoi chet ededonsaemuiewendsieiorundoats 3 l 8 Pre entered data ssscnisiiesns casati a R E 3 19 Data eld See e E E T N A E 3 1 10 Logging onto CALC S sos csscica sancateousanssnnnsancaxminbncenniesmtacnimeshenaveeaninniady 4 1 11 Important Conventions for Entering Data cee eeeeeeeeeeesneeceeeeeees 4 1 12 Exiting CALCS isere eeens ne n wen eee unr ea entrar se emer 5 2 CALCS OVERVIEW sicsssncssesssticcsscsccnsetes
4. Begin_Date End Date Streamid Throughput Thru a CVT Throughput ciel Po 05 TKTNONENE M galest RA mzs ooms C OE a ma oms fisiese ra gues ef 053 ma os faso pues 000 e e r E Fa TF 24_ 0201 05 02128105 TkEWNDETF____j46359 gavest z 1103 7857 ma osmos osmos peor prest foale zi 448 524 z Tras ostm osoro rn orao at b TF 23 TF 23 TF 23 TF 24 0140105 01 31 05 TKEIIINDFTF 40088 954 4762 TF 24 TF 24 TF 24 Click Export to save the list as a spreadsheet normally Excel5 with headers or some other file type Then edit the spreadsheet delete the column headers remove times from dates if required change 1 1 2007 00 00 00 to 1 1 2007 and save as a tab delimited text file Then you can re import the edited file by clicking the Load File button browsing for the file and clicking OK and the Save button This can of course be imported from a throughput spreadsheet other than an exported one if you use the same format ACM CALCS Manual Page 77 4 10 Import Screen This differs from the Quick Edit import function in that this screen is used to import Manually Entered Emissions Again this is faster than editing them one Source at a time on the Detail screen Click the drop down just to the right of the Sources button then on the Load File toolbar item You will be prompted to locate the upload file The data file can only be a Tab delimited text file such as from a spreadsheet using the Save As option Th
5. 9 and select Fuel Usage Units mmscf est which is per estimation period Enter Estimation Dates 1 1 2007 to 12 31 2007 Click Save and Close 3 2 6 Create a Formula Click the Formulas button Select the Source Type COMBUSTION SOURCES Enter the Factor or Formula ID XBOILERNOX Enter the Specific Description EXAMPLE BOILER NOX Select the General Description BOILERS from the pick list Select the Compound NOX Enter the Emission Factor 100 and pick the Units Ibs mmscf Put the cursor after ef Double click the desired variable in the Columns box COMBS cvt_fuelusage in ACM CALCS Manual Page 20 mmscf est e Click the button e Double click the hours COMBS utililized_operating hours in hr e Click Save and Close 3 2 7 Create a Profile Click the Profiles button Select the Source Type COMBUSTION SOURCES Enter a Profile ID XBOILERS Type a Profile Description EXAMPLE BOILER EMISSIONS Click the Estimation Method drop down arrow then Emission Factors General Click on the EF Code XBOILERNOX and OK Click Save and Close 3 2 8 Link the Profile to the Source Click the Sources button Pick the Source Type COMBUSTION SOURCES Select the Equipment ID XBOILER Pick the Profile XBOILERS Click Save and Close 3 2 9 Calculate the Example Click the Calculate button Select the Begin Date and End Date 1 1 2007 to 12 31 2007 Click the Source Type COMBUSTION SOURCES Check t
6. Delete Estimation Dates fi2m 2005 12 31 2005 v Delete fE General K Detail Days Maximum Average Max Vapor Average Vapor Pumping Rate Potential Utilized Online Temp F Temp F Press psia Press psia gals min Operating Hours Operating Hours 37 00 J 0 00 37 00 0 00 0 00 37 00 0 00 0 00 37 00 0 00 0 01 37 00 0 00 0 26 37 00 0 00 0 12 37 00 0 00 0 03 37 00 0 00 0 01 ACM CALCS Manual Page 57 4 8 3 2 11 Detail Tab Oil Water Separator Source Type An Oil Water Separator or more specifically a VOC Water Separator is a tank or basin with baffles to trap floating VOC on a wastewater Stream by simple gravity separation VOC evaporation can be controlled by a cover and or other control device or may be open and uncontrolled The radio buttons for the choice of control only generate a label to that effect in reports They do not change calculations The Flow Rate in Gal min is the water flow rate Concentration of VOC must be entered in the Stream Properties screen ACM Calcs Emission Calculations Program File aa Window Help z a 2 oF Be 2 RA A E amp Ms b Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit Add Edit Sources 1 Facility Code Source type OIL WATER SEPARATION Equipment id fi Delete Estimation Dates v E General K Detail Manually Enter Emissions Comment Stream processed Separator Typ low rate in g
7. Manual Page 111 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 Dates ie 01 01 2007 01 31 2007 02 01 2007 02 28 2007 03 01 2007 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 act
8. Percent Use Flow Ozone Feeding CIH TA Use Co Tro Use Ozone fv Use Co Ee re rene Edit Control Device Add Control Device Saparan eee a ae aonga aa m mammaa ACM CALCS Manual Page 108 Either the Add or Edit choice will bring up a window like the one below Enter the mandatory information shown by the asterisks a control efficiency and click OK Edit Control Device FLARES WASTE GAS ELEVATED 30FT SMOKE arene 1 Nomber BAE Emission Point Number zl EEEE n i 8760 Active C Shut Down ACM CALCS Manual Page 109 5 6 Rename Screen Click the Rename button to open the screen If a Source ID in CALCS does not match the FIN in EI you can use the pick list to rename the Source ID for PIPELINE transfer purposes Then click Save This feature may not be used to add new Sources in PIPELINE or EI nor can it change Source ID s in EI CALC to EI Pipeline File Actions Window Help 2 amp 2 2 4 Parameter Emissions Contam Equip Rename Exit 2 g P Save Print Close Align CALCS Sources to EI FINS Facility v Account H Source IDs in CALCS that do not correspond to FIN IDs in WINCEIS 4 Sreid__ _ Rename to FIN BP4IA48 QLEAK P4 EQ LEAKS FROM TK A48 Epaass ROLeaK GPa EO LEaKSFROMTK Ase Bras o Foe GPa EOLEAKSFROMTKAa Eraso Foe PAEO LEAKSFROM TK Aso o Epaaae o Foe GPa EO LEAKSFROMTKAaS Epaaa Te Beak Br
9. Stream Prop screen enter a MW reference temperature and click Calculate button OR enter a value directly in liquid or vapor MW field Pick list does not contain a recently entered item The Unit has not yet been selected on the Source screen General Tab Pick the Unit and Save The screen containing the item was not saved While in the screen of the item s origin click the Save button The stream is linked to the wrong Unit Check the Stream in Unit Stream screen for correct Unit The screen containing pick list was not refreshed since adding the Stream etc If in Stream Properties or Unit Stream screen close and reopen screen If in Source screen select another Source and return If in Formula screen choose another Source Type and return If in Calculate Estimate Emissions screen uncheck and recheck the Equipment ID box Refreshing after entering a new Component Type may require exiting and reopening CALCS and perhaps Metaframe if operating in Citrix ACM CALCS Manual Page 126 Symptom Possible Cause Resolution Cyt Concentration is not calculated automatically after entering concentration Missing concentration units Enter missing units Not yet saved Click the Save button Missing concentration s for other compounds CALCS computes Cvt Weight Percent in alphabetical order It must have concentrations from the
10. 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 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 2 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 maintenance of the system The extra time that is spent in set up for Streams and Compositions is more than offset by the ACM CALCS Manual Page 40 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 enti
11. m haszo Date ranges can be a year 1 1 2007 12 31 2007 month 1 1 2007 1 31 2007 or as little as a day 1 1 2007 1 1 2007 It is important to recognize several concepts You can calculate annual emissions from 12 monthly date ranges but you cannot calculate monthly or rolling 12 month emissions from a single annual date range Also if you want to calculate monthly or 12 month rolling emissions your date ranges cannot bridge two months 1 15 2007 2 15 2007 You must express month bridging dates in parts 1 15 2007 1 3 1 2007 then 2 1 2007 2 15 2007 Also your date ranges should not have gaps 1 1 2007 1 15 2007 then 1 29 2007 1 31 2007 ACM CALCS Manual Page 44 unless the Source was truly idle for that period CALCS will however allow more than one date range within a month 1 1 2007 1 27 2007 then 1 28 1 31 2007 such as for change of contents of a tank CALCS also allows overlapping Estimation dates 1 1 2007 1 31 2007 and 1 1 2007 12 31 2007 but it could cause confusion and should be avoided unless there is a real need to do so 4 8 2 Potential and Utilized Operating Hours These values are used by CALCS in conjunction with the Formulas The Formula calculates pounds per hour The Calculate function multiplies the resulting pounds per hour by the Potential or Utilized Operating Hours to get tons per year depending on whether the Formula is for Actual or Maximum Potential to Emit emissions CALCS computes a defau
12. not the same in Source Formula and Profile screens Pick the same Monitoring Program in Source Formula and Profile screens ACM CALCS Manual Page 133 Symptom Possible Cause Resolution Error Message Emissions could not be estimated Possible causes 1 A Profile is not linked to the equipment 2 Values for columns referred in the Formula are not entered 3 Estimation dates are not within specified date range Needs refresh sometimes after multiple Zoom Report uses Close and reopen Calculate screen Wrong year Check and correct year End Date is not the end of the month ie 8 30 vs 8 31 Check and correct End Date If running SARA summary Select SARA Yes No for no SARA radio button Compounds selected for affected Compounds If Use Existing Results got this error it may not yet have been Calculated data has been changed since calculating or this may be a Secondary Source whose emissions were Summed and Deleted in the Inventory screen previously Change option from Use Existing Results to Cale Emission Results If it is a Secondary Source however it will necessitate summing and deleting again along with piping the Primary Source to EI In an Equipment Leak Source with manually entered emissions and no Leak Counts the Source Detail and Emission Parameters reports will not run due to lack of data Run
13. starting with User Defined Delete one of the Sources or Save As another name ACM CALCS Manual Page 129 Symptom Possible Cause Resolution Error 193 194 196 for an Equipment Leak or Loading Rack Source when saving Equipment Leak Source ID only allows 8 characters Shorten Source ID to 8 or fewer characters or use another Source Type If official Equipment Leak FIN is gt 8 characters enter FIN under different Source Type with zero emissions Create a Secondary Source with a shorter ID to Calculate emissions Link the Secondary to the Primary A fix for this error is in process Same Stream is already saved under same date range Change Stream ID or date range Error Message A database error has occurred Database error code 3114 Database error message ORA 03114 not connected to ORACLE No changes made to database when saving a Source screen Connection lost Close CALCS without saving and reopen Error Message TVP Calculation Errors Pvx Calculation for Stream No vapor pressure calculation data was foundat _ deg C for CASNo ID i when clicking Vapor Pressures button in Storage Tank Source screen Tank temperatures are outside the valid temperature range in Compounds screen for one or more Compounds In Compounds screen enter data for one of the three vapor pressure data sets with a temperature r
14. up_pr_dhy_ avlq_sftmp 1 1 0 053 vp_pr_dly avlq_sftmp vp_sp_outage_hvo 0 0010 mw_tank_vapor vp_pr_dly_aviq_sftmp throughput_q turn_over_factor_kn work_loss_prd_fac_kp tanks_operating_hours tempf_std The object of a Formula is to calculate pounds per hour of emissions from the Source You will not normally consider abatement or individual stacks at this time The Calculate function will later automatically multiply the pounds per hour by the hours entered in the Source screen to compute tons per estimation period The Formula should calculate pounds per hour before controls While abatement efficiency can be entered into a Formula it may not be the same one entered in the EI module for reporting This inconsistency would later cause confusion It is best to let CALCS compute the unabated emissions and let the PIPELINE module transfer them to the EI module The PIPELINE later ACM CALCS Manual Page 79 uses the efficiency entered in EI One exception is a Loading Rack Source that abates gasoline but not diesel loaded from the same rack The control efficiency must be entered in the Source screen for each Stream and the Formula must contain the efficiency as a variable You must however check the efficiency entered in the EI module for consistency To enter a new Formula select the Source Type and enter a Factor ID of 10 characters or less and a Specific Description of your choosing Then pick the General Description and C
15. 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 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 ACM CALCS
16. 3 1 Humber Fitting Type Loss Factor Of Fittings ecess hatch 24 in diam Bolted cover gasketed 600 ot iccess hatch 24 in diam Unbotted cover gasketed Broo o id ccess hatch 24 in diam Unbolted cover ungasketed peoo 8 ooo eck drain 3 in dia 90 closed B00 l eck drain 3 in dia Open 500 T eck leg 3 in dia Adjustable center area gasketed 530 Doo eck leg 3 in dia Adjustable center area sock 490 rts eck leg 3 in dia Adjustable center area ungasketed 820 tt eck leg 3 in dia Adjustable double deck roots 820 o otal Deck Fitting Loss Factor 3 4 Fa 4 gt ACM CALCS Manual Page 69 4 8 3 4 2 Tank Fittings Tab External Floating Roof Tank Type The Tank Fittings tab for this type roof has the same choice of fittings E General K Detail Tank Data T Tank Fittings Calculation Method Tanks 3 1 ai Fitting Type of Fittings Fitting Los Jaccess hatch 24 in diam Bolted cover gasketed ff6000 JAccess hatch 24 in diam Unbottedcovergasketed pooo Jaccess hatch 24 in diam Unbolted cover ungasketed pooo Peck arain 3 n dia 90 closed o o SSS e oo Deck darain Gin dia Open SSS e oo Peck leg 3 in dia Adjustable center area gasketed pooo Peck leg 3 in dia Adjustable center area sock f 0000 Peck leg 3 in dia Adjustable center area ungasketed f 0000 Total Roof Fitting Loss Factor 1 6 Number of Rows 44 x b TE Scrolling to the right you can see that CA
17. 4 12 6 1 Link Sources Sereen ss icienusvsivenscnetecadenntindsvndeniatsinnciies 89 4 12 6 2 Profiles Repoti siret a epr nenian a ete 90 A T3 Calculate Sereen marone eena e AE A E AE 91 4 13 1 Selecting What You Calculate ss sastencntatncansuatiecanins 92 4 13 2 Calculation Criteria sseeeeeesseeeeseeessesessseessesesssresseresssresssseess 92 4 13 3 Other Report Variations ssssesoseessesessseessssessseessereesssresserees 92 4 13 4 Calculate Button OW sssessessessssseessesesssressssesssresseressseesssseess 93 4 VSS Opti S ee ne r e eate 94 4 l4 Inventory Screen wa enoii esenea te aa E EAE Lr EEE e eiis 95 4 14 1 Data Menu for Primary and Secondary Sources 00 98 CALCS Manual 5 PIPELINE MODULE osssssssssoissscossssorscsossssosss oosstsorsososssso ss oosstsorsssossss 100 5 l Main SONU iacanasieracutevasintacsschonstuaaueinavaccecsvaniwiaasisbermnaiwecetatiasnaeneceis 100 5 2 Parameter Sereen essesesssererererererererererererererererererererererererererrirererere 101 5 3 Emissions SCreCn sassinatisieansminieinviaiatsi ccna Oraa TEENETE 102 5 3 1 Error Reports sas cose ceed siecle chien naaisindidndatiedendomsinediy dGhcenaiedeben 103 5 3 1 1 Equipment Report ssc usetnsauscsalsstaasnseceasetnanndinosdinasewenseer 103 5 3 1 2 Percent Flow Report sssssessesseessesesssersseseessersssseessee 103 5 3 1 3 CAS Number REDO sssssdwsiieeiacecadhiebaieehecastadaceaiens 104 5 4 Contaminant SC
18. Error Message No records match these criteria Please try again error when Retrieving Missing Calculate or earlier step Run Calculate and earlier steps if needed for desired Sources and try again ACM CALCS Manual Page 139 8 2 PIPELINE Troubleshooting Chart and Steps If you encounter errors or problems running PIPELINE find a possible solution in the following chart or go through the steps below the chart to ensure a correct transfer of emissions to the EI module 8 2 1 PIPELINE Troubleshooting Chart Symptom Possible Cause Resolution Equipment error report lists desirable FIN s Summed and Restored instead of Summed and Deleted thus leaving emissions in Secondary Sources not recognized by PIPELINE EI In Inventory screen select the Primary and all related Secondary Sources Retrieve Data Sum Emissions select just the Primary and then Sum and Delete Recheck error reports FIN EPN CIN relationships not established In PIPELINE click Equipment button in the toolbar and edit or insert a relationship using pick lists Right clicking a line will open an option to add or edit a CIN If no CIN is needed enter a hyphen rather than leaving a blank Error Message There are no emissions to be piped over when listing emissions The box is clicked for Apply Control Efficiencies is checked when there are no controls Uncheck
19. Firing Rate and NOx Load Reduction Factor are automatically computed by CALCS and can be referenced in a Formula later Add Edit Sources H 3 Facility Code Source type COMBUSTION SOURCES Equipment id j 3 Delete Estimation Dates jot 01 2005 12 31 2005 v HB General M Detail Manually Enter Emissions Comment Design rate 2s mmBTU hr Potential horsepower uel type combusted euoweas o Utilized horsepower Fuel usage pizza C Cut fuel usage 12 24 mmsctiest Fuel usage units Jmmscfiest Liquid fuel used gals Estimation dates 01 01 2005 x 1281 2005 x Potential operating hours 87600 Days online z Utilized operating hours 760 Current firing rate p Ale mmBTU hr NOx load reduction factor p74 ACM CALCS Manual Page 50 4 8 3 2 5 Detail Tab Cooling Tower Source Type The fields below are mostly self explanatory The Plant Feed Amount has reference to AP 42 Table 5 1 2 footnote b It says if you don t know a refinery s cooling tower circulation rate it could be approximated as 40 times the crude oil feed rate to the atmospheric distillation column in the same units Add Edit Sources F CT1 COOLING TOWER SOURCES F CT1 i 12401 2005 12 31 2005 ACM CALCS Manual Page 51 4 8 3 2 6 Detail Tab Drains Sumps and Junction Box Source Type The fields in the screen print below are self explanatory Add Edit Sources 1 DRAINS SUMP
20. LAB LIGNTE DUST ABDUST_ LABORATORY SLUG FUGITIVE STREAM LicnTEDUST IGNTEDUST LIGNITE HANDLING SLUG FUGITIVE STREAM INES DIESEL DUESEK MINES DESEL FUELOL MNES LIGNITE DUST MNELGDST MINES S5LUG _FUGMIVE STREAM POTLNE POT LINE POTLINE v SLUG FUGITIVE STREAM POT LINE DIESEL PLNEDESEL POTLNE DIESEL FUELOL POT LINE GASOLINE PLGASOLINE POTLINE y GASOLINE GASOLINE POWER HOUSE DIESEL POWER HOUSE DIESEL FUEL OIL POWER HOUSE FUEL OIL FUEL OIL POWER HOUSE FUEL OIL FUEL OIL POWER HOUSE GASOLINE PWWRGASOLINE POWER HOUSE X GASOLINE GASOLINE POWER HOUSE NATURAL G amp S NAT GAS POWER HOUSE X NATURAL GAS NATURAL G bt ACM CALCS Manual Page 39 If you scroll to the right you can enter more Stream data The Cleanup Streams button will delete all Streams not linked to a valid Source A warning will pop up that requires confirmation Add Edit Streams Cleanup Streams Search for Stream name Temp F TYP psia Stream Phase voc Leak atprocess at process at process service TYP contractor conditions conditions conditions status at 68 F stream id Eqleak stream catego 69 80 pss 00 Tigi imi pe rene 69 80 E Light Liquid 10 VOC e frome There are two reasons for separating the Streams from Stream Compositions in the system 1 First when process history is entered for a Source users are asked to identify the Stream s that are used by the Source during the process history time period Sources
21. Print or Close buttons ACM CALCS Manual Page 94 4 13 5 Options Before clicking Run you can also click Options at the top of the screen to show a menu of report styles General Reports has six options of varying detail The default report is Source Generic The most detailed report is Emissions Calculation Parameters which shows the Formula and variables used to Calculate the results This is useful to send to the agency if they ask for the basis of previously reported emissions ACM Calcs Emission Calculations Program Estimate Emissions i File Options Window Help inal General Reports Source Detail Facility Process Unit Reports General Description Summary Pr oe zoom Source Summary 7 Prior Source and Stream Summary Next wf Source Generic Emissions Calculation Parameters Process Unit Reports opens the options shown below The SARA Compounds must be checked in the Compounds screen to use the last report option Process unit Reports xi Report Selection C Sitewide Process unit Summary By Category C Process unit Summary By Category and Contamcode C Sitewide Summary By Category and Contamcode OK C SARA Compounds Summary By Process unit The Zoom Prior and Next menu options are the same as the buttons mentioned earlier ACM CALCS Manual Page 95 4 14 Inventory Screen The Emission Inventory Summary is a data table that contains all of the emissions for all Sources and date ranges t
22. QA code 12 Such user notifications can be very helpful to identify problems and ensure correct emission calculations E E F Formulas Profiles CaleCont Inventory Exit Batch Calculations olx Feciitycone ce st gt Equipmentun i23 x Delete vearfos JZ Delete Rolling SumEmiss Description fest unit T12001 Volume 4200 gals Machine PKS Step Parameters Charge Reaction Process Control Calculations 9A codes 88901 test test test Step 1 Vessel volume is missing or Step 1 does not contain any charging Ether density or My data is missing for one or more compounds e or more operational parameter for Step 1 is missing or is not correct Step2 Step 3 Step4 Oyo 3 7j ig 3 2 i g a B or this step the end pressure may not be correct P or this step the start temperature may not be correct or this step the end temperature may not be correct g or this step the vp override temperature may not be between the start and end temperature p or this step the total vapor mole fractions sum up to greater than 1 0 For this step the nitrogen sweep rate may not be correct For this step the time may not be correct or this step the volume of the material inthe vessel exceeds the volume of the vessel itself ic wermi 1 test ACM CALCS Manual Page 122 7 4 NY Rolling Sum of Emissions al EI module data is used to produce a report
23. YOC 0 00 0 00 SP1 SPILOAD L_RACK 14 2005 1 31 2005 YOC 0 00 0 00 SP1 SPILOAD L_RACK 14 2005 1 31 2005 YOC 0 00 0 00 SP1 SPILOAD L_RACK 14 2005 1 31 2005 YOC 0 00 Li r I f i MAAA nS 4a raa In special cases you may click Sum And Restore Emissions which sums the emissions of all Secondaries assigns the total to the Primary and restores eaves the subtotals in the Secondaries If you check the box at the upper right you can Remove Zero Emission records ACM CALCS Manual Page 99 from the totals which is the normally recommended default Now the PIPELINE module can transfer just the emissions of the Primary to EI module The Secondary Sources will not be transferred or reported ACM CALCS Manual Page 100 CHAPTER 5 PIPELINE MODULE 5 1 Main Screen The data PIPELINE is a module designed to copy Calculated emissions from the CALCS module to the Emission Inventory EI module It is accessed by selecting the PIPELINE icon from the COMPASS folder on the Start menu As shown below the main tool bar enables choices to be made as to whether to Pipe 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 Ib CALC to EI Pipeline File Actions Window Help 2 8 2 E Mo t Parameter Emissions Contam Equip Rename Exit ACM CALCS Manual Page 101 5 2 Parameter Scree
24. a SQL Anywhere user you may leave the default entries as is and then click OK A password is not required for SQL Anywhere CALCS Login A Component of PDC s Compass2000 Suite me ACM Calcs Emission Calculations Program 5 01 Proprietary and Confidential Information of PDC Corp Protected by the Copyright Laws as an Unpublished Work User ID dba Password Database ACM SQL Anywhere CALCS can handle more than one Facility site If a Select Facility screen pops up pick your Texas account number to start Then the CALCS Main Screen will appear 1 11 Important Conventions for Entering Data Identifying numbers ID s should be in all upper case letters and have no spaces Otherwise confusion may arise over the difference between TANK1 Tank and TANKI space For simplicity leave the cap lock on for all entries You will find that the Enter key is not active for all fields In that case use the Tab key or click on the next desired field Click the Save button to save entries into the database If your screen does not have the minimum mandatory data when attempting to save a pop up window will advise you what is missing Enter the missing data and click Save again Items entered on one screen often become pick list items on a second screen For instance if the Source screen does not have a desired Unit on the pick list it must be added on the Units screen If the Source screen was left open dur
25. 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 another year This would normally be done annually to save the time of creating new date ranges for every Source separately That feature is accessed by clicking on the Process menu and then clicking on the menu item called Copy Data To Another Year E ACH Calce Emission Calculations Program File Process Reference Emissions Options Emission Sources Stream Properties and Compositions Emission Source Profiles Copy Data To Another ear 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 values in the base year In fact all Sources located in Unit 2 will have their pro
26. family In the next window pick the Stream ID Stream Pick List Search for Stream ID Stream Id Stream Hame CPU DOVWTHERM FUEL GAS PU F C1 Either Select All or click Compounds individually and click OK Stream Composition for Stream CPUF C9 ae ae Ge TER Casno Id Compound Hame HYDROGEN SULFIDE H25 MERCAPTANS U MERCAP U ACM CALCS Manual Page 88 4 12 4 Equipment Leak Monitoring Program If this is for an Equipment Leak Source Type select the same Monitoring Program that you selected in the Sources screen f Emission Source Profiles New Select source type EQUIPMENT LEAKS X Enter profile id v Profile description Use vapor phase No Monitoring composition program Estimation method Speciation Current emissions profile Emission factors Stream Compe Component The choices of Monitoring Programs are created with all screens closed by choosing the Reference menu Equipment Leak Reference Data and Leak Monitoring Programs 4 12 5 Linking the Profile to the Source After creating a Profile you must go back to the Source screen General tab and select that Profile from the pick list and Save to link it to the Source Add Edit Sources H 3 Facility Code Source type COMBUSTION SOURCES Equipment id H 3 Delete Estimation Dates fot 01 2005 12 31 2005 v H General neh Detai General description Specific description f
27. in the screen print below Many fields have pick lists Others have buttons for automatic calculation The Total Deck Fitting Loss Factor is carried forward from the tab labeled Tank Fittings See Tank Fittings section for details fi General K Detal Tank Data T Tank Fittings Method Construction Type Welded Riveted Shell Condition Light Rust v Seal Type Mech shoe seal primary only z Product Stored Gasoline Atmospheric Pressure Pa 14 7 psia Column Type it up wigask well Throughput 109 845 00 Shell Paint Solar Abspt 017 tid Thru_Units faaet gt Roof paint solar abspt bir xz Tank Diameter D 6 00 ft Paint Solar Abspt p47 Cut_Throughput Q 615 36 BBL r Tot Deck Fitting Loss Fac i75 300 Potential Throughput P00 BBLar Pumping Rate in galsimin f0 000 00 Product Factor Ke A0 z Avg Clingage Factor fooo1so00 x Deck Type velded Decks x Column Diameter Fe h10 Deck Seam Lngth Fac sd 0 z Humber Of Columns He o0 Deck Seam Loss Per Unit Seam Lgth Fac p 00 Seal loss Factor Kr psa ACM CALCS Manual Page 67 4 8 3 3 4 Tank Data Tab External Floating Roof Tank Type External Floating Roofs have the same data as Internal Floating Roofs except for the added Seal Wind Speed Exponent n The Total Deck Fitting Loss Factor is carried forward from the tab labeled Tank Fittings See Tank Fittings section for details ACM CALCS Manual Page 68 4 8 3 3 5 Tank Data Tab Domed Ex
28. is VOC PM etc Multiple Species Compounds CATALYST ALL TYPES Then a new row will be added to the bottom of the Profile list Pick the Compound PILL ACM CALCS Manual Page 86 For Speciation from a Compound List you must first have created a Compound List The Compound List section above shows how to create such a list You must have also have added a Formula for VOC etc to have something to speciate With both of those done you can click the Speciation drop down arrow click Compositional Analysis Using a List choose the chemical family and choose a list Compound Lists Select a compound list BEHTVX BEHTVxX1 COOLING TOWER VOC S COOLING TOWER VOC S 2 EQUIPMENT LEAK COMPS Either Select All to add the whole Compound List to the Profile or click Compounds individually while holding down the Control Key and click OK Compound List for TRI Select All Clear All Ql Cancel Compound Deminimus BENZENE BUTADIENE 1 3 CUMENE ISOPROPYLBENZENE CYCLOHEXANE ETHYL BENZENE HEXANE N METHYL TERT BUTYL ETHER MTBE TOLUENE ACM CALCS Manual Page 87 For Speciation from a Stream Composition you should have already created a Stream Composition Property and Unit Stream earlier and you must have already added a Formula for a Multiple Compound like VOC to speciate Click the Speciation drop down arrow and Compositional Analysis Using a Stream Comp select the chemical
29. management Before clicking Run if you want to add your own explanation to the recipient check the User Defined Report Heading box and type a special heading 4 13 4 Calculate Button Row The Run button performs whatever calculation you specify in the Calculate screen displays them in a results screen see below and writes the results to the database EMISSIONS INVENTORY SUMMARY BY SOURCE SOURCE GENERIC EFFECTIVE FOR 01 01 2005 to 12 31 2005 The User Defined Report Heading appears here GENERAL DESCRIPTION OTHER SOURCE ID H 3 CPU EAST DOVWWTHERM FURNACE UNIT SPU UNIT FUEL STREAM TYPE CPU DOVVWTHERM FUEL GAS ESTIMATION DATES 1 1 2005 12 31 2005 ESTIMATION EMISSIONS EMISSIONS EMISSIONS COMPOUND METHOD Ibsihr Ibs est tons est NOX 0 15 Ib mmBTU 3 17 27 760 99 13 8805 PM10 13 70 Ibsmmsct 0 33 2 907 69 1 4538 CARBON MONOXIDE 35 00 Ib mmsct 0 85 7 428 40 3 7142 SULFUR DIOXIDE 502 0 66 Ib mmscf 0 02 140 08 0 0700 Voc U 2 80 Ib mmscf 0 07 594 27 0 2971 PAGE 1 OF 1 SEE E After results are Run you can use the PIPELINE Module to distribute FIN emissions to EPNs add abatement and transfer Pipe them to the EI module to for reporting The Save As button will save the results as a file of your choosing such as a spreadsheet The Zoom Report button toggles back and forth between the results screen and the main Calculate screen Prior and Next buttons thumb through the results pages You can also use the
30. number is the ID that links to other entities and should be all upper case if it contains letters with no spaces to avoid confusion Do not change or delete a CAS number after using that Compound in Stream Properties or further into CALCS This will cause all emissions for ACM CALCS Manual Page 35 that Compound to be lost If you must change the CAS number follow the steps in the Troubleshooting chapter in the section PIPELINE Steps with Troubleshooting A Single species example would be xylene whereas a Multiple species would be VOC Multiple species can be further speciated and will appear at the top of emission reports when using Calculate Although unspecified contaminants like VOC U could be considered Multiple they would normally be entered as Single because they are generally used when further speciation is unknown and they are usually part of the Multiple Compound VOC That way total VOC will be listed at the top of a report and all species which are subtotals would be listed below including VOC U xylene etc You can also edit or delete existing Compounds Be careful when you are deleting Compound records as there is no confirmation window in this section All fields to the right of the first three columns are optional and need be completed only if they are referenced by a Formula or needed for an automated CALCS computation like vapor molecular weight which requires the vapor pressure and molecular weight of all Compound
31. one of the other four report options The two other reports will not give much additional information for manually entered emissions Error Message Expression is not valid pops up once for each Emission Factor being processed Error in Formula perhaps an open parenthesis missing or double math sign or Keep clicking OK or hold down Enter key until boxes disappear Review and edit Formula Make sure all opened parentheses were closed there are no missing or double signs Source screen has blank fields referenced by Formula Complete blank fields ACM CALCS Manual Page 134 Symptom Possible Cause Resolution Error Message Wt not calced missing parameters Use Vapor Phase Composition is checked yes in Profile but Composition Phase in Stream Properties is not selected as vapor Change yes to no or liquid solid to vapor OR change Composition phase in Stream Composition Check to see how other Sources are affected by any Profile change Error Message Null object reference at line 10 in clicked event o object m_Source detail of m_calcemissions System Error Err 2 on white pop up Calculate Estimate Emission screen has allowed two report types to be selected at once perhaps due to repeating Zoom Report too many times and needs a refresh A quick fix is to choose Options General Reports an
32. operating parameters for each step for example the temperatures pressures etc The user also chooses a flow condition which points to a control device network configuration utilized for emissions abatement BT vma a ACM CALCS Manual Page 119 al The second tab displays material input output information 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 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 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 ACM CALCS Manual Page 120 all Chemicals charged into the vessel can participate in one or more reactions The software identifies the limiting reactant based on the qua
33. retrieve and Save update the original key data is lost CALCS thus won t be able to save the data The solution is to click List again to retrieve the current Source key data and edit again Unfortunately previous changes are lost The single user preventive measure is to Quick Edit without opening any other screens until saved The multiple user mitigative measure is to save often so as to minimize the amount of time lost if another user changes key data ACM CALCS Manual Page 132 Symptom Possible Cause Resolution Abatement percent in EI is not the percentage used in CALCS Abatement credit is Calculated in CALCS Formula instead of in PIPELINE EI Delete the abatement part of CALCS Formula if prudent In EI click File Equipment Relationships right click the CIN and enter the abatement percent in the CIN screen Run Calculate Inventory and PIPELINE steps again During piping check the Use Controls box Actual Hours not used in calculation rather Maximum Hours Label is reversed with Maximum Hours field in CALCS Enter actual hours in Maximum Hours field and vice versa A fix for this error is in process Compounds recently entered in Formula and Profile are missing after clicking Run Calculate screen needs refresh Close and reopen Calculate screen Equipment Leak emissions are not found in reports Monitoring Program
34. specific emissions to transfer from CALCS to EI it is necessary for the correct CALCS assigned CAS Number to be correlated with the related EI Contaminant Code CALC to El Pipeline File Actions Window Help 2 amp amp 2 B BF Parameter Emissions Export Contam Equip Batch Pipe Fiename Exit The Batch Pipe icon provides a list screen to select batch Sources for transferring emissions from CALCS to EI as shown below The Emissions icon provides a list screen to select non batch Sources for transferring emissions from CALCS to EI 8 2 4 b Print Err Reports List Pips Close lbj Batch Emissions Pipeline Select Parameters For Building Emissions List Yearfisse x Facility z 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 cas Num Contam Code Point Tonsi r Lbr Tons Yr __ Lbs Hr ERP Tons pe E e E TCC E e rows J Do TE 73 5 30 p7003 l o oo ACM CALCS Manual Page 124 CHAPTER 8 TROUBLESHOOTING If all screens are not properly linked you will encounter difficulties in calculating emissions or using some other CALCS or PIPELINE function problems 8 1 CALCS Troubleshooting Chart Symptom Possible Cause Resolution CALCS is not finding database file The
35. the Flared Units drop down is expanded to show options TPE means tons per estimation period Although the Flare Efficiency field is presented for flexibility it is still best to enter this efficiency in PIPELINE or EI Note that the flare is not the source of the VOC it burns The VOC source s are somewhere upstream and the flare is only the abatement device The flare is the source of NOx CO SO2 and PM from the flame itself gt Add Edit Sources FL 1 Facility Code Source type FLARES Equipment id JFL 1 Delete Estimation Dates o 401 2005 12 31 2005 v E General Kf Detail Manually Enter Emissions Comment Type of gas flared ag Soot _ Flare efficiency Bao o Cut crude processed Poo Crude processed fo Potential quantity flared Poo Processed units Bbvest xz Utilized cut quantity flared p1 8 572 00 Ib est ilized quantity flared h5929 Potential operating hours 784 Flared units Utilized operating hours B784 Estimation dates Days online ACM CALCS Manual Page 55 4 8 3 2 10 Detail Tab Loading Rack Source Type The Loading Rack Source Type can pertain to loading of barges rail cars trucks or even drums This screen can accommodate any number of Streams under Product type Streams can be changed for every set of Estimation Dates entered Enter the Throughput and Units and CALCS will compute Cvt Converted Throughput in standard Mgal units Click Insert or Delete buttons at the bottom to
36. top of the list of Compounds down to the Compound in question Enter missing concentrations A false concentration such as 1 ppm can be entered If no formula refers to this number this will cause no error Error Message Calc button for vapor or liquid MW does not work Missing MW reference temperature stream temperature or Compound MW or vapor pressure data Enter missing data ACM CALCS Manual Page 127 Symptom Possible Cause Resolution Error Message The Stream ID _ is referenced by one or more Source Emission Calculation Parameter s and hence cannot be deleted when attempting to delete a Unit Stream One or more Sources is linked to this Unit Stream Open Source screen choose first Facility in pick list then using the drop down to the right of Unit Stream click Relations button Scroll down to find Unit Stream ID in question Write down all related Source Types and Sources Repeat for all Facilities sites In Source screen choose one Facility and Source Type Delete all unwanted Sources Repeat for all related Facilities and Source Types Retry Unit Stream delete ACM CALCS Manual Page 128 Symptom Possible Cause Resolution Calc TVP button does not work normally for Storage Missing vapor pressure data in Compounds screen Enter either Antoine coefficients 2 point or
37. transferred to the EI Emission Inventory section of COMPASS for reporting CALCS also keeps a history of past years calculations Other modules of PDC s COMpliance ASsurance System COMPASS are e Utilities module imports state EI download Extract files e PIPELINE module transfers CALCS emissions to the EI module e Emissions Inventory EI module views and creates a state upload Delta file for submission e TaskTrakker assigns and tracks Title V permit tasks 1 2 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 m ORACLE 7 3 and higher m Sybase SQL Anywhere 5 5 and higher CALCS Manual 1 3 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
38. type a new ID in the blank to the right of Enter Factor ID To find an existing Formula select the Source Type and the Factor Formula ID from pick lists ACM Calcs Emission Calculations Program File Data a Window Help 4 g ft Bb we A A E E F a b Compounds Stream Prop Unit Streams Import Formulas Profiles Calculate Inventory Exit 2 8 amp 9 a As Erase Print Close Comments i Add Edit Emission Factors and Formulas HORIZFIXED Select source type STORAGE TANKS v Enter factor id HORIZFIXED v Specific Description JaP 42 HORIZONTAL FIX ROOF Type of factor General description horizontal fixed roof General Site Specific Compound YOC X Emission factor EF units jomr Emission Type Actual Data source jap 42 SUP E C Maximum Columns Column labels Columns to include STREAM MASTERtempf_std in F tempf_std Seif Stream Data V STREAM_MASTERtup_std in psia tempf_std STANDA Stack Test STRMCOMP cut_Conc in WT STRMPROP density in Lbs gal STRMPROP heat_content in HHY BTU scf STRMPROP low_heat_content in LHV BTU STDRADDAD mia in SEnae B El a Formula for estimatina E Ib hr Embed Formula ef 365 shell_length_hs diameter_d vp_sp_outage_hvo mw _tank_vapor vp_pr_dly aviq_sftmp 10 731 dialy_avg_sftmp_tla diy_vp_tmp_rng_deltv dialy_avg_sftmp_tla up_pr_dhy_mxlq_sftmp vp_pr_dhy mniq_sftmp brtr_vent_pr_setrange 14 696
39. z P1 LOAD RACK SOURCES pre pock 2 CAN AND DRUM a fSP2DUMP DEFINED pi pock 2 DUMP TANK je BP2FUG EQUIPMENT LEAKS Er F sP2 EMISSIONS SP2 BP4At EQUIPMENT LEAKS ae Epa EQ LEAKS FROM TAM sea i ACM CALCS Manual Page 75 4 8 5 2 Source Report When the Source screen is open you can also click Options Source Reports then Retrieve for a list of all Sources with their Source Type General Description Specific Description Unit and Profile f Source Report Ale E Facility code v Retrieve Brief Source Report for Facility Source Type QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS QUIPMENT LEAKS General Description UGITIVES UGITIVES Specific Description UGITIVES UGITIVES UGITIVES UGITIVES CycyCcyCcyCcyc cycyc G GD GD G G gt S S S SS S SIENE LEENE a E e m rm rm f rm f ri f r miim m LO Oo Oo ea oo Loy oo GG Ie Ie Ee Ee ee ee Ee ee ee ee ee keli iel AO Gf ol Ol el ol EEJ 5 s 5 s e s 5 el s s s sls miimi miim iim m m iim iim i m ffm ffm ol IOPOVOPO OO OVO POO O OW oy oo amd Gad Gad Gad Gaa Gaa aa aa leche che llchelic miim m m m m i i f en mim ffm BEJE EE E SISSY E
40. 00 PART CHEMICAL U jM Display fi1000 00 0 v Total Suspended Particulate Matter TSP v Iv Active j SARA J HAP 1 00 4 fi10s0 JURETHANE Iv Display Joo0s1 79 6 v Total Suspended Particulate Matter TSP x v Active v SARA M HAP 1 00 otal Rows 1713 v List Criteria ACM CALCS Manual Page 106 5 5 Equipment Screen FIN EPN CIN relationships must be established before CALCS emissions can be Piped because CALCS only knows the total emissions from a FIN CALCS does not know what EPN or EPNs will exhaust the emissions the percentage to each EPN whether there is a CIN or what its efficiency is These relationships are normally imported from the state download file Click the Equip and List buttons to see all relationships To see a smaller list type the first few characters of the FIN to the right of Facility ID Number Like As an option use the drop down arrow to pick Emission Point Number Like or Control Device ID Like type a few characters and click List This screen is also viewable from the EI module by clicking File and Equipment Relationships CALC to EI Pipeline File Actions Window Help 2 8 amp 8 E a F Parameter Emissions Contam Equip Rename Exit 2 amp 8 2 F Save List Print Insert Delete Close List ano Criteria Info gt gt Facility Id Humber like Emission Point Humber like Control Device Id like Row FIN EPH CIH Feedin
41. 5 Special Menu Options sseseessseseessseessssessseessssesssressereessseesssress 74 4 8 5 1 Equipment Maintenance ss ssssssssesesseeesseresssresserssssresssees 74 A S9 2 DOUCE REPO gacncdeneasutcewBaserteasslage secede O ead ens Cee 75 49 Quick GIS CRG OM Gccccabcsccctavosnctauesasatactctebacestatesaaceacleutiacabaeteebacereckcweluest 76 A LOM Import Serec serna e EE E E EE Ea tinge 77 AED OMIM ba SCTE CN ast aen eane ro e e oe Sac oeh area ktede Avance 78 4 11 1 General versus Site Specific Formulas cccceeesceeeereeees 79 4 11 2 Maximum versus Actual Formulas 0 ccccccssseceesteeeeeeeeees 79 41136 olumins Variables yessest cc cenest vecieusgavensdecthas coaekavneamstieonants 79 4 11 4 Operators Powers Parentheses and Embedding 80 4 11 5 Equipment Leak Formulas 2 s cc c sevelsecnacaacedenssedsanconceasageansa cone 81 4 l2 Profile Sreem srren ae E RE caceulesrnacust E ria 82 4 12 1 Using Vapor Phase Concentration sssseseseesseseseereesseesserees 82 4 12 2 Estimation Method seco cnlawssisice de cnteracer soresededeou teas pcavenstoudssnise 83 Arh DDS PCO AION ies oa sai b hacohs oy siseiatoaahaducvat suas paren EE A EEE nous 84 4 12 4 Equipment Leak Monitoring Program eeeeeeeseeeeneeeeeeees 88 4 12 5 Linking the Profile to the Source eee eeeceeseeeteeeeteeeneees 88 4 12 6 Special Profile SCreens i145 xi ss onarensinaneseenaseemumuneietocmaciatacinenasebius 89
42. 5 point data in Compounds screen for each Tank Source Type Compound in Stream Missing vapor MW in Enter vapor MW or click Calc if Stream Properties screen supporting data is entered Constant Temperature Set to No if appropriate Tank is set to Yes Daily Avg Liq Surf Constant Temperature Set to No if appropriate Temp and or Daily Tank is set to Yes Vap Temp Range buttons do not work Error Message Integrity Constraint Violation index eqleak_counts for table equipment leak coun ts may not be unique database error code 196 More than one Equipment Leak Source is linked to the same Stream Equipment Leak Streams are allowed only one link Create another Unit Stream with a unique name Error Message Integrity Constraint Violation primary key for table eqleak is not unique database error code 193 In the Leak Counts tab there may be an extra Stream usually called Stream with a blank Stream description Click the delete button next to this name The actual Stream below the erroneous one should still be there Error Message Integrity Constraint Violation Primary key for table equip is not unique database error code 193 The same Source ID is trying to be entered twice perhaps under two different Source Types Search other Source Types for same Source
43. ALT 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 ACM CALCS Manual Page 114 For each estimation period 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 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 Str
44. AND FUEL UNDER FUEL USAGE current_firing_rate CURRENT FIRING RATE cvt_fuelusage CONVERTED FUEL USAGE designrate DESIGN RA liq_fuel_used LIQUID FUEL USED noxirf NOX LOAD REDUCTION FACTOR operating_hours POTENTIAL OPERATING HO potential_horsepower POTENTIALHORSE POWER tup_std STANDARD TRUE VAPOR PRESSURE tempf_std STANDARD TEMPERATURE tup_reid REID TRUE VAPOR PRESSUF sulfur_content_ppm SULFUR CONTENT IN PPM mw_tank_vapor VAPOR MOLECULAR WEIGHT mw LIQUID MOLECULAR WEIGHT low_heat_content LOW HEAT CONTENT PAGE 1 OF 4 40 2507 10 38 7 4 aaa IZ ACM CALCS Manual lel FORMULA OR COMPOSITION U ef cvt_fuelusage heat_content of ef cvt_fuelusage operating_hours ef cvt_fuelusage operating_hours ef cvt_fuelusage operating_hours ef cvt_fuelusage operating_hours Page 16 2 11 Inventory The Inventory button allows a spreadsheet view and editing of all emissions after calculating is complete Emissions Inventory Summary 2 12 Exit The Exit button closes CALCS ACM CALCS Manual Page 17 2 13 Linking Related Items Data saved in certain screens appears in a pick list on later screens Thus one screen feeds another If you pick a Compound from the pick list in the Stream Properties screen you link the two Stream Properties are linked to Units as Unit Streams A Unit Streams is linked to a Source A Source is linked to a Profile which is linked to o
45. ARBON MONOXIDE JO VWWTHERM HEATER OX BNOX H 8 NOX Ox FLPNOX FLP 1 OR 2 NOX NOX NORTH PAINT amp BLAST NOX bol ACM CALCS Manual Page 84 When choosing Manually Entered Emissions a line appears at the bottom Use the pick list on that line to select the Compound Compound Methodtype Methodcode CARBONMONOXIDE S Factors Dowco C SP ERCTORS DOWNOX mo YP ERARCTOR S OEM SULFUR DIOXIDE 603 v ERATOR DOWSOD S EFCTORS DONOR es Add as many Formulas and Manually Entered Emissions as needed 4 12 3 Speciation If the Formula calculates Total VOC a Multiple Compound it may be necessary to divide it into species or Compounds Likewise SOx could be speciated into SO2 and SO3 PM into various metals etc There are three ways to do this by Manual selection by Compound List or by Stream Composition The latter two methods allow adding many Compounds at a time Speciation Compositional Analysis Manual Compositional Analysis Using a List CARBON MONOXIDE Tan wl Fractars Nann For CALCS to compute every Compound s emissions you must have every Compound listed in the Profile Also before Speciation you must first have added a Formula for a Multiple Compound like VOC PM SOx etc to have something to speciate ACM CALCS Manual Page 85 If you click the Speciation drop down arrow and Compositional Analysis Manual a window will pop up asking you if it
46. CS terms in a sentence are often capitalized and refer to labels on the described screen 1 8 Pre entered data CALCS contains a standard library of chemical Compounds with their Properties as well as many AP 42 formulas already in place You may first be supplied with a demonstration database with example Sources to use for practice Often your company will later have PDC enter all your site s Sources Stream Properties and other data previously in spreadsheets This allows the user to start with a ready to use application 1 9 Data fields CALCS has a number of different screens with fields for data Some fields are mandatory before data can be saved Other fields may need data because they are variables in a calculation Formula Some fields must be completed to take advantage of certain CALCS features For instance all Compounds in a Stream must have molecular weight entered before you can use the Calc button next to the MW Liquid Phase field to automatically calculate that value The rest of the fields can remain blank or be used as a storage place for miscellaneous data thus changing that data will not necessarily affect calculation results ACM CALCS Manual Page 3 1 10 Logging onto CALCS When you click on Start All Programs COMPASS and Calculations Module a login window will appear If you are using an Oracle database enter your User ID and Password select Oracle as the database and then click OK If you are
47. Emission Results ACM CALCS Manual Page 26 4 1 5 Options Menu The Options Setup menu 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 ACM Calcs Emission Calculations Program e Process Reference Emissions Options Maintenance 4 Fil z fh 2 86 F a iad Compounds Stream Prop Unit Streams Sources E E E 4 1 6 Maintenance Menu The Maintenance menu 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 Facilities or Sources Options Maintenance Window Help b Stack Tests op Unit Stre Compound Lists __ Source Type Display Disable Formula Edit Cleanup Database Profiles ACM CALCS Manual Page 27 4 1 6 1Stack Test This screen all
48. Haps Yolatile Organic Compounds VOCs IC Yes No EC Yes No 30 00 1737 40 00 Yolatile Organic Compounds VOCs Yes No E Yes No 30 00 1601 40 00 Volatile Organic Compounds VOCs as Yes No E Yes No 0 00 0 00 0 00 IF Yes No E Yes C No Yolatile Organic Compounds VOCs Mis Yes No E Yes No 26 70 3 30 37 80 Volatile Organic Compounds VOCs ME Yes No G Yes No Volatile Organic Compounds VOCs vE EER Bo 0 00 0 00 0 00 Carbon Monoxide AJC Yes No E Yes No Lead Containing Compounds 30 00 5 71 40 00 Nitrous Oxides C Yes C No E Yes No 30 00 5 52 40 00 Sulfer Dioxide C Yes No E Yes No Particulate Matter lt 10 microns PM10 30 00 9 48 40 00 on Methane Organic Compounds NMOt Yes C No E Yes No 0 00 0 00 0 00 Total Suspended Particulate Matter TSP C Yes No E Yes No 3 2670 3 30 37 50 Meena anie compounds Yes No Yes No E Yes No E Yes C No yy 4 O ACM CALCS Manual Page 37 4 5 Stream Properties Screen Each Source must have a related Stream in CALCS Stream Properties are not related to any specific operating Facility nor to any Unit The ID will be the key to link a Stream Property to other entities and can be up to 12 characters long It should be all upper case with no spaces to avoid confusion To add a new Stream Property just start typing the ID in the blank provided To edit an existing Stream Property us
49. LCS automatically computes four related factors EH General K Detail Blank Data Tank Fittings alculation Method Tanks 3 1 ed of Fittings Fitting Loss Kfa Kfb m v ing Loss Factor 1 6 Humber of Rows 44 v 4 b ACM CALCS Manual Page 70 4 8 3 4 3 Tank Fittings Tab Domed External Floating Roof Tank Type These fields for Domed External Roofs are the same as for Internal Floating Roofs ACM CALCS Manual Page 71 4 8 3 5 Leak Counts Tab Equipment Leaks Source Type This has been used in the past to quantify all leak emissions More recently leak contractors quantify all but non monitored leaks which are normally calculated here For details on the former method see the separate Equipment Leaks chapter Only the non monitored functionality will be explained in this section Multiple Streams can be entered on the Detail tab each with its hours of presence within the section of pipe or equipment defined by the Source ID CALCS will list all components for each separate Stream entered with a VOC of 100 on the Detail tab If there are Streams with less than 100 VOC a single list of components for all those Streams will be under Combined Streams lt 100 VOC You can delete the entire component list for a given Stream by clicking the Delete button at the top of that Streams list by the Steam ID For each Stream enter the count of each non monitored component in that section of pipe This coun
50. Link Tracing Chart To trace missing or mismatched ID s write all ID s on this chart All ID s in a vertical column should be the same Source Type Equipment Leak no ID FIN Range Facility Proces Compound need to unless Monitoring Component for BELOW IN Code s Unit CAS will Enter lab Stream match Secondary Estimation Formula Prog foreq Descr for eq Gen Acct No link to El sample ID ID El Source Dates ID Profile leaks eq leaks leaks Desc Calculate or Inventory Source Profile Formula Unit Stream Stream Prop Compounds Facility ACM CALCS Manual Page 145 ACM CALCS Manual Page 146
51. Properties Screen seseesseeeeeseesseeesssreessrressrtessrssssresseresssresseres 35 46 Umt Streami Sereen kooni ipene ii rees radins arros tucsaacn EDESTEN PEA TEEDE 38 4 7 Relations Screen seseseseseresererererererereresosesesesesesessveresertsereserereresererereses 41 CALCS Manual 4A S OEE CCS CEOCM cis tia wes Sesto a a foie btee a a cadets Lente Conta Neel ots 42 AS A Estimation Dates sarosa Oe iveh suas E E ea 43 4 8 2 Potential and Utilized Operating Hours sssseessesesereesseesseeees 44 ae a NI o E E A E E E AETA 44 AO Sl General TaD riscia a anes 44 4 8 3 1 1 General Description sss asceivestsn hotel sndintee Gtbacvens 44 4 8 3 1 2 Specific SSCL MEO sete 5 cice sacks cudyo8 2 0s solvate cance Oeeeeb ads 45 Ap Lig LING AE E clebaceedmesntes 45 ALS DWAR PROUC serecssoctesbe ernneecuetedest E AE S 45 4 8 3 1 5 Comment button n 0 205 55 ecbeens colo vaavca tater Qestendevee bene ceneetbans 45 48 32 Detail Ta bcorien n ESA a E a a E 46 4 8 3 2 1 Manually Entered Emissions cccsscceeeeseeeeeeees 46 4 8 3 2 2 Detail Tab Air Stripper Source Type 068 47 4 8 3 2 3 Detail Tab Catalyst Handling Source Type 48 4 8 3 2 4 Detail Tab Combustion Source Type eee 49 4 8 3 2 5 Detail Tab Cooling Tower Source Type 50 4 8 3 2 6 Detail Tab Drains Sumps JB Source Type 51 4 8 3 2 7 Detail Tab Equipment Leak Source Type
52. S AND JB ACM CALCS Manual Page 52 4 8 3 2 7 Detail Tab Equipment Leak Source Type For Equipment Leaks you can enter multiple Streams by clicking the Insert button at the bottom Highlight a line and click the Delete button to remove it The Streams can be different for each date range Each Stream can also have different hours within the same pipe or equipment Although the note below the Stream list says combined Streams should add up to 100 it is not necessary unless designed that way in the Formula The days and hours need not match unless the Formula references both The Leak Counts tab will be discussed in the Leak Counts section and in the Equipment Leaks chapter Add Edit Sources F P24 Facility Code Source type EQUIPMENT LEAKS Equipment id F P24 x Delete Estimation Dates i Peirce HA General K Detail Dd Leak Counts Manually Enter Emissions Stream VOC percentage Days Online sho E A S S a C e a t t CS CS a a e a C e a S S TOTAL combined streams should add up to 100 800 Insert Delete tot Operating Hours ACM CALCS Manual Page 53 4 8 3 2 8 Detail Tab Fluid Catalytic Cracking Unit Source Type This screen is mostly self explanatory The Type of Flue Gas is the Unit Stream Add Edit Sources 1 ACM CALCS Manual Page 54 4 8 3 2 9 Detail Tab Flare Source Type In the screen below
53. Tank C Yes No Hote Selected parameters can be recalculated by clicking on the buttons next to them The four pick lists on the right side will automatically show monthly or annual Maximum Ambient Temperature Minimum Ambient Temperature Insolation Factor solar heating and Wind Speed for the chosen city CALCS uses these to compute Daily Average Liquid Surface Temperature and Daily Vapor Temperature Range Max ambient Temp Tax b52 xz deg F Min ambient Temp Tan 427 v deg F Insolation Factor I 730 v BTU FT Daily Avg Liq Surf Temp E6620 deg F Daily Vap Temp Range P4 1716 Wind Speed fg z mph Potential operating hours Wind Speed constant Temperature Tank B9 October the buttons next to them December Utilized operating hours Due to the number of variables in the AP 42 tank formulas CALCS has an additional Tank Data tab See the Tank Data Tab section for details ACM CALCS Manual Page 60 4 8 3 2 14 Detail Tab Sulfur Recovery Source Type Enter the sulfur Recovery Efficiency Sulfur Produced and Produced Units in Long Tons Per Day LTPD Short Tons Per Day STPD Long Tons Per Estimation Period LTPE or Short Tons Per Estimation Period STPE Enter Tail Gas Emitted and Emitted Units in lb hr or Tons Per Estimation Period TPE CALCS automatically converts both quantities to STPE and TPE respectively Pick the CEM type either H2S or SO2 and enter the CEM Concentration for that per
54. Units Screen Click on the Units icon for this screen All Sources and Unit Streams must be linked to a Unit While this takes more effort it allows for unit specific emission calculations generally for internal use 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 You may delete an existing Process Unit by selecting that record and clicking on the Delete icon You will be asked to verify the deletion so choose Yes To print the listing of Process Units click on the Print icon The Process Unit Number is the identifier used to link a Unit to a Stream Property or Source It can consist of up to 20 characters After entry the Units will appear in a pick list in other screens The ID is the link to other entities and should be all upper case with no spaces to avoid confusion Add Edit Process Units Search for Unit name Process Unit Hame Process Unit Humber Area Scaling Factor s m nn COOLING TOWERS Re a CPU UNIT Boeru o poe T FLARES BORFLARES ff GENERAL BORGENERAL C lt i S MPU UNIT BORMPU O Po pe PPU UNIT E SHIPPING BorsHP ff SYNTHESIS UNIT Bosu D T TANK BATTERIES BORTANKS ff UNIT 5 1 Bonusa o PoS TeS UNIT 5 2 Bornus2 0 ff WASTEWATER ORV TION poo o o T o mo 3 ACM CALCS Manual Page 33 The Units screen includes a
55. YEE SSeS PAIERA ESI ESI ENIES EAI EA EA EA EAI EA EAI EAEN 97 091 091 09 091 09 O91 C9 Oo en ea oo ean i ai i ai fl a of a of a SO A EJE DY DY Dalal alalia OYONOHOPOYPO O ONoPoOyoyOo Ooo a ee ee EE mee AIAKAS IAIA HISIS ISAIA ISAIAS ne DDD Dy Dy oy 0 0 0 0 ca ca f c f c f co Ro ea Ro Tmo ISa mo r Ra no Ra S alaala Bf ca S SS A em em em em em em em em em em em em em rmi ACM CALCS Manual Page 76 4 9 Quick Edit Screen Click on the drop down arrow just to the right of the Sources button Select Quick Edit The Quick Edit screen allows entering throughput and other data in a list rather than on one the Source screen at a time Each line of data is for a Source for a specific time period Not all process variables are displayed on the Quick Edit screen In general only the variable s that are likely to change from one period to the next such as throughput or fuel usage are editable Pick the Facility Source Type Unit only if desired and Year and click List Edit data and click Save ACM Calcs Emission Calculations Program TE window 3 z Ff B 5 RN E E F a b Compounds Stream Prop Unit Streams Quick Edit Formulas Profiles Calculate Inventory Exit a a amp F a File List Export Print Close Source Quick Edit Facility v Type STORAGE TANKS vy Unit ALL v Year JALL z
56. a Formula or its variables and click Run again it will overwrite the old results with the new results Repeat the edits as many times as needed to create a final draft so to speak Calculated results can later be transferred by the PIPELINE module to the EI module for reporting to the agency You can think of the database as being in three parts CALCS raw data CALCS draft results and EI reportable results Manual entries and Download Extract imported plant data file from state CALCS PIPELINE UTILITIES MODULE MODULE MODULE PE raw data Ir EI reportable results Streams results routed to EPNs Sources unabated abated Formulas emissions formatted for reporting by FIN DATABASE ACM CALCS Manual Page 92 4 13 1 Selecting What You Calculate Select a Facility Site ID a Begin Date an End Date a Source Type a Unit only if you want to narrow the Source search and the Source Equipment ID You must check the box by Unit or Equipment ID to see the filtered list 4 13 2 Calculation Criteria When you Calculate the first time use the default Calc Emission Results and Cale Vapor Weight options If you later want to see earlier results that were previously Calculated you can check the box for Use Existing Results which is faster than recalculating If you later re Calculated with a new Profile and want to see or re Calculate old results check the box called Use Profile Matching Selected Time Period E acM Calcs Emiss
57. a carbon monoxide CO Formula below Note the standard AP 42 emission factor ef of 84 lbs CO per million cubic feet of natural gas is multiplied by the fuel usage converted to million cubic feet then divided by operating hours to obtain pounds CO per hour Ge Add Edit Emission Factors and Formulas FURNCO a ef cut_fuelusage operating_hours ACM CALCS Manual Page 14 2 9 Profiles An emission Profile is a list of Formulas Each Source is linked to one such Profile A boiler Profile would have 5 Formulas to calculate NOx CO SO2 PM and VOC Note the Formula FURNCO from the figure in the previous section is on the Methodcode list below Emission Source Profiles FURNACEA ACM CALCS Manual Page 15 2 10 Calculate The Calculate button runs calculations for a selected Source s and date range The results are stored as a history so that you can later determine the basis of reported emissions for any year Estimate Emissions ESTIMATION EMISSIONS EMISSIONS EMISSIONS EMISSIONS TOMPOUND METHOD Ibs hr tons yr Ibs est tons est NOX 0 15 Ib mmBTU 3 1691 13 8805 27 760 9927 13 8805 PhO 13 70 Ib mmscf 0 3319 1 4538 2 907 6881 1 4538 CARBON MONOXIDE 35 00 Ib mmsetf 0 8480 3 7142 7 428 4000 3 7142 SULFUR DIOXIDE 02 0 66 Ib mmsct 0 0160 0 0700 140 0784 0 0700 VOc U 2 80 Ib mmsef 0 0678 0 2971 594 2720 0 2971 Comments UPDATE BY ENTERING RUNTIME UNDER POTENTIAL OPERATING HOURS
58. a eoLeaKSFROMTKAa a Se Beak GPa EO LEAKSFROMTKEID Eras Te Foe GPa eOLEAKSFROMTKEIS o Bama ooo o Foe EPEa LEAKS FROM KeA Bas o o Foe GPa EOLEAKSFROMTKEIS o e es Beak T Bms SS Foe GPa EO LEAKSFROMTKAga o Brass o Foe Bra eoLeaKSFROMTKAga o r e Beak a Aa ACM CALCS Manual fa Page 110 CHAPTER 6 EQUIPMENT LEAKS 6 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 6 2 Setting Up the Data Before importing contractor data
59. a local or network hard disk under the directory structure lt drive gt PDC ACM CALCS The installation program creates this structure below the target installation folder chosen by the user The application and database file can both be on the desktop both on the network drive or split with the application on the desktop for speed and the data on the network for security The application file is dadams exe and the database file is acm db Multiple COMPASS modules can use the same database file The installation routine creates a COMPASS folder under All Programs 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 ID and Password 1 4 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 When you click on Help and Contents a dialog box will appear with selections for using the help features of the system Users can search for a specific topic of interest by 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 5 Technical Support of CALCS Technical Support of the system is provided by PDC Corp Please be aware that support t
60. acm db file used in SQL Anywhere databases is not in the folder where CALCS is looking Normally acm db is in the C or network drive PDC ACM folder Move acm db there If that is not successful click Start Administrative Tools ODBC and look for acm in the two left tabs When found highlight it and click Configure to see the target where CALCS is looking Either change the target folder or move the acm db file to the existing target folder Cannot copy acm db Someone is using the database Wait and try later if another is using the database Database is set to run continuously in Citrix server If at Citrix keyboard click Start Programs Sybase SQL Anywhere 5 Sybase Central Services double click acm_cpcpa and click Stop Copy the acm db Repeat the procedure only click Start ACM CALCS Manual Use the guides below to resolve those Page 125 Error message Missing Stream Property Data Missing Molecular Weight data for stream 2 Converted values for quantity flared or other calculation may not be correct Compound s in Stream Properties for stream is missing MW or MW reference temperature gt CALCS will allow user to continue by clicking OK If no Formula will use MW this warning can be ignored If MW needed it must be entered in Compounds screen for every chemical in every Stream involved then in
61. add or remove Streams Add Edit Sources SP54 Facility Code bai Source type LOADING RACK SOURCES X Equipment id Psa Delete Estimation Dates i201 i2005 12 31 2005 v Delete HB General K Detail Manually Enter Emissions Control Saturation Product type Throughput Units efficiency factor Cut throughput 100 0000 fi 450000 0 00 mgal est 0 0000 1 450000 x 0 00 mgal est 0 0000 1 450000C y 0 00 mgaliest 95 0000 1 450000C 77 00 mgaliest 0 0000 f 4500000 j23 00 maalest 0 0000 f 4500000 59 00 mgal est i oe Insert Delete Calc TYP Highlight a Stream and click Calc TVP to calculate true vapor pressure This function only works if all Compounds in the Stream have vapor pressure data and Stream temperature See the next page The Control Efficiency is allowed here for the case where some liquids are controlled and others are not Ifthe Source is always controlled it is better to enter the efficiency in Pipeline or EI modules ACM CALCS Manual Page 56 Scrolling farther to the right you can see other variables that can be added Average Temp F must be entered to use the Calc TVP button which calculates the true Average Vapor Press psia CALCS also automatically enters the Days Online and Operating Hours from the Estimation Dates assuming 24 hour per day operation Add Edit Sources SP5A Facility Code Source type LOADING RACK SOURCES bil Equipment id EP54 z
62. al min ACM CALCS Manual Page 58 4 8 3 2 12 Details Tab Spills Source Type VOC spills are calculated from the Spill Amount Spill Units and Percent Vaporized amp CM Calcs Emission Calculations Program moa haa ACM CALCS Manual Page 59 4 8 3 2 13 Detail Tab Storage Tank Source Type The Product is the Unit Stream which you must pick from the list Pick the State and closest City for meteorological data If the Compounds in Stream Properties have vapor pressure data you can click the Vapor Pressures button to automatically calculate Daily Minimum Average and Maximum Liquid Vapor Pressures These values are then used in the standard AP 42 Formula If the Constant Temperature Tank radio button is clicked Yes it sets the Daily Vapor Temperature Range to zero which zeroes out the daily breathing losses in the standard AP 42 formula E General K Detail BB Tank Data Manually Enter Emissions Comment Product TKPR8 z Max ambient Temp Tax 652 gt deg F State Meas J Min ambient Temp Tan fan7 x deg F City Houston x Insolation Factor I 730 v BTU FT Estimation dates 12 16 2005 v 12 31 2005 v Daily Avg Liq Surf Temp 16620 deg F Days online he ooo Daily Vap Temp Range Bsiz Daily Min Liq Vap Press s80 Wind Speed Bo zl mph Daily Avg Liq Vap Press 6805 Vapor Pressures Potential operating hours Ba Daily Max Liq Vap Press 738 Utilized operating hours Bea Constant Temperature
63. ange that includes __ deg C in error message Ifthe user considers it accurate enough increase the temperature range for existing vapor pressure constants Multiple Streams not saving in Equipment Leaks or Loading Rack screen Streams cannot be saved more than one at a time Save each Stream individually after entering it ACM CALCS Manual Page 130 Symptom Possible Cause Resolution Column labels are missing in User Defined Formula screen General Description is mismatched Use the same General Description in User Defined Sources screens and their Formulas Same labels are not used in every date range Check each date range in the Source screen and enter exactly the same labels in each as required Columns need refreshing Click the checkbox for Stream Data ACM CALCS Manual Page 131 Symptom Possible Cause Resolution Error Message Row changed between retrieve and update No changes made to database error code 3 This is a safeguard When you click List while in the Quick Edit screen you retrieve data If you edit and save you update the database CALCS looks for key data of a Source to make sure the changes are saved to the original Source with the original Stream etc If another user or even the same user changes any of the key data probably from another screen between List
64. aossstixvnssccscscuaisteishecenasenavscsecsaesecs 6 2 CAMS Main Sereen sessies turesi ieoten aote a en eraai Eyo 6 PAPA EE E E E E A E 7 23 UNUS en E A a E ieeseeneaat ea tes 8 2A NG AG S eee a e E E A 9 2 3 Stream POOP TIS Sine siees acess i dosnsctupenchedacssaneanolaaibiet e aa E Eate 10 2 0 NII Ee AMIS ernsctas anced entrances dahon eet e e eE dv Ges NEEE Sa Ga Eai E 11 2 I IS ae pe ase veces E E E uel tea oes eae nnd ome sens A 12 2S FOnmmalaS en A E E E A EE tention 13 P i KO TE E A E 14 210 Cal l te sneinen e ei s 15 BATT AN OIV ereere ae E E E E E rane 16 2A EXI eee e E a eeuetpn Gonvdamceemia oveacdaansians 16 2 13 Linking Related Items 1 05 winctsexcadcacdensutennadecatuniveacdiatncentsentacedasdentinions 17 CALCS Manual 3 ENTRY ORDER AND EXERCISE scccsssscosscseesssesscssscessscsees 18 ITEN a v6 Lc eee net emt ee ene ne ee ere eee enter Mee ae mn ene Ment oe 18 BE ROTC Sesano tise Wea gig ned aa en e a wich Se Attend sa wenn caehou das eiiean 18 Fee VC Pe abe es CI oe hs canta vate ten Sead aucune tea a eee 18 3 2 2 Create a Compound yscccssciscuaiapluciniseietedieninoscaeaeonaeiedaeniaeoss 18 3 2 3 Create Stream PrOperie sive sscci ar raanesienviorsdensinddienencnsirvetivens 18 3 2 4 Create a Unit Stream cccccccccccscecececececececececececececececsceeeees 19 3 2 5 Create A DOUN CO arrir a a E EENE RA 19 3 2 6 Create a Formula esesesesesesereserererererererererererererererererererererere
65. as emissions ACM CALCS Manual Page 74 4 8 5 Special Menu Options Some menu options are only available if certain screens are open 4 8 5 1 Equipment Maintenance When the Sources screen is open you can click Options and Equipment Maintenance or Source Reports The Equipment Maintenance screen default is to show all Sources You can click Primary Secondary to see just those Sources that are thus linked and then you can click Full List to view all Sources Primaries and their related Secondaries are grouped with the Primary highlighted in black The Equipment ID Source ID is in the left column If it has no Primary Secondary relationship the right column will be blank A Secondary Source will show its Primary Source ID in the right column The Primary will have its own Source ID again in the right column A drop down arrow in the right column shows a list of Source ID s to use as a Primary Source Click OK to save changes 4CM Calcs Emission Calculations Program File Options Window Help H Equipment Maintainance xi Cancel Tac aa Equipment id Source type General description Specific Reset ll Primary Srcid DEFINED G ae A ee fereSocTi00 SER DEFNED VACUUM VENT PoLunnS 6a7 vac vent ore gt Ficsor USERDEFNED VACUUM VENT PoLuwnS ear vac vent ere gt ereSocT170 SER DEFNED VACUUM VENT oc ear vac vent ere gt Ecsta USER DEFNED VACUUM VENT PoLUmnS 6a7 vac vent ere 0 st _____ FUG ee LEAKS FOSS EMISSIONS
66. at will be explained in another section The ID can be up to 10 characters long It should be all upper case with no spaces When first opening the Sources screen pick the Facility the Source Type then an existing Equipment ID using the drop down arrows If your Source is not under the expected Source Type search under the User Defined Source Type ACM Calcs Emission Calculations Program i Options Window Help Add Edit Sources Facility Code X0025U06 Source type Equipment id Estimation Dates j v a Bs 2 oF b 2 i E Ml Units Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit 0 amp F Sav Save As Print Close To add a Source pick the Source Type enter a new ID in the Equipment ID field and a General and Specific Description The Source Type does not need to be the same as in the EI module As soon as you click Save you create the new Source in the CALCS database To delete a Source and all of its data click the Delete button to the right of the Equipment ID If you are adding several nearly identical sources you can add one manually then click Save As A small window will pop up asking for the new Source ID Type in the ID for the next Source and click OK This will save all data from the first Source as a new Source including all date ranges while leaving the existing Source intact ACM CALCS Manual Page 43 4 8 1 Estimation Dates Data on all tabs is s
67. aved by Source and date range If you change the beginning and ending dates and click the Save button you copy all data on all tabs and save it as a new date range Reports under the Calculate function show emissions in tons per est which is the estimation period chosen for the report This period could be a year month day or any number of days bounded by the beginning and ending dates for the report There are three fields labeled Estimation Dates The upper right field is read only and is a pick list of previously entered date ranges If you pick an existing date range the data on every tab will correspond to those dates To delete data for just one date range select the Estimation Dates from the upper right pick list and click the Delete button to the right Estimation Dates 01101 2005 143112005 m m 01 M01 2005 127812005 0101 2004 12 51 2004 Delete The other two fields are on either the General or Detail tab and are the editable begin and end dates If you wish to enter data for a new date range enter the new begin and end dates edit any data fields like throughput and click the Save button All data on all tabs will then be associated with the date range while leaving the existing one intact If you look at the Estimation Dates pick list in the upper right corner you will see the new date range It can be viewed at any time in the future and can be used to calculate emissions Estimation dates
68. 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 output 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 on Resolving Unprocessed Data 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 6 3 3 Calculating Emissions ACM CALCS Manual Page 113 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 If correlation equations are used to estimate emissions the user must enter estimation dates that correspon
69. blem is in process VOC is not at the top of the report Other constitutents like alkanes u are above it instead of below like most contaminants Reports will put Multiple contaminants at the top alphabetically Alkanes u and similar contaminants are listed as Multiple in Compounds screen Change Compounds to Single in Compounds screen to put them at bottom of report The disadvantage is that they cannot then be further speciated in a Profile Zero emissions for a Stream after running Calculate Formula variable is referring to a blank field In Formula screen in left variable pick list click on each variable found in equation to determine location of referenced field Look at each referenced field in the applicable screen and fill in blank field No vapor MW Enter or click CALC button for vapor MW in Stream Properties Compound in Profile but not in Stream Prop Verify Compounds in both locations Blank wt Add wt in Stream Prop ACM CALCS Manual Page 137 Count is entered for wrong Stream under Leak Counts tab Verify number is in proper Leak Count Stream Range Group mismatch for Equipment Leak Source Verify Range Group used in Leak Counts tab of Source screen is same as in Formula and Profile screens ACM CALCS Manual Page 138 Symptom Possible Cause Resolution
70. ccncecsdtuccntscnndtacsdeacavertcncidec 122 LA NY PIPEHINE icardiviretrannoavenitannumneaismncaeaocnis 123 CALCS Manual 8 TROUBLESHOOTING ssssesis ssssess cosceticnte uti evetediectend siete teidessdeceessdeteteces 124 8 1 CALCS Troubleshooting Chart cecccccsseceesseeeceeneeeeesteeeeneneeees 124 8 2 PIPELINE Troubleshooting Chart and Steps cececeeeseeeeeereeees 138 8 2 1 PIPELINE Troubleshooting Chart ccceeceeeereeeeenees 138 8 2 2 PIPELINE Steps with Troubleshooting 0 0 0 0 eeeeeeeeee 138 8 3 CALCS ID Linking Diagram 5 00cccesnoucd dseiissisebdesiesvokcroecmctestneedenst 141 8 4 CALCS Missing Link Tracing Chart 0000 00 cece ceceeeseceetteceeetteeeeneees 142 CALCS Manual CHAPTER 1 INTRODUCTION 1 1 About CALCS The COMPASS Emission Calculation and Process History COMPASS CALCS or CALCS module facilitates the collection calculation and reporting of air emissions data for Emissions Inventory and other reporting CALCS uses a relational database as opposed to a spreadsheet for calculations A database allows entry and editing of data like in one place which prevents searching for every instance of that data in many spreadsheets This also improves consistency in reporting CALCS is also arranged in screens to provide a visually intuitive system that can be passed from user to user CALCS relates Sources Streams and Formulas to compute emissions Once the data is calculated it can be
71. cess 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 The Scaling Factor is only useful if all or most process rates in an entire Unit change by the same ratio The Area column may be completed by the user for information purposes only To see all Sources in a Unit highlight the Unit click the Options menu and then Unit Equipment Information This option is available only when the Unit screen is open Click on the Close icon when finished editing the process Units data to return to the main CALCS screen ACM CALCS Manual Page 34 4 4 Compounds Screen Compounds are not related to any operating Facility the same Compound list can be used for all plants Click the Compounds button to open this screen Compounds default to alphabetical but can be sorted by any parameter by clicking on the heading for the column A Compound can also be found by searching for the CAS number o
72. cility Identification Number or FIN You may upon entering CALCS need to select a default Facility site to work with H Select a Default Facility x Select Facility PDC AG CHEMICAL PLANT YCOO08G POC SPECIALTY CHEMICALS Click on the desired facility and choose The Facility section of CALCS is the same as Facilities set up in COMPASS TaskTrakker 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 the account number once the Facility is in the Database ACM CALCS Manual Page 7 Edit Facility Information New ACM CALCS Manual Page 8 2 3 Units Units are process unit types such as sulfur recovery units tank farms and powerhouses 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 Add Edit Process Units ACM CALCS Manual Page 9 2 4 Compounds Compounds can be ingredients xylene etc in a Stream or air contaminants NOx Compounds are linked to Stream Properties and Formulas The Compounds screen contains physical and chemical data such as molecular weight density vapor pressure coefficients and reporting categories like SARA Toxic Release Inventory and HAP Add Edit Compounds fomos AO OOOO CEE E A ACM CALCS Manual Page 10 2 5 Stream Proper
73. click the Units button Click Insert Type a Unit Name EXAMPLE UNIT and Unit ID XUNIT Click Save and Close 3 2 2 Create a Compound e Click the Compounds button e Click Insert e Type the Compound EXAMPLE GAS and CAS number XGAS Note that the CAS number does not need to be real especially where none exists as for VOC U 3 2 3 Create Stream Properties e Click the Stream Prop erties button ACM CALCS Manual Page 19 Type an ID XFUELGAS in the blank labeled Enter Lab Sample ID Type a Sample Description EXAMPLE FUEL GAS Enter the High Heat Value HHV Btu scf 1000 Click the Compound drop down arrow at the bottom and select XGAS Type 100 for Concentration and select wt for the Units of measure Click Save and Close 3 2 4 Create a Unit Stream Click the Unit Streams button Click Insert Type the Stream Name TEST EXAMPLE FUEL GAS Type the Stream ID TESTXFGAS Select the Unit TESTUNIT and Stream Composition or Properties XFUELGAS Click Save and Close 3 2 5 Create a Source Click the Sources button Select the Source Type COMBUSTION SOURCES Type XBOILER for the Equipment ID and hit the tab key Type in a General Description BOILERS Type a Specific Description EXAMPLE BOILER Pick the Unit TESTUNIT Leave the Profile blank for now Click the Detail tab Enter the Design Rate 100 in MMBtu hr Pick the Fuel Type Combusted TESTXFGAS which is the Unit Stream Enter Fuel Usage
74. ctor is from AP 42 or a Site specific factor in pounds per hour per Component lbs hr source The Type of Factor must be specified either Correlation Equation or Emission Factor Correlation Equations will be discussed in the separate Equipment Leaks chapter Since most monitoring is done by contractors only the unmonitored Emission Factor Formula is discussed here Enter the Emission Factor and create a Formula normally ef leak count which multiples the emissions per Component by the number of Components previously entered in the Source screen Enter the same Monitoring Program that was entered in the Sources screen Also enter the same Range Group in the Formula screen as the one where component count was entered in the Source screen In other words if you entered the Component count in the Source screen next to SOCMI Average you must choose SOCMI Average in the Formula screen This is explained above in the Source screen Leak Counts tab section Enter a Stream Category if one is used Add Edit Emission Factors and Formulas LLF Select source type EQUIPMENT LEAKS v Enter factor id LLF Description of EF LIGHT LIQUID FLANGE FORMU Type of factor Range group fToraLs z Correlation Equation es Emission Factor Monitoring program NONE v Component LIGHT LIQUID FLANGE v EF units LBHR S0URCE Y Emission factor Stream none v Category Data source Columns Column labels EQLEAK leak_count in com
75. d 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 3 1 2007 CALCS will prompt 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 Sel
76. d uncheck the unwanted report A better fix is to close and reopen the screen Error Message Out of memory message while calculating Too many zero emission records in database for your computer to handle In CALCS main screen with no other screens open click Maintenance Cleanup Database from dropdown 0 tpy of speciated emissions Retrieve Select All Delete Save Close Saving may take 1 5 seconds per 1000 deleted records If calculating causes Out of memory again try calculating in smaller batches of Sources or date ranges Error Message Profile Select Error The Source has been deleted without refreshing Equip ID list on Calculate screen Return to Calculate screen uncheck and recheck Equip ID checkbox Emissions not found for manually entered emissions Compound is not entered in Stream Properties or Profile Trace links backward from Source through Unit Stream to Stream Properties Enter missing Compound In Profile screen under Estimation Method not Speciation pick Manual and enter Compound No manual emissions were entered or imported In the Source screen on the Detail tab click the Manually Enter Emissions button and enter emissions If the emissions were imported check the import file for the correct FIN stream etc ACM CALCS Manual Page 135 Symptom Possible Cause Resolution
77. e Sources that are linked to those Unit Streams Rerun Inventory and the Sum and Delete selection above for all affected Primary Secondary families It may be advisable to first delete all emissions existing in the Primary Source Rerun PIPELINE for those FINs having the Compound In EI delete the erroneous Compound if still there e Click the first FIN with the erroneous Compound to see the emissions e Double click the erroneous Compound line where emissions are shown e Add Emissions No e Double click the erroneous Compound in the detail screen to open the record e Click Delete Are you sure Yes e Return to the main screen e Refresh or choose another FIN and go back to the subject FIN to see if the deletion worked e Repeat for all FINs with the erroneous Compound o Click Emissions and List if not already done in PIPELINE If error message says No emissions capable of export for Facility account for YYYY check in EI module to see if Source is labeled idle for current year If so change to active and try List again in PIPELINE o Check all 3 Err Reports or CALCS Estimate Emissions to make sure all expected contaminants are found when clicking PIPELINE Emissions List o If there are unwanted contaminants with zero emissions in CALCS click Inventory button find Source Retrieve delete all lines with zero emissions and save Then List agai
78. e column order in the data file should match the order in which the columns appear on the screen The first column in the file should be the Source ID Once the data file has been loaded successfully you can click on the Import button to save the data into the database All records that are saved successfully will disappear from the list The remaining records should be examined for errors There could be various reasons for a record being rejected The record could be one that already exists in the database and you did not choose to overwrite it An invalid Stream CAS ID or Source ID will also lead to rejection You can also use buttons to manually Insert or Delete lines or Find Replace before Importing or to Print ACM Calcs Emission Calculations Program File Data Window Help t4 g F b RAN B E F fa b Compounds Stream Prop Unit Streams Import Formulas Profiles Calculate Inventory Exit 2 FF 8 GG amp F Import Load File Inzert Delete Find Replace Print Close gt Import Manually Entered Emissions Overwrite Existing Records Facility Sep oat Usage Notes Casno Id Cor ALKANES U yl Stream CPUF C10 Begin Date End Date RRORS NOTES ACM CALCS Manual Page 78 4 11 Formula Screen Formulas use variables from fields in the Compounds Stream Properties Unit Stream and Sources screens to calculate emissions Click the Formulas button to access this screen To add a Formula
79. e same screens as the Stream Properties and Profiles buttons A sub menu of Emission Sources allows selection of Sources Quick Edit and Import These open the same screens as clicking the Sources Quick Edit and Import buttons Quick Edit and Import will be discussed later ACM Calcs Emission Calculations Program File Process Reference Emissions Options Maintenance Window A Emission Sources Sources i Quick Edit Gay Stream Properties and Compositions Import Emission Source Profiles Copy Data To Another Year The last item Copy Data to Another Year copies all process history records from 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 new records will be created in the target year for that tank ACM Calcs Emission Calculations Program e Window Help a F E 2 RN B E F Facility Units Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit a Ms Copy Delete Close Copy Process Data To New Year Select Account From Year 2004 v To Year 2005 JV Use Unit Scaling Factor To Determine Hew Process Rates If desired a Scaling Factor may be entered in the Units window before using this feature If the user enters a scaling factor of 0 5 for say Unit 2 and checks the Unit Scaling box above then all process histo
80. e the pick list to find its ID edit and Save The ID and Description at the top are mandatory Other fields are optional F add edit Stream Properties and Compositions FWW6 2005 Enter lab sample id SVAiv6 2005 m Sample description pnr 5 OILAWATER SEPARATOR High heat value n Low heat value r HHY Btu scf LHV Btu scf MW liquid phase CALC MW vapor phase CALC RYP psia Composition phase Vapor zi Density in Ibs gal p34 Sulfur content in ppmw MW Reference F Sample date Temperature Data source or Lab jenn AVG SCREEN YALUE Compound Concentration Units Cvut_concentration Cvt_units CYCLOPROPANE sw f 1000 mgt 0000 ft mimi at Click Insert to add new Compounds to the Stream Property and select them using the drop down arrow Enter the concentration and select units CALCS will convert the concentration to weight percent provided the Compound data is sufficient The prefix Cvt means converted Formulas usually use the converted quantities The total concentration is displayed below the list for reference CALCS will allow the total to be other than 100 if that is desired Composition data may be entered 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 mandatory Click the CALC buttons to Calculate liquid or vapor molecular weight or enter them manually if known Compound data must be
81. eam 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 The 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 6 3 5 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 6 3 6 Common Erro
82. echnicians will be handling many users so you can help them by doing the following Please carefully read this manual 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 using 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 this manual and you are satisfied that your system configuration is correct feel free to call PDC Corp Please have information about your system including Windows version and type of network ACM CALCS Manual Page 2 1 6 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 access the CALCS main screen 1 7 About This Manual This manual assumes that the user knows some basic chemistry environmental spreadsheet and Microsoft Windows concepts Uncommon terms and CALCS terms will be explained CAL
83. ect 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 report 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 6 3 4 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 ASPH
84. er a count next to SOCMI Average for a Source you must later choose SOCMI Average in the Formula screen Otherwise the Formula will not find the count Add Edit Emission Factors and Formulas New Select source type EQUIPMENT LEAKS v Enter factor id Description of EF Type of factor Range group SOCMI AVERAGE a Correlation Equation Emission Factor Monitoring program P 1 and lt 1000000 Component Ol EF nits o g gt 0 and lt 1000000 Emission factor Stream fre gt P Category Data source Columns EQLEAK leak_count in ca EQLEAK leak_rate in ppm EQLEAK operating_hours in hrs EQLEAK voc_percentage in STREAM_MASTER tempf_std in _F STREAM_MASTERtup_std in psia m Formula for estimatina E Ib hr Embed Formula ACM CALCS Manual Page 73 4 8 4 Primary and Secondary Sources When a Source is complicated or has multiple scenarios such as a boiler that burns coal oil and gas there may not be enough fields in the Sources screen to cover all possibilities This would also be the case for any Source for which the emissions must be calculated using more than one Formula CALCS can facilitate this by allowing several partial Sources to be linked together as one total Source Suppose the boiler s official ID reported to the state is BOIL1 First create a Source called BOILI and calculate zero emissions by showing zero fuel usage This will avoid confusion or double co
85. etail Manually Enter Emissions Comment ream processed AAPAN low rate Cut flow rate fises mgalest Flow rate units fi 2 01 2005 T f 2 31 2005 bA Bi p ACM CALCS Manual Page 63 4 8 3 3 Tank Data Tab This tab was added because of the number of fields needed to enter the many variables used by the standard AP 42 formulas The tab varies by tank type The five tank types in CALCS are in the General Description pick list as follows Horizontal Fixed Roof Vertical Fixed Roof Internal Floating Roof External Floating Roof and Domed External Floating Roof No other General Description is available for the Storage Tanks Source Type 4 8 3 3 1 Tank Data Tab Horizontal Fixed Roof Tanks Tank dimensions Throughput with units shell and roof colors see second small screen print and Liquid Type can be entered or selected Ambient Atmospheric Pressure can be entered depending on the height above sea level Items on the right can be calculated automatically by clicking the button or they can be entered manually The pressure and vacuum settings of vapor conservation vents can also be entered Pumping rate can be used to determine maximum hourly emissions If the Constant Level Tank radio button is clicked Yes the working losses will go to zero in the standard AP 42 formula ACM Calcs Emission Calculations Program File ars Window Help Z Ff 2 RN E E F a b Compounds Stream Prop Unit Strea
86. g Percent Use CIH Flow Ozone Control M Use Ozone MZ Use Co p feos ifr2 ifr PAY 100 00 J se Ozone IV Use Co Boer mfr mfr f Af 100 00 J se Ozone fV Use Co Boofers ifers Ne f f 100 00 use ozone f Use Co Boe zifea ff 10000 use ozone f use co Boyer mfeca Hf Af Af 10000 use ozone Use Co pfe mfeco f NY mif 10000 use ozone f Use Co B fcecs xlfeccs zf Nf 10000 use ozone J Use Co Bofa a o o f 100 00 J Use Ozone f Use Co ACM CALCS Manual Equipment Relationships Fa Page 107 There must be one line per FIN EPN CIN combination If FIN1 exhausts partly through EPN1 and CIN1 and partly through EPN2 with no CIN there must be a line for FINI EPN1 CIN1 and another line for FIN1 EPN2 with no CIN If you want to add an EPN to a FIN click Insert to receive a blank line Use drop down arrows to pick FINs EPNs and CINs If there is no CIN select the hyphen rather than leaving a blank The Feeding CIN column is for a second CIN in series where CIN1 is feeding CIN2 To add or edit a CIN right click the line where the CIN belongs A window will pop up to allow you to add or edit Note the small Add Control Device Edit Control Device box in the screen below CALC to EI Pipeline File Actions Window Help 2 2 2 2 F Parameter Emissions Contam Equip Rename Exit a 2 F Save List Print Inzert Delete Close List J z Jann Criteria Facility Id Humber like X Info gt
87. ge 12 2 7 Sources Sources are the generators of the emissions you will be calculating They are often identified in Texas by the Facility Identification Number FIN Sources include boilers engines flares manufacturing process Units and other equipment See a tank example below Add Edit Sources 1 Facility Code 0028U06 Source type STORAGE TANKS Equipmentid h v _Delete Estimation Dates xz EH General K Detal BH Tank Data Shell Diameter 000 ft Paint Solar Abspt P39 Shell Length 2000 ft Breather Vent Press Setting Range delPb 1 06 psig Throughput f11 111 00 _ Vapor Space Outage Hvo ho Thru_Units gaest v Work Loss Product Factor Kp foo Potential Throughput 1 00 BBL Turnover Factor Kn foo Shell Paint Solar Abspt 039 x Humber Of Turnovers H 1 65 Roof paint solar abspt 033 v Cut_Throughput BBLir 264550 0 wr Volume 1 602 90 BBL Liquid Type Atmospheric Pressure far Pumping_rate in gals min poo Vent Vacuum Setting Pbv 0 03 psig Constant leveltank 7 ves No Vent Press Setting pbp po psig Hote Selected parameters can be recalculated by clicking on the buttons next to them ACM CALCS Manual Page 13 2 8 Formulas The Formula is the equation that calculates Source emissions It uses raw data previously entered in the Source and Stream Properties screens A Formula calculates average pounds per hour of a single air contaminant like NOx or perhaps a category total like VOC See
88. ght and there is a dome or cone roof option The Vapor Space Outage is automatically calculated depending on the roof type ACM Calcs Emission Calculations Program Options Window Help a b go b FF NA B E F Units Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit 2 BE 4 amp 4 F Save Save Az Print Close Add Edit Sources TA 07 Facility Cot Source type STORAGE TANKS Equipment id fra OF Delete Estimation Dates EJ i2005 12 31 2005 v E General K Detal Tank Data Shell Height ft Volume Shell Diameter 500 Ft Cut_Throughput BBL i et Throughput 610 00 Paint Solar Abspt 17 Thru_Units galest v Liquid Height 3 000 Potential Throughput 1 00 BBL r Breather Vent Press Setting Range delPb p psig Shell Paint Solar Abspt 0 17 Roof outage 2592597 Roof paint solar abspt 0 17 x Vapor Space Outage Hvo B 2592597 Roof Type Dome Root Work Loss Product Factor Kp foo Liquid Type Organic Liquids x Humber Of Turnovers H S3 mospheric Pressure faz Roof Height psoo ft Turnover Factor Kn a Vent Vacuum Setting Pbv p Constant level tank 7 Yes No Vent Press Setting pbp P Pumping Rate b ote Selected parameters can be recalculated by clicking on the buttons next to them ACM CALCS Manual Page 66 4 8 3 3 3 Tank Data Tab Internal Floating Roof Tank Type Additional fields are offered for this tank type as seen
89. ghted rows You may also enter Permit limit and reference data into rows of the Emissions Inventory Summary window after moving the horizontal scroll bar to the right ACM CALCS Manual Page 97 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 fe Retrieval Criteria xj You are about to sum emissions based on selection criteria Please select the criteria and click OK to proceed or CANCEL to terminate CRITERIA C ALL SOURCE IDS AND SELECTED COMPOUND MATCHING DATE RANGE C ALL SOURCE IDS AND SELECTED COMPOUND WITHIN DATE RANGE SELECTED SOURCE ID AND ALL COMPOUNDS WITHIN DATE RANGE emen 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 You can edit or Delete results and Save The Search Criteria button takes you back to the main Inventory screen ACM CALCS Manual Page 98 4 14 1 Data Menu for Primary and Secondary Sources If you have Secondary Sources linked to Primary Source
90. gram ess Reference Emissions Options Maintenance Window Help File Process Reference Emissions Options Maintenance Wince 7 4 Tile EF Bm 2 ofp b P 1 Units Compounds Stream Prop Unit Streams Sources Cascade z Layer gt Toolbar Ea Arrange Icons ea O Hide pee b Done C Floating I Show Text JV Frame Toolbar jui ug 4 1 8 Help Menu The Help menu in CALCS gives you access to the on line Help system Contents and version information relating to CALCS and COMPASS Window Help Contents Ctrl F1 About 4 2 Facilities Screen You may view and modify Facilities that exist in CALCS If 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 a screen where you may add modify or delete company and ACM CALCS Manual Page 32 contact information The screen is shown in the CALCS Overview chapter To select an existing Facility click on the drop down list on the Facility Code field 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 the rest of the data Once you have made any modifications to the data select the Save icon The ID is the link to other entities and should be all upper case with no spaces to avoid confusion 4 3
91. hat have been Calculated by the user along with critical explanatory information After running Calculate the Inventory Screen shows you numerous Sources in spreadsheet view You can edit results individually and sum Secondary Sources for reporting as the Primary Source ID The Inventory Screen looks much like the Calculate screen ACM Calcs Emission Calculations Program i Data Options Window Help b amp F b F N E HB F a b Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit o F Retrieve Close Emissions Inventory Search Criteria SELECT FACILITY ID BEGIH DATE 01 01 2005 a EHD DATE 1231 2005 2 JV Source Type Process Units JV Equipment Id T Compound List Unselect All Select All Select All AIR STRIPPERS F CT1 MAIN COOLING CATALYST HANDLIN F CT2 COOLING TOWEI COMBUSTION SOURC F CT3 COOLING TOWEI COOLING TOWER SO DRAINS SUMPS AHL EQUIPMENT LEAKS FCC SOURCES FLARES LAANA pace oul gt ACM CALCS Manual Page 96 You make a selection the same way as you do for Calculate and click Retrieve to get the following listing Emissions appear by Source date range and Compound but can be sorted by clicking any column heading A4CM Calcs Emission Calculations Program File Data Options Window Help m Bi oF Be 2 El Ms Facility Units Compounds Stream Prop Unit Streams Sources Formulas Calculate Inventory Exi
92. he box by Equipment ID and select the Source XBOILER Click Options General Reports then Emissions Calculation Parameters to see the most detail Click Run e You should get 0 45 tons est tons per estimation period Congratulations ACM CALCS Manual Page 21 CHAPTER 4 CALCS SCREEN DETAILS 4 1 Main Screen Besides the obvious buttons discussed above the Main Screen has drop down arrows that reveal more buttons The drop down just to the right of the Unit Streams button shows a Relations button The drop down just to the right of the Sources button shows the Quick Edit and Import buttons These buttons open screens which will be discussed later ACM Calcs Emission Calculations Program File Process Reference Emissions Options Maintenance Window eee ee SE File Process Reference Emissions Options Mainten Facility Units Compounds Stream Prop Unit Streams Sources 25 a Facility b En n Prop Unit Streams Sources Unit Streams Quick Edit 28 a Relations Import When a screen is opened a second row of two to seven buttons will appear depending upon the screen Save saves the screen entries edits to the database Save As copies all data on a screen and saves it under a new name chosen by the user Erase completely deletes a Stream Property Formula or Profile Insert opens a new blank entry line as for another ingredient in Stream Properties Delete deletes only the first li
93. ing work on the Unit screen the Source screen will need to be refreshed to display the new Unit While in the Source screen click Save select another ACM CALCS Manual Page 4 Source ID and go back to the original Source ID or close and reopen the Source screen Fields in yellow are the ones that normally must be updated each time period but there may be others in your case See the Profile and Formulas linked to the Source to find the variables that must be changed It may be advisable to list those fields in the Source Comments 1 12 Exiting CALCS To exit simply select the Exit icon on the main screen or choose the Exit selection from the File menu You will be presented with a confirmation window so select Yes ACM CALCS Manual Page 5 CHAPTER 2 CALCS OVERVIEW 2 1 CALCS Main Screen Upon logging in the main screen appears with a row of buttons to open other screens for entering or viewing data 4 amp CM Calcs Emission Calculations Program Above the buttons are menu items for File Process etc Clicking on these will often give an option to the buttons For instance clicking Reference then Facility Information opens the same screen as clicking the Facility button The menus also open advanced functions ACM CALCS Manual Page 6 2 2 Facilities Note that a CALCS Facility is a site often designated by an Account Number This should not be confused with a CALCS Source which is often associated with Fa
94. iod Pick the Unit Stream for the Type of Exit Flue Gas ACM Calcs Emission Calculations Program Options Window Help b Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit Er se Be JS M E E F 3 Add Edit Sources 1 Facility Code Source type SULFUR RECOVERY SOURCES Equipment id E Delete Estimation Dates z E General K Detail Manually Enter Emissions Comment covery efficiency pooo Cut sulfur produced f0 88000STPE ifur produced hooo Cut tail gas pe mme kmo zl Type exit flue gas 44n 0000 oe TE mear omr x Days online B65 Operating hours 760 ACM CALCS Manual Page 61 4 8 3 2 15 Detail Tab User Defined Source Type If a Source either does not fall into one of the other Source Types or the desired data fields are not found there you can create your own set of up to seven parameters under the User Defined Source Type Each of the seven parameters has three fields a label a number and a label This can be used for a name for the parameter a quantity and the units of measure The Formula can be set up to read these fields as desired The example below is a degreaser solvent parts washer with the inches of solvent added during the period the width and length of the degreaser and the density of the solvent The Formula calculates the pounds of solvent added emitted from those ACM Calcs Emission Calculations Program File Opti
95. ion Calculations Program BEE File Options Window Help m F b 7 E H F Facility Units Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit i v amp gt E Run Saveas Zoom Repor Print Prior Next Close Estimate Emissions SELECT FACILITY ID IV Begin date ety 0101 2005 1 IV End date it 2 31 2005 V Source Type Process Units JV Equipment Id CALCULATION CRITERIA Unselect All Select All Unselect All CalcMo calc AIR STRIPPERS F CT1 MAIH COOLING Use profile matching CATALYST HANDLIN F CT2 COOLING TOWE peloria maparin COMBUSTION SOURC F CT3 COOLING TOWEI_ V Calc emission results COOLING TOWER SO Ir lal ap aii A DRAINS SUMPS AHC EQUIPMENT LEAKS J Use existing results FCC SOURCES FLARES LOADING RACK SOUI x Compound List gt User Defined Report Heading Z Ready J J J J J 10 29 07 06 22 PM A start e agamo co 0 2 M gt mca met ez Cv Links OJ YY 5 24 em When Calculation Criteria are set click the Run button That will show you the results and write them to the database simultaneously ACM CALCS Manual 4 13 3 Other Report Variations If you check the box for Compound List you can pick a previously constructed list of Compounds by the name of the list Then when you click Run you will Calculate only the emissions of those Compounds Calculate also produces useful internal reports for a
96. l 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 Use Ozone feature in the Equipment screen allows calculation of pounds per ozone day but this is best done globally under Emissions Maintenance and Global Maintenance in the EI module later 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 Check all three Error Reports and resolve any errors before clicking the Pipe button Highlight the emissions that you want to be copied to EI or leave it as is if all are to be copied Then click the Pipe button to transfer emissions to the EI module ACM CALCS Manual Page 103 5 3 1 Error Reports Review all three Error Reports before Piping emissions to the EI module First click the Err Reports button 5 3 1 1 Equipment Error Report The default first report is the Equipment Report Ifa Source ID from CALCS does not match any FIN in the EI module its emissions cannot be Piped to the EI module The CALCS exercise in an earlier chapter produced the error shown below because the Source ID was arbitrary and not in EI The EI module gets its list of previously rep
97. les of liquid and percent control efficiency achieved from the process control step If there is no process control then the potential and calculated emissions are the same b amp t b A C A B Hw Fady Unis Compounds SteamProp Unin Strewmz Sources Batch Fotmihe Profile Calc Cont Inventory Ext E z3 aA amp F Swe Swo s Calculate Batch Count Print Close Batch Calculations Mie reniy coace fe pmen Jie pete Yew c TE Delete Fonna sumemiss Description fest Unit 2001_ F Volume 1200 gals Machine PKS GRADE EXPLORER Step Parameters charge Reaction Process Control Calculations GA Codes 88901 test E A test test apor Press Phase Moles Liq Wapor Frac CALC Lbr apc Eff Potential Lbr Step1 CALC LbsStep fi Override Potential Lb Step 0 00 4 5 0 0000 Liquid o 000d 0 0000 0 000 0 0000 0 0000 Step 4 _ sR ES oo Step5 TOTALS 0 0000 0 0000 0 0000 0 0000 QE 1 00 C ro Step SS IM Steps Step3 Step 10 Step 11 Step 12 a wermi l test 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 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
98. lt product of 24 hours per day times the number of days within the Estimation dates These hours can be overwritten manually if desired 4 8 3 Tabs Sources have more parameters than can be shown in one view The Sources screen has two to four tabs with different data views but all tabs are just parts of a single record When you click save you save data on all tabs at once 4 8 3 1 General Tab The General tab shows the Source s General Description Specific Description Unit Profile and sometimes the date range and comment button E General We Detaii General description Specific description Unit Profile 4 8 3 1 1 General Description Field You can type any General Description you wish except for Storage Tanks which will be explained shortly The General Description has a specific meaning in relation to the Formula and Profile screens for some Source Types Any General Description you type in the Sources screen such as VENT will then be on the pick list for General Description in the Formula and Profile screens For User Defined Sources there are seven fields in the Source screen with user defined labels ACM CALCS Manual Page 45 before and after the quantity So you would enter a label then a quantity then a label like FLOW 8500 CFM These labels are not already in the Formula pick lists You must pick VENT from the General Description pick list in the Formula screen Then the For
99. mat From the main window select Reference Equipment Leak Contractor Data Import and Process ACM CALCS Manual Page 112 Leak Counts This will bring up the Import window 6 3 1 Leakers Always enter 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 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 on how to resolve data that could not be processed Correct the data and repeat Step 5 6 3 2 Totals and Zeroes 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
100. ms Sources Formulaz Profiles Calculate Inventory Exit 2 a amp F Save Save As Print Close Add Edit Sources TA 08 Facility Code Source type STORAGE TANKS Equipment id fra 08 Delete Estimation Dates fi2m 2005 12 31 2005 v fi General K Detal Tank Data Shell Diameter 00 ft Paint Solar Abspt a Shell Length hss ft Breather Vent Press Setting Range delPb psig Throughput po Vapor Space Outage Hvo boo Thru_Units gaet gt Work Loss Product Factor Kp ho Potential Throughput p 00 e Turnover Factor Kn foo Shell Paint Solar Abspt TKS Number Of Turnovers N poo Roof paint solar abspt EE _Cut_Throughput BBL yr po ooo OO Votume Pre ook Atmospheric Pressure fi47 Pumping_rate in galsimin 1 00 Vent Vacuum Setting Pbv D psig Constant level tank 7 Yes No Vent Press Setting pbp D psig Hote Selected parameters can be recalculated by clicking on the buttons next to them ACM CALCS Manual Page 64 The shell and roof paint color factors can be picked from drop down lists ACM CALCS Manual Shell Paint Solar Abspt 039 Number Roof paint solar abspt E xl Cvt_Thro Liquid Type Atmospheric Pressure Vent Vacuum Setting Pbv Vent Press Setting pbp ote Selected parameters Page 65 4 8 3 3 2 Tank Data Tab Vertical Fixed Roof Tank Type The Vertical tank data is the same as that of the Horizontal tank except the Shell Length is now Shell Hei
101. mulas screen will show FLOW with units of CFM available for use in a Formula The term VENT will now also appear in the General Description pick list for other User Defined Sources so you can select VENT again for another Source if you know the labels will be the same For Storage Tank Sources you cannot type in a General Description You can only pick from the hard coded list The choices are Domed External Floating Roof External Floating Roof Horizontal Fixed Roof Internal Floating Roof and Vertical Fixed Roof When one of these is picked in the Sources screen CALCS will present the tabs and fields appropriate for that tank type Likewise the Formulas and Profiles screens will have a pick list of the appropriate parameters 4 8 3 1 2 Specific Description Field The Specific Description is a comments field to type anything you want to further identify the Source This field is 25 characters long and often appears on reports next to the Source ID FIN 4 8 3 1 3 Unit Field This links the Source to its Unit Use the drop down arrow to pick the Unit for the Source If the Unit is not on the pick list you must add it in the Units screen 4 8 3 1 4 Profile Field The Source must be linked to a Profile which contains the emission Formulas Use the drop down arrow to pick the Profile that has the Formulas for this Source If the Profile is not on the pick list it must be added in the Profiles screen 4 8 3 1 5 Comment Button The Comme
102. n Click the Parameter button on the main screen This screen is used to transfer only the Source parameters from CALCS to the EI module No emissions will be piped Instructions are on the screen itself IE CALC to EI Pipeline x File 2 amp o E M F Parameter Emissions Contam Equip Rename Exit 2 k Pipe Close lbj Export Parameters to Emissions Inventory Facility Source Type COMBUSTION SOURCES v Year v Available Sources Selected Sources Source Description Source Description Note Please select the sources for which you wish to transfer process parameters from CALCS to El and then click on the Pipe toolbar icon Ready E start e 3 m o b ola micr gt w2 micr gt g 3 Cite m catcs Links amp oa SOY 4 52PM ACM CALCS Manual Page 102 5 3 Emissions Screen This screen is used to Pipe emissions from CALCS to EI Click the Emissions button Pick the Year Facility and Source ID Pick the Unit and Source Type only if desired to reduce the size of the pick list of Source IDs Click the List button to get the view below CALC to EI Pipeline File Actions Window Help 2 8 amp 8 o E MM F Parameter Emissions Contam Equip Rename Exit amp EB w E Print Err Reports List Pipe Close Select Parameters For Building Export List so poo poo co Braz a fp In addition to copying emissions the PIPELINE feature also applies contro
103. n It saves the time of reconstructing long Formulas that were inadvertently changed After clicking this item you will only need to click Yes or No for confirmation ACM CALCS Manual Page 30 4 1 6 5 Cleanup Database With time a database will accumulate many obsolete records The Cleanup Database option opens a screen to choose among four types of unnecessary data to remove from the database as shown in the figure below Removing such data will remove unused items from pick lists speed up the Calculate function and save hard drive space Streams Not Used In The Database are those that are not linked to any Source Stream Comp or Stream Properties Not Linked To Any Stream is self explanatory Zero 0 Tons Yr of Speciated Emissions occurs when one Profile is used for many Sources A Profile may call for calculation of xylene because it is in one Source If a different Source using that Profile has no xylene its speciated emissions will also list xylene but with zero tons Profiles with long lists of Compounds can cause accumulation of thousands of zero emission records in the database This function removes them Emissions Not Linked To Current Accounts Sources are orphaned emissions that can be deleted After choosing one of the four options click Retrieve to see the list of unnecessary data You can highlight data individually or click Select All then Delete and Save Clicking Invalid Accts will delete data pertaining to ob
104. n in PIPELINE The other option is to pipe them to EI and delete them there by selecting the Source and double clicking one of the contaminants The entire contaminant list will appear Select the row for deletion and making sure the green arrow at left is pointing to the correct row click delete below Repeat as needed and save o Click Pipe button YES and OK o Check EI Module for correct numbers Click on desired FIN in center left window ACM CALCS Manual Page 142 Look at center bottom window for FIN emissions ACM CALCS Manual Page 143 8 3 CALCS ID Linking Diagram Use this diagram to understand the links that exist in CALCS The ID s of the same color must be the same throughout all screens for all functions to work properly SCREEN LINKING FIELD HAMES EXAMPLE Facility Facility Code Acct Unit Process Unit No UNITS3 Compounds Compound CASH linkS to El BENZENE cam Prop Enter lab sample ID BENZPURE m CC m Prop BENZENE Source Type no need to match El USER DEFINED Unit UNITS3 Monitoring Prog for eq leaks NON MONITORED Leak Range for eq leaks TOTALS Gen Desc fe les User Def column units in formula LEA De ab ser Defined column units in Formula Range Group For q leaks Monitoring Prog for eq leaks NON MONITORED USER DEFINED Monitoring Prog ffor eq leaks NON MONITORED iation BENZPURE pund BENZENE Facility ID ACM CALCS Manual 8 4 CALCS Missing
105. n the Detail tab The screen below will pop up Select the Compound emitted enter the lb hr and any Comments and click OK You can also Insert or Delete individual lines The Compound must be in the Stream Properties screen for it to save emissions to the database Manually entered emissions H 1 xi Emissions Compound Ib hr Comments ACETONE I 5 30 FROM SAMPLING Days online B66 Utilized operating hours 754 ACM CALCS Manual Page 47 4 8 3 2 2 Detail Tab Air Stripper Source Type The Air Stripper Source screen assumes a gas like air is stripping VOC from a liquid like water You can enter the Stream Processed Flow Rate Inlet VOC Concentration Sand Filter Effluent VOC Concentration and Outlet VOC Concentration Add Edit Sources 1 AIR STRIPPERS ACM CALCS Manual Page 48 4 8 3 2 3 Detail Tab Catalyst Handling Source Type For Catalyst Handling the Catalyst Type is the Unit Stream CALCS automatically converts the Unloaded Amount to pounds in the Cvt Unloaded Amount blank depending upon the Unloaded Units of measure picked Add Edit Sources 1 CATALYST HANDLING SOURCES ACM CALCS Manual Page 49 4 8 3 2 4 Detail Tab Combustion Source Type A Combustion Source could be external combustion like a boiler or internal combustion like an engine The Potential and Utilized Horsepower are for the later The Fuel Type Combusted is the Unit Stream Cvt Fuel Usage Current
106. n to Use Vapor Phase Concentration of Compounds in the Stream Properties or not This may cause calculating errors if the Stream Properties shows the Composition Phase as vapor and the Profile Use Vapor Phase Concentration is marked No Sufficient Compound and Stream Properties data must be entered to use this function ACM CALCS Manual Page 83 4 12 2 Estimation Method This adds an emission calculation method to the Profile list at the bottom of the screen There are three options Click the drop down arrow and click Site Specific Formula General Formula or Manually Entered Emissions If you have a Formula to use select one of the first two If you Manually Entered Emissions in the Source screen choose the latter Estimation method E actors Site Specific Speciation Ea mee General Manually entered emissions A second window will pop up with a list of Formulas you can add to the Profile f Emission Source Profiles DOWTHERM Select source type COMBUSTION SOURCES v Enter profile id Down HERM v Profile descriptio os fe oy Use vapor phase Select All Clear All Cancel composition Compound Ef code Ef description Estimation metha ALKANES U ECON DECONTAMINATION UNITS Speciation ARBON MONOXIDE H 8co H 8 CO ARBON MONOXIDE PB1CO NORTH PAINT amp BLASTCO ARBON MONOXIDE SB2CO SOUTH PAINT amp BLAST CO ARBON MONOXIDE UTCHCO DUTCH OVENS C
107. ne or more Formulas A Source is also linked to a Facility and Unit With all the links complete you can calculate emissions See the examples in the diagram below Facility XX1234X Unit TKFARM Compounds TOLUENE Stream Prop Unit Stream XYLENE GASOLINE TKFARMGASO Formula Profile EXTFLOAT1 EXTFLOAT ACM CALCS Manual Page 18 CHAPTER 3 ENTRY ORDER AND EXERCISE 3 1 Entry Order When creating a new Source with its related Streams and Formulas you would normally do so in the order below generally using buttons from left to right Of course if some of the data is already present some steps can be omitted Create a Facility Create a Unit Create necessary Compounds Create Stream Properties using the above Compounds Create a Unit Stream by linking Stream Properties and a Unit Create a Source and select a Unit and Unit Stream Create a Formula s Create a Profile using the above Formula s Return to the Source screen and pick the above Profile Calculate emissions Use Inventory to view and edit emissions optional 3 2 Exercise Print and do the following exercise to get a taste of how CALCS works We will assume as is usually the case a Facility site already exists in your database USE YOUR CAPS LOCK to prevent mixed case confusion later Also don t use spaces when typing an ID Note that some unneeded fields will be left blank 3 2 1 Create a Unit Starting from a blank CALCS main screen
108. ne or the highlighted line of data Print prints the screen or list Close closes the screen ACM Calcs Emission Calculations Program File Data Options Window Help B b Founn SOD ef E Facility Units Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit 28 G amp F Save Save As Erase Inzert Delete Print Close 4 1 1 File Menu Above the Main Screen buttons are menu items Depending which screen is open the menus change to offer options related to that screen Some menu items are available only when all button activated screens are closed Other items are only available when the related screen is open ACM CALCS Manual Page 22 The File menu of CALCS only allows one selection if no screens are open which is to Exit the CALCS program Use this selection when you are finished working in CALCS gt A A Calcs Emission After opening a screen other File options appear depending on the screen These options are familiar to Windows users ACM Calcs Emission Ca File Data Options Windos New Close Save Ctrl S Save As Erase Print Ctrl P Print Setup Alt F4 Exit ACM CALCS Manual Page 23 4 1 2 Process Menu The Process menu in CALCS gives you access to Emission Sources Stream Properties and Compositions Emission Source Profiles and Copy Data to Another Year The Stream Properties and Emission Source Profiles items open th
109. nk CIN or add if needed If CIN not in pick list right click blank choose add and complete add screen then OK Go back and pick FIN EPN CIN etc o Click Save button e Reconcile CAS if needed o Look in CALCS Compounds to see the listed CAS number s for the FIN s contaminants o In PIPELINE click Contam button Search for same Contam s o If CAS shown in EI PIPELINE needs to be changed type it in exactly as it is in CALCS If the CAS in CALCS needs to be changed do the following Write down the ID of all Stream Prop screens with that Compound and write the concentrations Write down all information similarly for Formulas and Profiles with that Compound Correct the CAS in Compounds and save That Compound will now be missing from all associated Stream Prop Formula and Profile screens Insert it correctly in Compounds screen Add that Compound and concentration back into all Stream Prop Formula and Profile screens and save If a non unique error pops up close and reopen the screen and retry Rerun Calculate for the FINs that have been previously Calculated with that Compound by first finding affected FINs O OOO O ACM CALCS Manual Page 141 e The PIPELINE error report will show you the FINs emitting the Compound e Alternatively CALCS Unit Streams can be sorted by Stream Properties written down above to find Unit Streams involved and then Equipment Relationships show th
110. nt button is either found on the General or Detail tab Click the button to open a Comment field type comments and click OK This field is useful to document the basis for calculations The first three lines of comments will appear on the Emission Calculation Parameters report This report is often useful to send the agency when they ask for calculation methods For this reason type your public comments on these first three lines Hit Enter until beyond the first three lines to enter confidential comments ACM CALCS Manual Page 46 4 8 3 2 Detail Tab This tab contains details about the Source itself Contents of these tabs vary by Source Type Various versions of the Detail tab are shown in later sections EH General K Detail Manually Enter Emissions Comment Design rate 2s o mmBTUhr Potential horsepower OoOo uel type combusted euoweas i a Utilized horsepower poo Fuel usage pra 0 C Cut fuel usage 12 24 mmscfiest Fuel usage units mmsctiest gt Liquid fuel used OoOo y gals Estimation dates foro12005 y f2s12005 v Potential operating hours Bro ooo Days online Bes Utilized operating hours B70 0 Current firing rate pas mmBTUhr HOx load reduction factor pre 4 8 3 2 1 Manually Entered Emissions Button If pound per hour emission rates are already known without calculating you can enter them directly If there is more than one Stream highlight the desired Stream Click the Manually Entered Emissions button o
111. nter To eliminate No Wt data from printout delete zero emission lines from Inventory screen Click Inventory choose Source Type and Equipment ID Retrieve click Methodcode to alphabetize all SC lines likely zeroes will be together click top SC row hold down Shift Ctrl while clicking bottom SC row to highlight rows click Delete and Save Then go back to Calculate as before ACM CALCS Manual Page 136 Symptom Possible Cause Resolution Slow to Calculate after clicking Run Too many zero emission records in database In CALCS main screen with no other screens open click Maintenance Cleanup Database from dropdown 0 tpy of speciated emissions Retrieve Select All Delete Save Close Saving will take 1 5 seconds per 1000 deleted records Too many users on Citrix server Wait and try again later Tank emissions are somewhat lower than expected Daily vapor pressure range lt breather vent range AP42 says if daily vapor pressure range gt breather vent range the difference is used to calculate breathing loss If lt breathing loss is zero CALCS formulas have no if statement thus formula always subtracts sometimes calculating a negative breathing loss The erroneous negative plus the working loss yields a low total Make the daily max and min vapor pressure equal to the average Also make the breather setting range zero A fix for this pro
112. ntify 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 ACM CALCS Manual Page 117 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 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 fls BS 25 e F Units Compounds Stream Prop Unit Streams Sources Fe Profiles Calc Cont Inventory Exit 3z ga amp F Close Save Ae Coleulsts Batch Count Print Batch Calculations ioj x Facility Code GE_SIL Equipment n 123 Detete Year 2000 Delete Rolling Sum Emies Description fest Unit 712001 volume 1200 gals Machine PKS GRADE EXPLORER Grade Detail Emissions 81865 test E 88108 test Pon 88901 test PIMS Batch Count Upload E test tesi Thi operation will upload the number of batches for each grade produced on the Machine e wemi test D mapped to this Source The current number in the Actual Number of Batches field will X overwritten Are pou sure you want to proceed A Batch icon appears on the main sc
113. ntities 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 Batch Calculations BEE jest 2s Dete _Detete Mo im Ps pc 35901 test Process Convoi calcustins a codes 5 fo fey eesctart_ uy 15000 z I frone a O aoon igus d fey Praa Te 19077 oa ei Step 11 Step 12 HA wemi test 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 ACM CALCS Manual Page 121 The Calculations tab displays vapor pressures vapor fractions mo
114. ompound emitted like NOx from the pick lists Enter an Emission Factor such as 100 or 1 if all coefficients are to be in the Formula pick or enter the EF emission factor Units such as Ib MMBtu and type in the Data Source The EF Units and Data Source will show up in certain reports when using the Calculate button The number entered for Emission Factor will be plugged into the variable ef in the Formula block below 4 11 1 General versus Site Specific Formulas The Type of Factor can either be General or Site Specific An AP 42 formula would be an example of a General Formula to be used at multiple sites and not likely edited A General Formula can be locked to prevent editing by closing all but the main screen clicking Maintenance then Disable Formula Edit A Site Specific Formula cannot be locked Click the radio button by the desired Type Of Factor 4 11 2 Maximum versus Actual Formulas The Emission Type can be Actual or Maximum depending on the intent of the Formula Click the appropriate radio button Normally you would choose Actual The Formula must be entered in such a way as to match the Emission Type 4 11 3 Columns Variables The Columns are data fields from previous screens for use in a Formula If you single click one of these variables you can see the abbreviation explanation and units to the right If you double click a variable you will add it to the end of the Formula or wherever you place the cursor in the bot
115. ons Window Help Facility Units Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit a e 3 9 8s 8 o m amp Add Edit Sources CC1 Facility Code Source type USER DEFINED Equipment id fect Delete Estimation Dates jot 01 2005 12 31 2005 v Delete E General M Detail Manually Enter Emissions e Process Stream Estimation Dates 01012005 z ec Potential Throughput J SOLVENT ADDED h A INCHES Utilized Throughput WIDTH p29 FEET Days on Line ps6 LEHGTH B 7300 FEET Utilized operating hours J760 DENSITY p 7900 LBSFT3 Maximum Operating Hours Bao ooo ACM CALCS Manual Page 62 4 8 3 2 16 Detail Tab Wastewater Source Type VOC often evaporates from wastewater Pick the Stream the Flow Rate and the Flow Rate Units CALCS will automatically convert the flow to thousands of gallons per estimation period for use in the Formula The Stream Properties must contain the VOC Compounds and concentration ACM Calcs Emission Calculations Program le Options Window Help j a i b A gii E amp T 28 Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit amp amp Save Save As Print Close Add Edit Sources FWW1 Facility Code Source type WASTENATER TREATMENT SYS v Equipment id Faw het Delete Estimation Dates fim 2005 12 31 2005 v Delete E General K D
116. orted FINs after you import the state download Extract file using the Utilities module which is normally done by this point Error corrections are explained in the Troubleshooting chapter Select Report Equipment Report Mismatch Of Equipment IDs between CALCS and El srcid casno_id e_Ibperhr etpy Max Lbperhr Max Tpy BOILER NOX p 1027 p 4500 5 3 1 2 Percent Flow Report If a FIN s emission percentages to EPNs are missing it cannot be Piped and an error will appear Click the drop down arrow to select the Percent Flow Report As shown below this error is rare Any error can be corrected as explained in the Troubleshooting chapter Select Report Percent Flow Report Percent Flow value is not provided in El Relationships Srcid Casno_id E_Ibperhr E tpy Max Lbperhr Max Tpy G No Rows Found in Percent Flow Report ACM CALCS Manual Page 104 5 3 1 3 CAS Number Report If you add a CAS number in CALCS that is not in EI the PIPELINE module cannot transfer emissions for that contaminant That error will appear on the CAS Number Report listing the CAS number and the related Source and other data This error is corrected as described in the Troubleshooting chapter If no emissions are associated with the error it may be ignored The default recommended setting is not to Pipe total VOC because EI will create its own total VOC number from the sum of individual Compounds Thus VOC will appear as an er
117. ounds AHSO2 List Hame Double click to select compounds 4CETAMIDE ACETIC ANHYDRIDE ACETONE 4l COHOLS U ALKANES U ALKENES U ALLYL ALCOHOL AMINES U AROMATICS U BARIUM BENZ AJANTHRACENE BENZENE 4 ACM CALCS Manual Retrieval criteria SARA C HAPS f ALL Deminimus Compound ACETIC ANHYDRIDE DICHLOROBENZENE 1 2 HYDROCHLORIC ACID SULFUR DIOXIDE 502 Humber of compounds in list 4 U Page 29 4 1 6 3 Source Type Display This allows one to change the order of Source Types in pick lists by changing the order number If all numbers are the same the list will be alphabetical Otherwise the list will be from lowest to highest number You can also Hide unused Source Types by dragging them from the right to the left column ACM Calcs Emission Calculations Program e Data Options Window Help E F b F 2 RN E E F Facility Units Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit 2 a amp F Save Insert Print Close Source Type Display Maintenance Hide Source Types Display Source Types A Description CC SOURCES SER DEFINED Note Double Click on a source type to move it from one list to another 4 1 6 4 Disable Formula Edit Some emission Formulas should not be edited such as from AP 42 The Disable Formula Edit function prevents users from changing Formulas labeled as General in the Formulas scree
118. ows entry of stack test results These results can later be used in a Formula ACM Calcs Emission Calculations Program File Data Options Window Help E4 b S amp S E F RN E E amp F a z Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit 2 8 8 F z ae As Erase Insert Delete Print Close Add Edit Stack Testing Information FL1JULO5 Enter Facility code nes Standard Conditions are 68 F 20 C and 29 92 in Hg Enter source type FLARES v 1atm Enter test id feu JULOS 7 Test description FLARE 1 STK TEST JULY 2005 Equipment id FiA X Method Stack temp in F Datasource or Lab MW of fluegas Date sampled Stack gas velocity Dry basis flowrate scfm ft sec Actual flowrate acfm Wet basis flowrate scfm Feedrate to the unit Feedrate comments Compound DL BDL Concentration Units Emissions Ib hr ACM CALCS Manual Page 28 4 1 6 2Compound Lists This screen allows the user to choose a number of Compounds and name the list Just enter the name of the list double click Compounds to be added to the list and Save Use the three radio buttons to limit the size of the pick list to the left 4CM Calcs Emission Calculations Program es Data Window Help E4 f 2 F b 2 E EE F a Units Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit 2 amp F gt ka As Erase Delete Print Close Add Edit Listed Comp
119. ponents EQLEAK leak_rate in ppm leak_count leak_rate LEAK R EQLEAK operating_hours in hrs operating_hours OPERAT x te E EQLEAK voc_percentage in tempf_std STANDA STREAM_MASTER tempf_std in _F Ei i al STREAM_MASTERtup_std in psia MIIE Formula for estimatina E Ib hr ef leak_count ACM CALCS Manual Page 82 4 12 Profile Screen A Profile is a list of Formulas or Manually Entered Emissions and their speciations A single Profile can be related to more than one Source A Profile ID and Description of the user s choice is entered The Profile ID is linked to the Source screen on the General tab ACM Calcs Emission Calculations Program Sfx File Data Options Window Help 26 3 7 8 SO D 8 oe amp lisesi Facility Units Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit 2 FB 2727 FH amp F Save Save As Erase Delete Link Sources Print Close Emission Source Profiles DOWTHERM Select source type COMBUSTION SOURCES v Enter profile id SOWTHERM Profile description pow HERM HEATER Use vapor phase composition Estimation method Speciation Compound Methodtype Methodcode Stack Test Multiple Species peee Jeans DOES eo NOX SSCS JP ERACTORS DOWNOX none mo oI e e S r SULFUR DoE e0 v eacroRs DOWSO2 o moe o o E 7 e none SSCS CJ 4 12 1 Using Vapor Phase Concentration You have the optio
120. r Compound Name by clicking the drop down list and typing the first few characters ACM Calcs Emission Calculations Program File Data Options Window Help a a DB E Mm S E Facility Units Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit 2 68 amp F Save Insert Delete Print Close Add Edit Compounds Search for Compound gt Multiple Single Molecular 4 Compound Compound SAS number Species Weight Density gm cc Ar ACETAMIDE OO060 35 5 Single 0 00 ACETIC ANHYDRIDE HOAC Single 60 55 E ACETONE 00067 64 1 Single 56 08 790000021 45767 ALCOHOLS U ALCU Singe ALKANES U ALKANES U Single ALKENES U ALKENES U Single ALLYL ALCOHOL 00107 18 6 Single AMINES U AMINES U Single BROMATICS U AROM U Single BARIUM 07440 39 3 Single BENZ A ANTHRACENE 00056 55 3 Single BENZENE 00071 43 2 Single BIPHENYL 00092 52 4 Single BROMINE 7726 95 6 Single 4 To add a Compound click Insert and enter at least the name CAS number and whether it is a Single or Multiple Compound and Save The CAS number can be up to 11 characters and is usually typed with hyphens in the form 00000 00 0 When no CAS number exists it can also be a name like VOC If there is a Texas contaminant code but no CAS number the CALCS CAS number can use the first 5 digits of the Texas contaminant code followed by zeroes For instance the PART U contaminant code is 10000 and its CALCS CAS number is 10000 00 0 The CAS
121. reen eeeeeeesesseesesesessesssesssssssssssesrsesesesesssreeseeeseseseeeses 105 5 5 Equipment Screen eeeeeseesseeessseesseeessstesseresssresseressseesssreessressereessee 106 5 0 Rename ORG dtc seis ecccestabtatscorticnad EEEa EE EEE EE EAE ERE 109 6 EQUIPMENT LEAKS eeseessssseecccccccccssssseceecccccccsseseccceccccssssseseccceecesssss 110 6 1 Calculating Equipment Leaks sccccssssecsscandssvsivessnsacvoserdaieaennsdcvasoneantees 110 6 2 Bere Up The aces casiesaharactscoddditewbapesceacnapi EE EEE EA 110 6 3 Importing Contractor Data si tesscsicsstsceasscctorioxinxaupaeerentooneiecwarnansenen 111 6 3 1 Leakers seseseseseserererererererererererererererererrrerererrerrrerererrrererene 112 6 3 2 Totals and Zeroes eesessesseseeeessesssssererressssssssrererersrsessseres 112 6 3 3 Calculating Emissions a isssiace decwsersentenaseatatininncnctakerienledte 113 6 3 4 Format of Contractor Data cc cccccccccececccsceseeeseeseeess 113 6 3 5 Resolving Unprocessed Data si siccciccssessecsescestocstvacanetodssraceaees 114 6 3 6 Common Errors That May Prevent Data Processing 114 7 NEW YORK STATE FEATURES isiiccccnisinstccccnccinnnasns 116 7 1 NY Siream Properties and Composition sssicccacsasasgussnrescersoncrieosavames 116 7 2 NY Emission Calculations for Batch Processes 116 7 3 NY Navigating Batch Calculation Screen Tabs eceeeeeeeees Li 7 4 NY Rolling Sum of HMiSStONS sscsscaccrcs
122. reen of CALCS as shown below which may be used to access all batch related functions SACH Calcs Emission Calculations Program File Process Reference Emissions Options Maintenance Window Help A b S rt b fA GW amp E HE F Facility Unite Compounds Stream Prop Unit Streame Sources Batch Formulaz Profiles Calc Conk Inventory Exit 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 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 7 3 NY Navigating Batch Calculation Screen Tabs 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 ACM CALCS Manual Page 118 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
123. ror because it wasn t Piped but it can be ignored in this case Emission Pipeline Select Report 7 Cas Number Mismatch between CALCS AND El Sum Sum Sum Sum casno_id srcid Start Date End Date e_Ibperhr e_tpy MaxLbperhr Max Tpy ACM CALCS Manual Page 105 5 4 Contaminant Screen Click the Contam button to open the screen below Click List to show all Contaminants To create a narrower list enter the first few digits of the 5 digit Texas Contaminant code to the right then click List If you don t know the Contaminant Code click the drop down arrow and pick Contaminant Name Like or CAS Number Like type in the first few characters and click List CALCS emissions must use the CAS numbers shown in this list to be able to Pipe emissions to the EI module This screen is also accessible from the EI module by clicking File and Contaminant Maintenance CALC to EI Pipeline Fie Actions Window Help 2 S 2 amp s E Parameter Emissions Contam Equip Rename Exit 2 E 8 azk Save List Print Inzert Delete Close Contaminant Maintenance Active All Category fale ano Ti Contaminant Code like Contaminant Hame like Display bar Cas Humber like Category 1 fioooo PART U v Display fi0000 00 0 x Total Suspended Particulate Matter TSP v v Active J SARA J HAP 1 00 2 fooro PART RADIONUCLIDES M Display fooooo0oo0 v Total Suspended Particulate Matter TSP x m Active j SARA J HAP 1 00 3 f1o
124. rs That May Prevent Processing 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 window in the Sources screen entering the Leak Count and saving ACM CALCS Manual Page 115 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 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 no
125. ru EAST DOWTHERM FURNACE unit fALLUNTS O Profile DOWTHERM DOWTHERM DOWTHERM HEATER DUTCHOYEMDUTCH OVENS o PB1 NORTH PAINT AND BLAST 6 582 NORTH PAINT AND BLAST pE ACM CALCS Manual Page 89 4 12 6 Special Profile Screens With the Profile screen open click Options to see two more screens related to Profiles 4 12 6 1 Link Sources Screen To more quickly connect various Sources to Profiles with the Profile screen open click Options and Link Sources Click on a Profile to the left To the right are the Sources that are linked or unlinked to that Profile Double click or drag Sources from the unlinked list to the linked list or vice versa ACM CALCS Manual Page 90 4 12 6 2 Profiles Report With the Profile screen open click Options and Profiles Report to see a printable list of all Profiles gt Profile Report Profile Id Profile Description ra o pa e a e SONNE a e Frond LE E N e AS PPU COLUMN 1 YENT QUIPMENT LEAKS LP2 CO AND NOX LARES RFIXDAYS AP42 HORIZ FIXED RF DAILY CALC STORAGE TANKS DOWTHERM DOWTHERM HEATER OMBUSTION SOURCES C3 C2 C4 CS 24 CB c8 c9 P2 is ACM CALCS Manual Page 91 4 13 Calculate Screen When all previous screens have been linked you can click the Calculate button When you choose a Source and click Run the results are simultaneously displayed and saved to the database for that Source Date Range combination If you edit
126. ry records will be duplicated but the process rate for all Sources in Unit 2 will ACM CALCS Manual Page 24 be changed to a value that is one half as large as the values in the base year Manually entered emissions may also be copied to a new year if this feature is selected by check box shown near the bottom of the screen ACM CALCS Manual Page 25 4 1 3 Reference Menu The Reference menu allows you more options to the button row Facility Information Facility button Compounds Compounds button Units Units button Streams Unit Streams button Stream Source Relationships Relations button Emission Factors Formulas button A4CM Calcs Emission Calculations Program File Process Reference Emissions Options Maintenance Window Help f Facility Information F im Ei EJ Facility Compounds Sources Formulas Profiles Calculate Inventory Exit Units Streams Streams Emission Factors Stream Source Relationships TVP and WT Vapor Values Equipment Leak Contractor Data gt Equipment Leak Reference Data gt The Reference menu is also where the Equipment Leak functions are found These will be discussed later under the Equipment Leaks chapter 4 1 4 Emissions Menu The Emissions menu shows the Estimate Emissions same as Calculate button and View Emission Results items same as Inventory button Emission Calculations Program Reference Emissions Options Mainten Estimate Emissions con View
127. s the Secondary Sources probably still have the Calculated subtotal emissions and the Primary Source has zero emissions To sum all Secondary Source emissions and assign the total to the Primary Source click Data at the top of the screen then Sum Emissions ACM Calcs Emission Calculations File Data Options Window Help Insert Ghrl 1 Delete Ctrl D Retrieve Search Criteria E Oi Sum Emissions fee Sorts HYV0013C F CT1 0101 2005 The following screen will open It lists all Primary Sources that have Secondary Sources Click on a Primary Source to see its Secondaries at the bottom or click Select All Primary Sources Normally you would then click Sum And Delete Emissions to sum the emissions of all Secondaries assign the total to the Primary and delete the original subtotals in all the Secondaries That will prevent double counting later PRIMARY EMISSIONS BY COMPOUND JV Remove Zero Emissions Primary Equipment ID Source type General Description Select All Primary Sources CIC OTHER YACUUM VENT SP1 LI OTHER Deselect All Primary Sources SP2 OTHER OTHER Sum and delete emissions SP4 L_RACK OTHER Sum and restore emissions SPSC L_RACK OTHER Close l SECONDARY SOURCE EMISSIONS hed Prim EquipID Sec EquipID Source type Startdate Enddate Compound e_Ibperhr e_tpy SP1 SPILOAD L_RACK 14 2005 1 31 2005 YOC 0 00 A SP1 SPILOAD L_RACK 14 2005 1 31 2005 YOC 0 01 0 00 SP1 SPILOAD L_RACK 144 2005 1 31 2005
128. s 19 3 2 Create a PEO I Esu nsee A A AETA aaas 20 3 2 2 Link the Profile to the Source eeeeeeceeeeeeererererererererererrerene 20 5 2 9 Calculate the Example isr ni reenter EE ae ae 20 CALCS Manual 4 CALCS SCREEN DETAILS oissctsscccstivisenseaccdccusesbudatadecsets cdscdcasasdivtienets 21 4l Mam Sereen aTa aD EE RT UT NEA CT 21 All File WiC iiss eccstdapeesetcatheditialartiaviesuatdicasencadsedatsuicaxioveluinctiasites 21 Balt e Process Menten a Gast uack a a e EAE 23 4 1 3 Reference Menu sesesssreerererererrrerrrrrrrerrrerererererrrrrrrerererereere 25 4 1 4 Emissions Menu ssesesesssererererererererrrrrerrrerererererererererererereere 25 Abed Options Menu ei a e E E E EA aat 26 4 1 6 Maintenance Menu ccccccccccccscssssscecscscscececscececscececeesceeeees 26 ln EStack Testene a T E 27 4 1 6 2 Compound Lists seeeeeeeeeseeeeseeeesseressseesserssssresserssssresseses 28 4 1 6 3 Source Type DISD AY csnceccesaceticountnasinsoasceiecavicecdduanetadetes 29 4 1 6 4 Disable Formula Edit cc ccccesssssececeseseeeseeeeeneees 29 4 1 6 5 Cleanup Database sicucteetseduncetiecnercuudsrtsievacdeecuanet tierce 30 4 1 7 Window MenU seeeseseserererererererererrrererererererererererererrrrererererere 31 Nc o kaa h o E Le SE E SE O A A 31 4 2 Facilities Sereen aaaea aai E A A A AEEA 31 A IUNIS Sree Nenei A E O O O aN 32 4 4 Compo nds Sereen taea tetera Cae EEEE EE e EE Ero 34 4 5 Stream
129. s in a Stream You can also type in data just for future reference By scrolling to the right you can view and edit vapor pressure data which can be entered in three ways CALCS will use the data in this preferential order e Three Antoine coefficients with their lower and upper temperature limits e Two parameter coefficients with their lower and upper limits e Five points of known vapor pressure at different temperatures Add Edit Compounds Search for Compound gt Log p A B t C p mmHg t C Temp Range C Log p A B T p mmHg T K Temp Range C Antoine A Antoine B Antoine C Antoine low Antoine high 2 Parameter A 2 Parameter B 2 Par low 2 Par high 6z 594990 256468 453 TT of ow ow owo o oof o za 4474082281314 BS 699 76843 28309 off ow 000000 of of ACM CALCS Manual Page 36 Scrolling farther to the right we see the five point entry fields Add Edit Compounds Search for Compound YP 1 psia Temp1 C VP 2 psia Temp 2 C VP 3 psia Temp 3 C VP 4 psia Temp 4 C VP 5 psi 3 88 200 5 54 1 0 00 8 36 20 00 12 22 30 00 17 3 52 1 70 5 08 10 00 756 20 00 11 24 30 00 16 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 E T Scrolling more we see options for putting the Compound in a VOC SARA HAP or other category using a drop down list Add Edit Compounds Search for Compound gt Temp 4 C VP4 psia Temp 5 C Category Sara
130. sion 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 feature that links to the MSDS database shown below ACM Calcs Emission Calculations Program mg amp r B A U D E HE F Facility Units Compounds Stream Prop Unit Streams Sources Batch Formulas Profiles CalcCont Inventory Exit SERRES B Save Save Az Erase Inzert Delete MSDS Print Close Mi Add Edit Stream Properties and Compositions New 7 2 NY Emission Calculations 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 rest of the CALCS user s manual Batch calculations require extensive setup data to be entered into the system to ide
131. solete accounts Some of these functions take a lot of time if there are large numbers of records so plan accordingly ACM Calcs Emission Calculations Program File Data Window Help 2 b Zubna 2 oe of E Facility Units Compounds Stream Prop Unit Streams Sources Formulas Profiles Calculate Inventory Exit 2 8 2 B OL E Save Print Delete Select All UnSelect All Invalid Accts Close Database Cleanup Streams not used in the database gt Retrieve Streams not used in the database Stream Comp not linked to any Stream 0 Tons Yr of Speciated Emissions Emissions not linked to Current Accounts Sources Row Streamnmame Streamid Unit st sed in the Database ACM CALCS Manual Page 31 4 1 7 Window Menu The Window menu allows you to arrange multiple screens into the familiar Tile Cascade or Layer configuration If you click Toolbar a pop up gives options of moving the button row to the left as in the figure below right top or bottom Also you can create a floating square window of buttons or hide the buttons altogether and use the menu bar You can uncheck the Show Text box to shrink buttons once you are familiar with the icons These options allow the best use of screen space Also when multiple screens are open they will be listed below the Toolbar item so you can switch between screens alcs Emission Calculations Program ACM Calcs Emission Calculations Pro
132. sufficient for this also as well as the MW Reference Temperature Other fields are entered manually if needed Most of the fields can be used later in a Formula ACM CALCS Manual Page 38 4 6 Unit Stream Screen Stream Properties must be linked to a Unit to form a Unit Stream combination which is the actual Stream A Stream can be searched by name by typing in the first few characters Rows can be sorted by clicking on any column heading Click Insert to add a new Unit Stream In the fourth column use the Stream Composition drop down to find the desired Stream Properties Likewise pick a Unit in the third column and assign the combination a Stream ID and Stream Name You can also edit an existing Unit Stream Click Save when finished with adding or editing Both the Stream ID and Stream Name should reflect the Stream Properties and the Unit For instance the Stream Composition Properties for GASOLINE could be linked to the CRUDE Unit given the identifier CRUDEGASO and the name CRUDE UNIT GASOLINE That way the name is intuitive when encountered later The Stream ID can be up to 12 characters long This ID is the link to other entities and should be all upper case with no spaces to avoid confusion Cleanup Streams Search for Stream name Stream name Stream id Unit Stream Compositi FASTING FASTING CASTING X Stus FUGITIVE STREAM QCOMBSTRMS ALL UNITS y o Lap LIGNITE DUST AB L DUST LABORATORY v SLUG FUGITIVE STREAM
133. t a amp AR FE Retrieve Save Save As Delete Print search Criteri Close F CT1 Facility code Source id Start date 01 01 2005 End date 01 31 2005 Compound ALKANES U E_Ibperhr E_tons est Max Ibperhr Max Tons est 0 0000 0 0000 F CT1 0101 2005 01 31 2005 PM10 0 0542 0 0202 F CT1 02 01 2005 02 28 2005 ALKANES U 0 0000 0 0000 F CT1 02 01 2005 02 28 2005 PM10 0 0542 0 0182 F CT1 03 01 2005 03 31 2005 ALKANES U 1 0699 0 3980 F CT1 03 01 2005 03 31 2005 PM10 0 0542 0 0202 F CT1 04401 2005 04 30 2005 ALKANES U 0 3159 0 1137 F CT1 04 01 2005 04 30 2005 PM10 0 0542 0 0195 F CT1 05 01 2005 05 31 2005 ALKANES U 0 3057 0 1137 F CT1 05 01 2005 05 31 2005 PM10 0 0542 0 0202 F CT1 06 01 2005 06 30 2005 ALKANES U 0 3159 0 1137 F CT1 06 01 2005 06 30 2005 PM10 0 0542 0 0195 F CT1 07 01 2005 07 31 2005 ALKANES U 0 3057 0 1137 F CT1 07401 2005 07 31 2005 PM10 0 0542 0 0202 F CT1 08 01 2005 08 31 2005 ALKANES U 0 3057 0 1137 F CT1 08 01 2005 08 31 2005 PM10 0 0542 0 0202 Multiple rows may be selected by clicking one row and then selecting another row while holding down the lt Shift gt key Click on the Delete icon to delete any highli
134. t use the existing Stream ID for any of the imported Streams If a is done add this new Stream to the emission Source record If 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 Page 116 CHAPTER 7 NEW YORK STATE FEATURES 7 1 NY Stream Properties and Composition 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 below mi b S F B J D E E F Facility Units Compounds Stream Prop Unit Streamz Sources Formulaz Profiles Cale Cont Inventory Exit 2 B22 See SE Save Save As Erase Insert Delete MsDs Print Close A material composition is referred to as a Lab Sample ID In the standard ver
135. t will be multiplied by an emission factor in pounds per hour per source per component A different count can be entered for each Estimation Period for the same Source E General K Detail 2 Leak Counts Stream COMBINED STREAMS lt 100 VOC Delete Component Description Leak Range Leak Counts COMPRESSORS Oande 0 o o ooo EompREssoRs f tand 1000000 P COMPRESSORS f O and lt 0 l OMPRESSORS f Oand lt 1 000000 GASFLANGES f Oande 0 ASFLANGES f tand 1 000000 GASFLANGES fEOams0 ASFLANGES f Oand lt 1 000000 maw HEAVY LOUD FLANGE f Oand 0 o o HEAVY LIQUID FLANGE n m HEAVY LIQUID FLANGE a zi Then a Formula must be entered for each type of component with a component count in the Source screen The Profile must also contain all of those Formulas and be linked to the Source ACM CALCS Manual Page 72 Although it will be explained more in the Equipment Leaks chapter the Leak Ranges for each component are listed in the following order with leak analyzer reading ranges in parts per million ppm gt 0 and lt 0 which indicates Zeros gt 1 and lt 1000000 indicating Intermediates and Leakers gt 0 and lt 0 indicating SOCMI average gt 0 and lt 1000000 indicating Totals You will find a Leak Range pick list in a field in the Formulas screen with the same four choices The Source and Formula Leak Ranges must match If you ent
136. ternal Floating Roof Tank Type Data fields for this type tank are seen below The Total Deck Fitting Loss Factor is carried forward from the tab labeled Tank Fittings See Tank Fittings section for details fi General K Detal BH Tank Data T Tank Fittings Method Construction Type welded Riveted Shell Condition Seal Type OoOo M Product Stored J ae Atmospheric Pressure Pa 14 7 psia Column Type a Throughput P00 t Shell Paint Solar Abspt 0 z Thru_Units JBBLiest Roof paint solar abspt po a Tank Diameter D P00 ft Paint Solar Abspt poo Cut_Throughput Q po BBLiyr Tot Deck Fitting Loss Fac z Potential Throughput 00 BBLiyt Pumping Rate in galsimin 0 00 Product Factor Keo z Avg Clingage Factor bo z Deck Type z Column Diameter Fe po Deck Seam Lngth Fac sd jo x Humber Of Columns He po Deck Seam Loss Per Unit Seam Lath Fac f 00 Seal loss Factor Kr poo x 4 8 3 4 Tank Fittings Tab This tab appears for Internal Floating Roofs External Floating Roofs and Domed External Floating Roofs It allows entry of the number of hatches wells etc 4 8 3 4 1 Tank Fittings Tab Internal Floating Roof Tank Type This tab lists 44 fittings with their AP 42 emission rates Note that the emissions are totaled at the bottom This total is carried over to the Tank Data tab for use by Formulas EH General K Detail TankData Tank Fittings FITTING LOSSES FOR 1 Calculation Method Tanks
137. 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 below When run for a specific Source this feature 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 EI 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 EI for any time period in which a Rolling Sum report is produced SACM Calcs Emission Calculations Program hh tr bh GW amp E HB o F Facility Units Compounds Stream Prop Unit Strcoms Sources Batch Formulas Profiles Cole Cont Inventory Exit Batch Calculations Bel Facility Code SE_SIL Equipment ID M Delete Year 2000 Delete Rolling Sum Emiss Description fest Unit 71 2001 ha volume 1200 gals Machine Prs ACM CALCS Manual Page 123 12 NY PIPELINE The data PIPELINE is accessed by clicking on the PIPELINE icon in the COMPASS folder As shown below the main toolbar has two reference lists to assist the user to synchronize data between CALCS and EI modules for the export of emissions They are Equip which displays equipment relationships and Contam which displays a list of chemicals with the El assigned contaminant code and CALCS assigned CAS Number In order for chemical
138. the box and retry listing emissions Error Message No emissions capable of Not shown as Active in EI module In EI main screen double click Source change to active and save export for Facility account Year YYYY No FIN EPN CIN link in PIPELINE Click Equip then Insert Use drop downs to fill in FIN amp EPN Enter for CIN rather than blank FIN name in CALCS is not identical to that in PIPELINE EI Compare FIN name in CALCS vs EI even for trailing spaces Correct in PIPELINE Rename 8 2 2 PIPELINE Steps with Troubleshooting e In PIPELINE click Emissions button o Pick year Facility and FIN filtered by Unit and Source Type only if desired ACM CALCS Manual o Click List button If FIN is not on pick list click Err Report button for clues Select Reports of all 3 kinds and do the following as needed e Run CALCS Calculate as usual Source will not appear on PIPELINE Emissions pick list if Calculate hasn t been run e Ifthe Source has Secondary Sources sum them o In CALCS click Inventory button Highlight the Primary and all Secondary Sources together Click Retrieve button Click Data and Sum Emissions Highlight the desired Primary only o Click Sum amp Delete normally e Reconcile equipment relationships if needed o In PIPELINE click Equipment button o Click Insert button o Pick FIN EPN CIN pick for the first bla
139. ties A Stream can be the contents of a tank the fuel for a boiler the material leaked from piping components or even the exhaust from a stack It may be a gas liquid or solid The Stream Properties screen shows the Compounds ingredients and their relative amounts in the Stream It also can contain data such as molecular weight of the mixture s liquid or vapor states sulfur content and heating value for fuels 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 but it may be left blank in a tank or loading Stream a Mi add edit Stream Properties and Compositions E85GASO Enter lab sample id E8scaso Sample description E 85 GASOLINE High heat value Low heat value zz HHY Btu scf LHY Btu scf MW liquid phase 6 80 _catc MW vapor phase 64 80 _catc RYP psia Composition phase Vapor zi Density in Ibs gal Sulfur content in ppmw MW Reference po F Sample date Temperature Data source or Lab Compound Concentration Units Cut_concentration Cvt_units ETHANOL v jes 0000 X js 0000 fmt GASOLINE 4P42 RYP 15 v i 5 0000 v ji 5 0000 pa Total Concentration in WT 100 0000 100 000 ACM CALCS Manual Page 11 2 6 Unit Streams CALCS links a set of Stream Properties Stream Composition with a Unit to create a Unit Stream which is the actual Stream Add Edit Streams ACM CALCS Manual Pa
140. ties 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 You may also modify existing Stream data by clicking on the field of the Stream record you wish to modify Simply overwrite existing data and click Save ACM CALCS Manual Page 41 4 7 Relations Screen If you click the drop down arrow to the right of the Unit Streams button you will see the Relations button This button opens the screen that shows relationships between all Streams and Sources You can also view and print the complete list gt Source Browser Stream Source Relationships for Account 1015400 LOADING RACK SOURCES SP5A 1015426 LOADING RACK SOURCES SP54 SPSCFROMSA 1016962 LOADING RACK SOURCES SPSA SPSCFROMSA 1016965 LOADING RACK SOURCES SP1LOAD ACM CALCS Manual Page 42 4 8 Sources Screen The Source ID or Equipment ID is usually the FIN The Source ID must be the FIN for the PIPELINE module to transfer the emissions to the EI module Secondary Sources can be different from the FIN but th
141. tom window To see more available variables in the Columns list check the box for Stream Data or Stack Test Stream Data shows fields from the Stream Properties screen Stack Test shows fields from previously entered stack test data Stack Test data is found with all screens closed except the main screen on the Maintenance menu under Stack Tests ACM CALCS Manual Page 80 4 11 4 Operators Powers Parentheses and Embedding Operators and powers 1E and x and parenthesis buttons can be clicked between entering variables The Embed Formula button presents a list see screen print of Formulas already saved which you can insert within the current Formula A Formula Picklist xi Formula ID Description x When the Formula is complete click Save Click Comments to keep a backup copy of a long Formula to explain variables or enter the basis for calculations Keep in mind that it is possible to put a variable in a Formula for which you did not enter data on a previous screen This will generate an error message during the Calculate step ACM CALCS Manual Page 81 4 11 5 Equipment Leak Formulas The Formula screen for Equipment Leaks looks different from that of the other Source Types Instead of selecting a Compound the Compound is assumed by CALCS to be total VOC That VOC can be speciated later in the Profile Instead of each Compound having a separate Formula each Component has its own Formula The Emission Fa
142. ual 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 upper 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 x You need to replace the x and y with the actual values For 3 instance 5 would be f_exp 5 3 and leak rate i 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 6 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 for
143. unting later Then create three more Sources named as you wish like BOILICOAL BOILIOIL and BOILIGAS Enter the usage of each fuel under the respective Secondary Source You would later also create a Formula and Profile for each Secondary Source Then with the Source screen open and at a minimum the Facility Code site selected click Options and Equipment Maintenance Find BOILICOAL in the left column In the right column select BOIL as its Primary Source Repeat this for the other two Secondaries Also find the Primary Source BOIL1 in the left column and pick BOIL1 again in the right column CALCS now knows that a Source with its own ID on the right is a Primary Source and a Source with a different ID on the right is a Secondary Source Later the Secondary Sources can have their emissions calculated summed all together and the total reported under the Primary Source This will be discussed more in the Inventory Screen section Only the Primary will be transferred to the EI module for reporting because the PIPELINE module only transfers previously reported Source ID s FIN s to EI The official Sources will be known by PIPELINE and EI modules from the download file from the state which is first imported into the database The diagram below shows Primary and Secondary associations Secondary Source Secondary Source Secondary Source BOILICOAL BOILIOIL BOILIGAS calculates coal emissions calculates oil emissions calculates g

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