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Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
Cem com example-qa_qc_plan
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Cem com example-qa_qc_plan

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  • 1. Example Quality Assurance / Quality Control Plan for Continuous Emission Monitor Systems and Continuous Opacity Monitor Systems (CEMS/COMS) The following is an example of a Quality Assurance / Quality Control (QA/QC) Plan forContinuous Emissions Monitoring Systems or CEMS. This QA/QC Plan meets the minimumrequirements of the Indiana State Rule 326 IAC 3-5-4 Standard Operating Procedures andChapter 20 of the Indiana Quality Assurance Manual. This example QA/QC Plan may be used as a guide for the construction of your CEMSQA/QC Plan. Please keep in mind that this example plan has the basic elements that comprise agood QA/QC Plan but, it may not cover all the areas that are specific to your plants CEMS. Besure to incorporate your specific operational knowledge, experience and applicable State andFederal requirements into the QA/QC Plan for your company. If you have any questions pleasecall Jarrod Fisher at (317) 233-2723, fax at (317) 233-6865 or e-mail at jfisher@idem.in.gov.NOTE: BOLD , UNDERLINED, UPPER CASE ITALICS in this Plans text isintended for areas in which company names, boiler numbers or other text can beinserted. Text which is bold, underlined lower case italics is intended for areaswhere additional text may be inserted into the Plan.
  • 2. Continuo u s Emission Monitoring Syste m s (CEMS) Quality Assura n c e /Q u ality Control Plan for COMPANY - PLANT UNIT - MONITOR( S ) DATE TABLE OF CONTENTS
  • 3. Section 1.0 Introd uc tio nSection 1.1 Quality Assura n c e and Quality Control (QA / QC) -Definition and FunctionSection 1.2 Quality Assura nc e Policy, Goal, and ObjectiveSection 1.3 Distribution and Docu m e n t ControlSection 2.0 Orga niz a tion and Respo n si ble Individu alsSection 2.1 Com m u nic a tio n of Inform a tio n, Data and Report sSection 2.2 Emission Data and Emission Report sSection 2.3 QC Data and Report sSection 2.4 QA Audit Data and Report sSection 2.5 QA Results and QA ReportsSection 2.6 Emission Data and Emission Report sSection 3.0 Description of Facility and CEMSSection 3.1 FacilitySection 3.2 Continuo u s Emission Monitoring Syst e m 3.2.1 Sa m pl e Probe s 3.2.2 Sa m pl e Trans p or t 3.2.3 Analyzers 3.2.3.1 NOx 3.2.3.2 Opacity 3.2.4 Support Hardw ar e 3.2.5 Data Acquisition and Handling Syst e mSection 4.0 TrainingSection 4.1 Quality Assura n c e Training 4.1.1 Gene r al Training 4.1.1.1 Quality Assura n c e Plan 4.1.1.2 Periodic Refres h e r TrainingSection 5.0 Quality Control/Quality Assura n c e ActivitiesSection 5.1 Quality Control Activities 5.1.1 Calibration Gas e s 5.1.2 Calibration Check 5.1.3 Syst e m s AuditSection 5.2 Quality ass ur a n c e Activities 5.2.1 Relative Accuracy Test Audit (RATA) 5.2.2 Cylinder Gas Audit (CGA) 5.2.3 Opacity Audit 5.2.4 Perform a n c e Specification TestingSection 5.3 Data Recordin g and Reportin g TABLE OF CONTENTS
  • 4. Section 5.4 Preve n tiv e Mainte n a n c eSection 5.5 Repair Progra mSection 5.6 Spar e Parts Invent orySection 5.7 Activity MatrixSection 6.0 Docu m e n t a t i o n and Report sSection 6.1 DAHSSection 6.2 Emission Measur e m e n t Data Proce s sin gSection 6.3 DAHS Report sSection 6.4 Mainte n a n c e RecordSection 6.5 Audit Report sSection 6.6 CGA Gas CertificationSection 7.0 Quality Assura n c e Proce d u r e sSection 7.1 Introd uc tio nSection 7.2 RATA Proce d u r e s 7.2.1 Prelimin ary Activities 7.2.2 Detaile d Proce d u r e s 7.2.3 Data Reduction and Analysis 7.2.4 Relative Accuracy Calculation s 7.2.5 Report Prep ar a tio nSection 7.3 Proce d u r e s for CGA 7.3.1 Introd uc tio n 7.3.2 Cylinder Gas Audit 7.3.3 Data Reduction and Analysis 7.3.4 ReportingSection 8.0 QC Proce d u r e sSection 8.1 Introd uc tio nSection 8.2 Daily Calibration CheckSection 8.3 Weekly Syste m s AuditSection 8.4 Quart e rly Syst e m s AuditSection 9.0 Routine Preve n tiv e Mainte n a n c eSection 10.0 Correc tive Action and Require d NotificationsSection 10.1 Sugg e s t e d Correctiv e ActionSection 10.2 Require d Notification sSection 11.0 Refer e n c e sSection 12.0 Attach m e n t s Section No.: 1 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7
  • 5. Page No.: 1 of 31. 0 INTRODUCTION A Quality Assura n c e (QA) Plan is the basis for ass e s si n g and maint ai ningof the qual ity of continu o u s emission monitoring dat a. This QA Plan hasbee n prep a r e d for the COMPANY oper a t o r s of Continuo u s EmissionMonitoring Syst e m s (CEMS) at the PLANT NAME in CITY OR COUNTY ,Indian a. Thes e CEMS are use d for me a s u r e m e n t of efflue n t pollutionconc e n t r a tio n s from boiler(s) No. BOILER NUMBER OR DESIGNATIONand stack opacity from boilers num b e r( s) BOILER NUMBER ORDESIGNATION . In th e Plan , lis t th e CEMS co v e r e d b y th e Plan . For ex a m p l e :The following CEMS hav e bee n inst alled and certified at PLANT NAME:CEM BRAND- MODEL SERIAL NUMBER SPAN LOCATIONNOx TECO 42 42D- 1234 5- 269 1000 pp m Unit # 1- Stack ACO 2 Milton Roy 3300 N1 E0392 4 20% Unit # 1- Stack A Thes e CEMS were installe d to com ply with the specific require m e n t s ofthe OPERATING PERMIT, STATE RULE, FEDERAL REGULATION ,AGREED ORDER, ETC . Thes e CEMS also provid e proc e s s dat a to aid in theoper a tio n and the maint e n a n c e of the pollution control equip m e n t require dat this facility. This quality assur a n c e plan was dev elo p e d from guide linesdevelo p e d by Indian a Depar t m e n t of Environ m e n t a l Mana g e m e n t , Office ofAir Quality (IDEM - OAQ) and the U. S Environ m e n t a l Protec tion Agency. Alldocu m e n t s used in the dev elop m e n t of this quality ass ur a n c e plan areliste d in Section 10, Refere n c e s .1. 1 QUALITY ASSURANCE AND QUALITY CONTROL (QA / QC) - DEFINITION AND FUNCTION Quality Assura n c e and Quality Control are two inde p e n d e n t andinterr el a t e d functions . First, Quality Assura n c e will be define d as a syst e m ofgen e r al progr a m m a t i c activities imple m e n t e d to ens ur e Quality Control isperfor min g ade q u a t e l y. Where a s , Quality Control is define d as a series ofspecific activities perfor m e d to provide a reprod u cible quality prod uc t.Cons e q u e n tl y, quality ass ur a n c e serve s as a “quality control” for the qualitycontrol function.. QA Plans consist of prim arily two function s: (1) the QA function which isthe ass e s s m e n t of the quality of the dat a (accur a c y and precision) and, (2)the QC functions which are the activities that maint ai n or improv e dat aquality. Thes e two functions com bin e d form a control loop. For inst a n c e ,
  • 6. when accur a c y or precision (a QA function) is unacc e p t a b l e , QC functionsmus t incre a s e until the quality of the dat a is acce p t a bl e . Section No.: 1 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 2 of 3 Quality Assura n c e involves me e ti n g progr a m m a t i c require m e n t s but onoccasion require s the imple m e n t a t i o n of ext er n al checks on dat a quality.Thes e ext er n al checks may includ e inde p e n d e n t syst e m audits, third partysa m pl e and analysis for accur a c y and precision, com p a ris o n to knowcalibra tion sta n d a r d s or interla b o r a t o r y audits. Conver s ely, Quality Control functions are usu ally a series of frequ e n t(daily, weekly, mont hly) routin e intern al checks, such as syst e m insp ec tio n s,periodic calibra tion s , and routin e maint e n a n c e . A compl e t e QualityAssura nc e Plan enco m p a s s e s both QA and QC function s and strives toidentify which function is addr e s s e d by a specific activity.1. 2 QUALITY ASSURANCE POLICY, GOAL, AND OBJECTIVE It is COMPAN Y NAMES policy to efficiently oper a t e and maint ai n itsfacilities and CEMS in accord a n c e with good oper a tin g practice s and allapplica ble local, stat e and feder al environ m e n t a l regul ation s . COMPAN YNAME is com mit t e d to collecting all nec e s s a r y dat a to de m o n s t r a t e that itsoper a tio n s are in com plianc e with its oper a tin g per mit. The COMPAN YNAME is also com mit t e d to ens urin g tha t all environ m e n t a l control syst e m sare oper a tin g within acce p t a bl e limits. The goal of this QA progr a m is to provide emis sion dat a of known andacce p t a bl e quality and in sufficient qua n tity to de m o n s t r a t e com plia nc e withthe following air pollution emission and monitoring regula tio n s: List th e ap p li c a b l e re g u l a t i o n s , for ex a m p l e : 40 CFR 60, SUBPART Db INDIANA OPERATING PERMIT NO. XXXXX 40 CFR 60, APPENDIX F 40 CFR 60 APPENDIX B
  • 7. 32 6 IAC 3- 1. 1 - 4 COMPAN Y NAME recog niz e s that the reliability and acc e p t a bility ofCEMS dat a is directly dep e n d e n t on satisfact ory com ple tion of all activitiesstipulat e d in a well- define d QA plan. Accordingly, the objective of this QAPlan is to define thos e activities nece s s a r y to guar a n t e e that CEMS dat aquality is maint ain e d at acc e p t a bl e levels. The Plan also provid e s thefram e w o rk for carrying out QA activities by addr e s sin g item s such asdocu m e n t a ti o n, training, correctiv e actions, and prev e n tiv e maint e n a n c eactivities. Section No.: 1 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 3 of 3 This Plan addr e s s e s oth er nec e s s a r y supp ort servic es and activities, suchas ma n u al met h o d s sourc e testing, dat a reduc tion, missing dat a routin e s ,inven t o ry control and report prep a r a tio n and sub mitt al, all of which arerequir e d to maint ain dat a qual ity. It should be not e d that som e QA/QC activities may not be discus s e d in asgre a t det ail as oth er more critical activities. Activities not fully discus s e dmay include, but are not limite d to, dev elo p m e n t of instru m e n t maint e n a n c ema n u al s (usu ally provide d by the man uf a c t u r e r ), procur e m e n t proc e d u r e s ,and plant oper a tion proc e d u r e s . Thes e proc e d u r e s are refer e n c e d is this QAPlan and may be upd a t e d as the CEM progr a m dev elo p s throu g h oper a tio n alexp e rie n c e .1. 3 DISTRIBUTION AND DOCUMENT CONTROL This QA Plan will be review e d ann u ally and any chan g e s and revisions willbe forward e d to all appro p ri a t e parties . In the eve n t a major revision to theQA Plan is require d, eac h copy will be reissu e d to all appro pri a t e pers o n s .All revisions to the Plan will be clearly mark e d on each pag e with a revisionnu m b e r and revision dat e. When modification s to the QA Plan beco m e nece s s a r y , TITLE isrespo n sibl e for ens urin g that curre n t revisions are includ e d in the QA Plan,and that distribution of the revis e d Plan is mad e to all appro p ri a t e partie s.
  • 8. A copy of this QA Plan will be sent to the Indian a Depar t m e n t ofEnviron m e n t a l Manag e m e n t Office of Air Quality (IDEM - OAQ) for theirreview and com m e n t . All futur e chan g e s or revisions to the Plan will also beforward e d to IDEM - OAQ. Section No.: 2 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 1 of 32. 0 ORGANIZATION AND RESPON SIBLE INDIVIDUALS Pro v i d e a lis ti n g or flo w ch a r t of th e indi vi d u a l s an d / o r th e i r titl e sin th e co m p a n y / p l a n t re s p o n s i b l e for CEMS an d CEMS- rel a t e dop e r a t i o n s . Inclu d e du t i e s an d re s p o n s i b i l i t i e s su c h as ba s i c pla n top e r a t i o n s , CEMS op e r a t i o n an d m ai n t e n a n c e , pr o c u r e m e n t ,QA/QC, da t a an d re p o r t re v i e w , tr ai n i n g an d su p e r v i s o r y fun c t i o n s .2. 1 COMMUNICATION OF INFORMATION, DATA AND REPORTS For a QA plan to be function prop e rly, provisions mus t be mad e for theeffective com m u nic a tio n of the results from QA/QC activities to all affect e dpartie s. Clear chan n el s of com m u nic a tio n and respo n sibility mus t existwithin the respo n sibl e dep a r t m e n t and throu g h o u t the Plant. Emissions dat a and emission s report s are crucial parts whe n det e r mi nin g
  • 9. the oper a tio n al stat u s of a CEMS syst e m . This Plan also provid e s for thecom m u nic a tio n of QA and QC inform a tio n and the nece s s a r y mec h a ni s m sfor trigg erin g correctiv e actions bas e d on the cont e n t s of the QA/QC report s.2. 2 EMISSION DATA AND EMISSION REPORTS TITLE is respo n sible for the prep a r a tio n and distribution of all emissionreport s. Therefor e, CEMs dat a must flow throu g h this position to ens ur e theaccur a t e and com pl e t e pre p a r a tio n of quart e rly report s. TITLE isrespo n sibl e for verifying tha t the dat a are reduc e d , validat e d , and report e dprop e rly. Addition ally, as an inde p e n d e n t QA/QC check, TITLE will decid e ifthe emission dat a is following an acc e p t a bl e tren d as bas e d on docu m e n t e dboiler and control equip m e n t oper a tin g record s. This review of emissiondat a is used to identify periods of unus u al oper a tion, which may beindicativ e of CEM oper a ti n g proble m s .2. 3 QC DATA AND REPORTS There are ma n y type s of QC checks perfor m e d routin ely. With resp e c t tothe num e r o u s type s and the various levels of string e n c y involved in the s etest s it is impra ctic al to discus s every possible direction of inform a tio n flowor exch a n g e . Section No.: 2 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 2 of 3 Howev er, an exa m pl e of a QC inform a tio n exch a n g e would be the dailyzero/s p a n calibration check. The CEMS auto m a tic ally switch e s to sa m plingknown gas conc e n t r a ti o n s once every 24 hours and the s e value s are logg e dto a com p u t e r dat a acquisition and han dling syst e m (DAHS). On a dailybasis, TITLE would review the me a s u r e d value s comp a r e d to the knownconc e n t r a tio n s to det e r mi n e if the QC check is within per mis sible limits. Ifvalue s are outsid e limits, the TITLE would proce e d to the instru m e n t tocompl e t e a visual insp ec tio n checklist. Norm ally, it the value s are confirm e dto be outsid e the oper a ti n g limits a recalibr a tio n of the instru m e n t isnec e s s a r y . After recalibr a tion, the visual checklist, the daily calibra tionreport and a description of corrective action would be sub mitt e d to the
  • 10. TITLE for review. If any unus u al conditions continu e to be obs erv e d , theTITLE will initiat e a maint e n a n c e requ e s t to det e r mi n e and rep air theobs erv e d proble m . Upon com ple tion of the maint e n a n c e rep air requ e s t , adet ailed description of the proble m and its’ resolution will be ent er e d in themaint e n a n c e log records and report e d to the TITLE for any furth e r post-maint e n a n c e QA/QC actions. After the review of the s e report s is com pl e t e d , each report will be place din a per m a n e n t file for later docu m e n t a t i o n and use in report sub mitt al.2. 4 QA AUDIT DATA AND REPORTS Quality ass ur a n c e audits includ e quart e rly Cylinder Gas Audits (CGA) ,annu al Relative Accuracy Test Audits (RATA) and quart e rly opacityCalibration Error (CE) audits. Thes e audits are perfor m e d in accord a n c ewith sta n d a r d proc e d u r e s and are use d to det er mi n e CEM accur a c y on aperiodic basis. The actu al perfor m a n c e of an audit may be conduc t e d by acontr a c t o r or by TITLE. Regar dle s s of whom actu ally conduc t s the audit,TITLE is respo n sible for the com pl e t e n e s s and the correct n e s s of the finalaudit report. This report det ails a com p a ris o n betw e e n results andcomp a r a bl e CEM dat a and consists of all raw dat a as well as final results.2. 5 QA RESULTS AND QA REPORTS TITLE is respo n sible for com pilation, pre p a r a tio n and distribution of QAresults and report s to all appro pria t e grou p s. TITLE is also resp o n si ble forprep a r a tio n of the final QA report and its sub mit t al to the Indian aDepa rt m e n t of Environ m e n t a l Mana g e m e n t Office of Air Quality (IDEM -OAQ). Section No.: 2 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 3 of 3
  • 11. 2. 6 EMISSION DATA AND EMISSION REPORTS In com plia nc e with our oper a ti n g per mit requir e m e n t s , all emission dat ais availa ble for review, eith er as a com p u t e riz e d dat a bas e or print e demission logs, and maint ain e d in a file for 24 mont h s . All quart e rlycomplia nc e report s will be sub mit t e d to the IDEM - OAQ within 30 days ofthe end of the quart e r as define d in the oper a tio n per mit. Section No.: 3 Revision No.: 0 Date: Se p t e m b e r
  • 12. 10 , 19 9 7 Page No.: 1 of 33. 0 DESCRIPTION OF FACILITY AND CEMS3. 1 FACILITY Pro v i d e a bri e f d e s c r i p t i o n an d a dia g r a m of th e pla n t / b o i l e r ( s )an d s t a c k s rel a t e d to th e CEMS, for ex a m p l e : BOILER NUMBER OR DESIGNATION is a Folster Whe ele r 200,0 0 0poun d s of ste a m per hour circulating fluidized bed, firing Indian a bitu mino u scoal. Dry limes t o n e injection into the furnac e are a is use d to control sulfurdioxide emission s. [DIAGRAM ]3. 2 CONTINUOUS EMISSION MONITORING SYSTEM Pro v i d e a g e n e r a l d e s c r i p t i o n an d dia g r a m of th e CEMS, forex a m p l e : The specific CEMS em ploy e d her e is bas e d on an extra c tiv e sa m pl eacquisition syst e m using a dilution prob e for moist ur e , gas e s and particula t econtrol. Major comp o n e n t group s of this syst e m include: sa m pl e prob e ,sa m pl e tran s p o r t , sa m pl e analyz er s , suppor t hardw a r e , and dat a acquisitionhandling syst e m (se e figure). Effluent com p o n e n t s monitor e d andme a s u r e d include LIST THE MEASURED GASES AND/OR FLOW S . Opacityis me a s u r e d using stack moun t e d in-situ devic es . [DIAGRAM ]
  • 13. Section No.: 3 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 2 of 33. 2 . 1 Sa m p l e Prob e s De s c r i b e th e sa m p l e pr o b e , its co n s t r u c t i o n m a t e r i a l s ,co m p o n e n t s , flo w ra t e s , dilu t i o n ra ti o , e t c . , for ex a m p l e : Each prob e consists of a 12- inch tip moun t e d on an ext e n sio n to positionthe tip at the sa m pl e extr ac tio n point. The sa m pl e point is a repr e s e n t a ti v elocation within the efflue n t stre a m . Cont ain e d within the prob e are: - a cours e ste el me s h particula t e filter, - a fine quartz wool particula t e filter, - a sonic orifice and, - an air pow er e d sa m pl e educ a t o r. The filters, cours e and fine particula t e , are design e d to prev e n t pluggin gof the sonic flow critical orifice. To minimize maint e n a n c e require m e n t s onthe s e filters, a high vacuu m (min. 15 inche s of Hg), low flow (1 to 5 cubicfeet per day) is utilized to reduc e the total am o u n t ofparticulat e being expos e d to the filters. This efflue n t sa m pl e is draw nthrou g h the filters using the air educ a t o r. A dilution ratio of 1:250 isachiev e d throu g h the use of a restrict e d flow (sonic) orifice.3. 2 . 2 Sa m p l e Tran s p o r t De s c r i b e th e sa m p l e tr a n s p o r t s y s t e m , for ex a m p l e : The sa m pl e umbic al trans p o r t is a multiple line unit use d to conn e c t theprob e , analyz er and calibration gas delivery syst e m . The umbilical cordconsist s of a polyet h yl e n e line for dilution air, a Teflon line for the dilut e dsa m pl e, a Teflon line for calibra tion gas e s , and a polyet h yl e n e line formonitoring vacuu m at the sonic orifice. This tube bundle is wrapp e d in aMylar R (thin plastic liner) and enclos e d in a PVC (he a vy plastic) jacket forprot e c tio n.3. 2 . 3 Analy z e r s De s c r i b e th e an al y z e r s , for ex a m p l e :
  • 14. After tran s p o r t to the instru m e n t location, the dilute d sa m pl e isdistribut e d to the an alyz er s for det e r mi n a ti o n of the various polluta n tconc e n t r a tio n s . The dilut e d sa m pl e flows into a ma n ifold at a rat e of 5 to 7liters per minut e (lpm). Each analyze r use s approxi m a t e ly 0.5 to 1.0 lpm.The exc e s s sa m pl e is exh a u s t e d to an at m o s p h e r e dum p ma nifold. Section No.: 3 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 3 of 33. 2 . 3 . 1 Nitro g e n Oxid e s (NOx) De s c r i b e e a c h ty p e of an al y z e r (e. g . , . SO 2 , NOx, CO 2 .O p a c i t y ) , forex a m p l e :(DISCLAIMER) The CEMS/COM S m o n i t o r i n g e q u i p m e n t us e d toillu s t r a t e thi s ex a m p l e ar e no t to b e con s t r u e s as e n d o r s e m e n t ofth e par t i c u l a r pr o d u c t or m a n u f a c t u r e r ) A Therm o Environ m e n t a l (TECO) Model 42 an alyz er is used to monitorand me a s u r e Oxides of Nitrog e n (NOx) emission s. This analyz er is a part ofan dilution extr a c tio n analysis syst e m , and receiv e s an effluen t sa m pl e thathas be e n dilute d in a ratio of 1:250 with clean dry air. This analyz er me a s u r e s NOx conc e n t r a ti o n s by reac tin g nitric oxide (NO)with ozon e (O 3 ) to form nitrog e n dioxide (NO 2 ). This che mic al reactionproduc e s a sm all am o u n t of light that is directly propor tion al to the am o u n tof NO pres e n t in the sa m pl e. To me a s u r e NO 2 conc e n t r a tio n s , the sam pl epass e s throu g h a conve rt e r unit which tran sfor m s any NO 2 pres e n t to NO.The sa m pl e is the n introd uc e d to the reaction cha m b e r wher e it com bin e swith O 3 . Aphoto m ul tiplier tub e det e c t s this light produc e d by the che mic al reaction ofO 3 with NO 2 and an outpu t signal is sent to the dat a syst e m .3. 2 . 3 . 2 Opa ci t y De s c r i b e th e op a c i t y m o n i t o r , for ex a m p l e : The COMS monitoring syst e m consist s of an opacity monitor (tran s c eiv e rand retror eflect or), control unit and a DAHS collection syst e m . Allcomp o n e n t s listed mak e up the COMS syst e m and are certified in conc ertwith each oth er thus providing a “CERTIFIED SYSTEM”. An exa m pl e of an
  • 15. opacity monitor which might be used are the Durag Model 281 units (in-situ) which are locat e d on the individu al s tacks (as det er mi n e d by theregula t o ry or per mit conditions ). The me a s u r e m e n t of a stack opacity isacco m plish e d by passin g a bea m of visible light acros s the stack (throu g hthe efflue n t) and reflecting it back thus me a s u ri n g the perc e n t absorb a n c ecaus e d by the particula t e mat t e r in the effluen t. This an alyz er use s adouble- pas s me a s u r e m e n t techniq u e that allows easi er zero and spa ncalibra tion checks.3. 2 . 4 Su p p o r t Hard w a r e De s c r i b e th e ap p li c a b l e s y s t e m s th a t su p p o r t th e op e r a t i o n ofth e CEMS .3. 2 . 4 . 1 Air Filt er/ Dr y e r3. 2 . 4 . 2 Pro gr a m m a b l e Tim er3. 2 . 4 . 3 Diluti o n /C ali br a t i o n Contr ol Section No.: 4 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 1 of 13. 2 . 5 Dat a Acq ui s i t i o n an d Han dlin g Sy s t e m (DAHS) De s c r i b e th e DAHS, for ex a m p l e : The CEMs DAHS is an auto m a t e d syst e m that record s both pollut a n t anddilue nt dat a for subs e q u e n t calculation s and report prep a r a ti o n. DATAgen e r a t e d by the syst e m includ e not only the sa m pl e dat a but monitoroper a tio n al dat a such as alar m stat u s , calibra tion dat a, and routin e emissionreport s. Table xx lists the pollut a n t/ dilu e n t dat a record e d by the DAHS.Listed in Table xx are the value s calculat e d by the DAHS.4. 0 TRAINING4. 1 QUALITY ASSURANCE TRAINING Training is an ess e n ti al ele m e n t of a succe s sful QA/QC progra m . Itprovid e s the basic knowled g e require d to acco m plis h a proce d u r e correctly.Training also provide s the und e r s t a n di n g of a given task or proce d u r e ,ther e b y en a bling the individu al involve d to mak e an inform e d and effective
  • 16. decision. Training is a fra m e w o rk abou t which require d activities are tau g h tin a consist e n t ma n n e r .4. 1 . 1 Gen e r a l Trainin g Gene r al training is viewe d as providing an initial found a tio n. It is notinte n d e d much to deliver det ailed or specific knowled g e but to provide angen e r al und e r s t a n di n g of the over all syst e m and progr a m goals. Thistraining is com m o n to all individu als directly involve d in the CEM progr a m .Gene r al training is training provide d by Co m p a n y Na m e which is specific tothis facility’s oper a tion and consid e r e d beyon d any monitor vendor suppliedtraining. This training is pres e n t e d in the following sections.4. 1 . 1 . 1 Qualit y As s u r a n c e Plan All em ploy e e s directly involve d in the CEMS progr a m mus t have acce s sto this QA/QC Plan. All employ e e s mus t at a minim u m beco m e familiar withthis Plan and review appro p ri a t e SOP’s.4. 1 . 1 . 2 Sp e c i a l an d Refr e s h e r Traini n g Special and refre s h e r training is nece s s a r y to maint ain curre n t levels ofmonitoring com p e t e n c y . All new hires are require d to att e n d QA plantraining progr a m s offer periodically. Addition ally all CEMS senior staff willreceiv e refres h e r training on SOP chan g e s , oper a tin g par a m e t e r s , or asQA/QC chan g e s are ma d e . Section No.: 5 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 1 of 65. 0 QUALITY ASSURANCE /QUALITY CONTROL ACTIVITIES5. 1 QUALITY ASSURANCE ACTIVITIES Quality Assura n c e audits are perfor m e d on CEMS in order to verify theprecision and accur a c y of the dat a . QA audits also serv e to confirmoper a tio n al and maint e n a n c e proce d u r e s are being prop e rly imple m e n t e d .5. 1 . 1 Rela ti v e Acc ur a c y Te s t Audit (RATA)
  • 17. A RATA as describ e d in EPA’s, 40 CFR 60 Appen dix B, is a test design e d toass e s s the accur a cy of the CEMS monitors relative to the appro p ri a t e EPArefer e n c e met h o d tes ts . Its prim ary use is in det e r mi nin g efflue n tconc e n t r a tio n s . RATA’s are cond uc t e d in accord a n c e with Perfor m a n c eSpecification 2 for SO 2 and NOx, and Perform a n c e Specification 3 for CO 2 .Should the me a s u r e d inaccur a c y exce e d + 20% of the refer e n c e met h o d(perc e n t expr e s s e d as the sum of the me a n differe nc e s plus the 95%confide n c e interv al), corrective action is imm e di a t ely take n by the staffrespo n sibl e for CEM maint e n a n c e and rep air. Norm ally a recalibr a tion isappro pri a t e followe d by a rea u dit of the “OUT OF CONTROL” (failed)monitor. This reau dit is conduc t e d to de m o n s t r a t e that the monitor is nolonge r “OUT OF CONTROL” and also reaffirms the effective n e s s of thetraining progr a m on incre a s e d QC proce d u r e s . In order in ens ur e theaccur a c y of the Refere n c e Metho d analysis being perfor m e d during a RATA,EPA audit sa m pl e s should be analyz e d by both the Refer e n c e Method andthe CEM. Thes e blind audit perfor m a n c e sa m pl e s are availa ble throu g h -IDEM.5. 1 . 2 Cylin d e r Gas Audit (CGA) CGAs is a quart e rly audit test employ e d to show monitor linearity. Thetest consist s of triplicat e non cons e c u tiv e injections of thre e (3) certifiedprotoc ol 1 gas e s covering zero (0), 20 to 30% and 50 to 60% of spa n foreach analyz er. The CGA is design e d to ass e s s calibra tion error, resp o n s etime, and the effect of the sa m pl e handling syst e m on repr e s e n t a t i v e n e s s . A CGA is perfor m e d by individu ally injecting thre e known gas e s at theprob e so that the entire sa m pling train will be use d to dilut e and trans p o r tthe gas to the analyze r. A total of thre e non- cons e c u tiv e rea ding s are take nfor eac h upsc ale gas conc e n t r a tio n. The individu al gas e s are inject e d singlyand the monitor oper a t e d in the calibra tion mod e . Once a sta bl e reading isobt ain e d , the respo n s e time s (minim u m 95% of known conc e n t r a tio n) andCEMS instru m e n t resp o n s e s are record e d . Section No.: 5 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 2 of 65. 1 . 3 Opa ci t y Audit (Calibr a t i o n Error - CE)
  • 18. Opacity monitor audits shall be don e accordin g to EPA’s 40 CFR 60Appen dix B Perfor m a n c e Specification 1. Thre e sep a r a t e and certifiedneutr al density filters are use d to challen g e the oper a tion of the opacitymonitors. A total of fiftee n (15) non- cons e c u tiv e reading s are take n, five foreach filter.5. 1 . 4 Perf or m a n c e Sp e c i fi c a t i o n Tes ti n g (PST) First a QA audit using Perform a n c e Specification Testing guideline s isperfor m e d to est a blish initial acc e p t a bility of the CEMS. It is perfor m e d inaccord a n c e with EPA’s 40 CFR 60 Appen dix B, (PST 1, 2, 3). Require dAppen dix B Refer e n c e Method testing is conduc t e d by a com p e t e n t ,profes sion al testing contr ac t or, in accord a n c e with approv e d EPAproc e d u r e s Should the PST not produc e acce p t a bl e results, correctiv e action is take nand the PST is rep e a t e d . Full docu m e n t a t i o n of all correc tive action’sperfor m e d is require d.5. 2 QUALITY CONTROL ACTIVITIES Quality control activities are design e d and perfor m e d to ens ur e tha tmonitor oper a tion s and maint e n a n c e are ade q u a t e and appro pri a t e .Application of the s e activities rang e s from syst e m inst allation to dat ahandling and reportin g proce d u r e s . Quality control activities rely upon aqualified and well- traine d staff. Initial installation of any monitoring syst e m is carrie d out in strictaccord a n c e with proc e d u r e s est a blish e d by the vend or. Thes e proce d u r e salso includ e d initial start- up, debu g gi n g , and inspe ction of the syst e m s toens ur e prop er oper a tio n. A compl e t e set of oper a tion al and maint e n a n c e ma n u al s for allcomp o n e n t s of the syst e m is maint ain e d by the TITLE OF RESPO N SIBLEPERSO N . Thes e ma n u al s provid e com pl e t e description s of the syst e mincluding the ory, installation, oper a tio n, troubl e shootin g, rep air and gen e r almaint e n a n c e .5. 2 . 1 Calibr a ti o n Gas e s The calibra tion of all gas e o u s emission monitors is acco m plish e d throu g hthe use of known conc e n t r a tio n zero and spa n gas e s of the applica bl e gasspecies . Thes e gas e s are requir e d to be protocol 1 gas e s , certified to within+ 2 ppm of the listed conc e n t r a tio n. Opacity calibra tion checks use an intern al filter syst e m which is factory
  • 19. calibra t e d . Extern al zero is perfor m e d eith er during actu al or stimula t e dclear stack conditions. Alignm e n t checks betw e e n the trans c eiv e r andretror eflec t or are perfor m e d during any ext er n al zero adjust m e n t or anyroutin e maint e n a n c e . Section No.: 5 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 3 of 65. 2 . 2 Calibr a ti o n Che c k Dyna mic calibration checks are perfor m e d by challen gin g the monitorsonce every 24 hours with a calibra tion gas of a known conc e n t r a tio n. Aprogr a m m a b l e timer auto m a t ic ally initiat e s the precision check. Thissyst e m can be man u ally calibrat e d at the oper a t o r s beh e s t . During the calibra tion check, the value s rea d by the analyz er are sent tothe DAHS, which auto m a t ic ally com p a r e s the value to the certified value s ofthe gas cylinder s. Should any individu al zero drift or spa n drift exce e d two(2) tim e s the applica bl e sta n d a r d or any rea din g exc e e din g four (4) time sthe applica bl e sta n d a r d , the DAHS initiat e s an instru m e n t "OUT OFCONTROL" alar m. During the calibra tion checks of the opacity monitors, the dat a syst e mverifies the prop e r compl e tio n of the calibration cycle. Should any individu alzero drift exce e d 2% of the instru m e n t spa n, or any calibration drift exce e d s2% of the instru m e n t span, an alar m condition is indicat e d and correc tiv eaction s as per the writte n QC SOP’s are initiat e d .5. 2 . 3 Sy s t e m s Audit A syst e m s audit involve s a gen e r al inspe c tio n of the monitoring syst e m .Walk- throu g h audits are use d to provid e quick ass e s s m e n t of theavailability of dat a, gen e r al effectiv e n e s s of oper a tion and maint e n a n c e ,and com ple t e n e s s of recordk e e pi n g proce d u r e s . Syst e m s audit involve s thefollowing are a s :Administr a tiv e - maint e n a n c e logs: com ple t e d in a timely and det ailed ma n n e r byaut h oriz e d perso n n e l - recordk e e pi n g: com ple t e n e s s , availability - verification: correct spa n value s ent e r e d into the dat a syst e mTechnic al
  • 20. - print er: oper a tion al, legible print, rea din g s consist e n t with the proc e s sconditions - dat a syst e m : shelt er cabine t s clean, are a s maint ain e d - monitor enclos ur e : clean, all oper a tio n al syst e m s , i.e., hea tin g &cooling - spa n gas cylinder s: with certification dat e s , in the correctconc e n t r a tio n rang e , abov e the 250 psi minim u mpres s u r e s - sa m pling/ a n aly sis: sa m pl e flows, vacuu m s , and pres s u r e s withinapplica ble rang e s - opacity monitor: align m e n t v e rifica tion, purg e air blowers oper a tio n al Section No.: 5 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 4 of 65. 3 DATA RECORDING AND REPORTINGData collect e d as part of the auditing of the CEMS falls into two cat e g o ri e s:(1) Routin e dat a from the nor m al oper a tion of the CEMS (See Section 6.3);and (2) Data gen e r a t e d as a function of the audit. The TITLE checks and prep a r e s both audit and routin e emission dat ainto a sum m a r y report.5. 4 PREVENTIVE MAINTENANCE The prev e n tiv e maint e n a n c e progr a m for the CEMS is bas e d on thevendor s reco m m e n d e d proc e d u r e s . Addition al proce d u r e s may be includ e das exp e ri e n c e dictat e s . Thes e proc e d u r e s may be modified to be morespecific for the inst allation. Preve n tiv e maint e n a n c e is sche d ul e d andperfor m e d in a timely man n e r by the TITLE.5. 5 REPAIR PROGRAM The CEMS rep air progr a m shall be maint ai n e d by TITLE OF
  • 21. RESPO N SIBLE PERSON ( S ). Syst e m faults are monitor e d by both TITLE(tech nicia n level) and TITLE (sup er visory level). In the eve n t of a syst e mproble m , the TITLE will be notified directly and in writing. A nota tion of theproble m is place d in the shift log book.5. 6 SPARE PARTS INVENTORY TITLE maint ai n s a spar e part s invent o ry ad e q u a t e to me e t the nor m aloper a ti n g require m e n t s . Emerg e n c y parts are availa ble throu g h the vendoron a next day basis. TITLE has the over all respo n si bility for maint ai nin g theade q u a c y of the spar e parts invent ory. The curre n t inven t ory is bas e d onthe vend or s reco m m e n d e d list for 90% dat a availability, and is modified onan as- require d basis.5. 7 ACTIVITY MATRIX An activity matrix sum m a rizing the various routin e QA/QC activities ispres e n t e d in the table on pag e s 5 and 6. Daily activities will include checksof daily zero and spa n value s and obs erv a tio n of routin e dat a from thenorm al oper a tion of the CEMS. Section No.: 5 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 5 of 6Activity/QA Checks Weekly Monthly Quarterly Annually1. Calibration Gas X Pressure2. Sample Gas X Pressure/Vacuum3. Sample Gas X Pressure/Flows- Analyzer4. NOx Analyzer X Desiccant5. Replace Filters X
  • 22. Analyzers6. Replace Filters/ X Scrubbers Air System7. Replace/Clean X Filters-Probe8. Temperature X Control Analyzer Enclosure9. AC Filter X Cleaned10. Clean Interior of Enclosure/ Analyzer11. Leak Check Gas Connections12. Clean Disc Drive Head13. Printer Maintenance14. System Audit X Section No.: 5 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 6 of 6Activity/QA Checks Weekly Monthly Quarterly Annually15. Clean Optical Surfaces16. Check Air X Hoses17. Clean/Replace X Filters18. Check/Adjust X Alignment
  • 23. Activity/QA Audit1. CGA X2. Opacity Audit X3. RATA X Section No.: 6 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 1 of 26. 0 DOCUMENTATION AND REPORTS The docu m e n t a t i o n of QA/QC dat a and inform a tio n syst e m is an inte gr alpart of this QA Plan. This section describ e s report s and oth er record s thatprovid e ade q u a t e docu m e n t a t i o n of QA/QC activities. The two prim a ryme a n s of docu m e n t a ti o n us ed are:
  • 24. (1) Data Acquisition and Handling Syst e m (DAHS)(2) Manu ally pre p a r e d QA/QC forms, logs and report s The following subs e c tio n s describ e the DAHS and its uses in QA/QCdocu m e n t a ti o n, and pres e n t s exa m pl e s of DAHS-gen e r a t e d routine dat areport s. During QA audits, the DAHS will be oper a t e d to collect dat a in anorm al fashion, but will print all insta n t a n e o u s engin e e rin g units for a realtime hard copy of tes t e d value s. The DAHS is use d not only to docu m e n t QA/QC dat a and inform a tio n, butit also serv e s as the CEMs dat a acquisition and proce s sin g syst e m . Each ofthe following type s of docu m e n t a t i o n are describ e d in subs e q u e n tsubs e c tio n s : hourly report s, daily report s, alar m report s, quart e rly report s. Writte n QA/QC report s are nec e s s a r y to provide suppor tin gdocu m e n t a ti o n of the continu e d oper a tio n of the CEM in an acc e p t a bl ema n n e r . Report s are used to notify individu als of proble m s relat e d to oper a tio n ofthe CEMS. Compilation of the s e report s is inten d e d to assist in identifyingthe nee d for prev e n tiv e maint e n a n c e , oper a tion al proce d u r al cha n g e s ,training upd a t e s , or surplus inven t ory action.6. 1 DAHSDe s c r i b e of th e Da t a Han dli n g an d Ac q u i s i t i o n Sy s t e m . Pro v i d e asi m p l i fi e d blo c k dia g r a m of th e DAHS sh o w i n g th e flo w ofinfor m a t i o n an d pr o c e s s si g n a l s . [DIAGRAM ] Section No.: 6 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 2 of 2
  • 25. 6. 2 EMISSION MEASUREMENT DATA PROCESSING De s c r i b e th e si g n a l pr o c e s s i n g b y th e DAHS. Pro v i d e ex a m p l e sof th e vari o u s re p o r t s th a t th e DAHS g e n e r a t e s .6. 3 DAHS REPORTS6. 3 . 1 Curre n t (Hourly ) Rep or t s6. 3 . 2 Daily Rep or t s6. 3 . 3 Alarm Rep or t s6. 3 . 4 Quart e rl y Rep or t s6. 4 MAINTENANCE RECORD This record is maint ain e d throu g h TITLE. The TITLE ent er s description sof routin e prev e n tiv e and maint e n a n c e actions perfor m e d on the monitoringsyst e m com po n e n t s . Thes e entrie s are kept in maint e n a n c e files or site logbooks. This record also docu m e n t s the us e of spar e part s, and its periodicreview by the maint e n a n c e dep a r t m e n t provid e s inform a tio n to the spar epart s invent ory.6. 5 AUDIT REPORTS Each audit proc e d u r e discus s e d in section 5 of this Plan is docu m e n t e d ina report. All supp ortin g dat a are kept on file by TITLE. Thes e audits serv eas verification of the accur a c y of emission s dat a in the quart e rly report.6. 6 CGA GAS CERTIFICATION Manufact ur e r/ dist rib u t or s of all Protocol 1 spa n gas e s und e r this QA Planmus t provide a gas conc e n t r a tio n certificat e for each cylinde r of gassupplied. TITLE is respo n si ble for maint aining a file of the s e certifications,including the dat e of prod uc tion, certified value, and cylinder serial num b e r . Section No.: 7 Revision No.: 0
  • 26. Date: Se p t e m b e r10 , 19 9 7 Page No.: 1 of 57. 0 QUALITY ASSURANCE PROCEDURES7. 1 INTRODUCTION The purpos e of thes e proce d u r e s is to ens ur e the CEMS syst e m provid e saccur a t e and reliable dat a. Thes e proc e d u r e s comp a r e the pollut a n t / dilue n tvalue s obt ain e d from the CEMS to value s obt ain e d by EPA Refer e n c e Methodor approv e d altern a tiv e testin g met h o d . The res ults of the s e test s provideverification of the continu e d comp a r a bility of the CEM dat a to, dat acollect e d by and com p a r e d to, outsid e refer e n c e s . The proc e d u r e s for the s etest s are publish e d in EPA 40 CFR 60, Appen dix A, B and F [OR OTHERAPPLICABLE RULES OR REGULATION S ] .7. 2 RATA PROCEDURES7. 2 . 1 Preli mi n a r y Activiti e s Prior to the actu al RATA tes tin g proce d u r e s ther e are testingprer e q ui sit e s require d by IDEM. Thes e activities include notification to IDEM,informing the m of the inte nt to tes t. This is done by sub mitt al of the testprotoc ol form. Verifications are ma d e tha t the boiler to test e d will not be und e r g oin gsche d ul e d maint e n a n c e and that no oth er condition exists which wouldpreclud e testing the boiler emission s und er repr e s e n t a tiv e oper a tin gconditions . Verify the availability of all pers o n n el require d to perfor m testing. Verify that all sche d ul e d maint e n a n c e on the CEMS has be e n perfor m e d . Verify that the test location conditions are ade q u a t e for testin g, and tha tnec e s s a r y supp ort service s are available. Review Refer e n c e Method s tha t will be used in EPA’s 40 CFR 60 Appen dixA and B proc e d u r e s .
  • 27. Section No.: 7 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 2 of 57. 2 . 2 RATA Tes ti n g De t a il e d Proc e d u r e s Thes e proce d u r e s are to be conduc t e d befor e, during and after RATAtestin g. Verify that the CEM oper a tin g conditions are norm al by conduc tin ga syst e m s audit.Notify TITLE OF RESPO N SIBLE PERSO N of testin g and requ e s t notificationshould any condition arise that would result in less tha n a 50% sta ble loadduring the testing.Proce e d to the test location and verify the following for the stack testingcrew. 1. Safe acce s s 2. Electrical power 110 volts @ 30 am p 3. Safety belts, if requir e d 4. Hoist equip m e n t 5. Small work spac e for proce s sin g sa m pl e sVerify availa bility of plant or pollution control equip m e n t oper a tin g dat arequir e d for the report.Upon com pl e tion of the testing, notify the TITLE that testing has bee ncompl e t e d .Obtain copies of CEM report s covering the test period.Perform the post test calibra tion, docu m e n t the results of the calibra tion.Docu m e n t results from CEM and Refer e n c e Method analysis of blind auditsa m pl e s .7. 2 . 3 Dat a Red u c t i o n an d Analy s i s
  • 28. The results of the ma n u al Refer e n c e Method s , as part of the RATA, arecalculat e d accordin g to proc e d u r e s includ e d in EPA’s 40 CFR 60, Appen dix A.Each test run is calculat e d individu ally, and the s e results are used with theconcurr e n t CEM dat a to calculat e relative accur a c y. Section No.: 7 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 3 of 57. 2 . 4 Rela ti v e Acc ur a c y Calc ul a ti o n s The calculation proc e d u r e for relative accur a c y is as found inPerform a n c e Specification 2. In this proce d u r e , the res ults of the Refer e n c eMethod tes tin g in units of the sta n d a r d are comp a r e d to the CEM dat a. For each test run, com p u t e the differe n c e betw e e n the Refer e n c e Methodresults and the corre s p o n di n g CEM results with the following equ a tio n: Diff = CEM Results - Refer e n c e Method Results Relative Accuracy = (d + |cc|) / Refere n c e Method x 1007. 2 . 5 Rep or t Pre p a r a t i o n A report of the results of each RATA is prep a r e d for inclusion in thecurre n t Quart e rly Emis sion Report. The RATA report follows the followingoutline. I. Introduc tio n - briefly describ e the audit and purpo s e II. Results -give the dat e of the audit & a brief description of the results - if correc tiv e action was require d, describ e
  • 29. - pres e n t the res ults of rep e a t audits, if requir e d III. Suppor tin g Dat a - includ e RATA sum m a r y report7. 3 PROCEDURES FOR CGA7. 3 . 1 Intro d u c t i o n During a CGA, the CEMs is challeng e d dyna mic ally throu g h the sa m plingand the analysis sys te m s . Zero, low, and mid- rang e audit gas e s areintrodu c e d in lieu of the norm al calibra tion gas e s . The DAHS calibra tionreport is use d in stre s sin g calibra tion error. Section No.: 7 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 4 of 5 The nor m al conc e n t r a ti o n s of low and mid- rang e audit gas e s use d ateach monitoring location are show n in table xx. Audit dat a andobs erv a tio n s , including conc e n t r a tio n s of gas e s actu ally use d during theaudit, are record e d on the CGA audit she e t (Form xx). Beside s this SOP, the following docu m e n t s are refer e n c e mat e ri als which,as nec e s s a r y , should be review e d befor e perfor min g the CGA:DAHS Oper a tion and Mainte n a n c e Manu al40 CFR Part 60, Appen dix F7. 3 . 2 Cylin d e r Gas Audit For each syst e m to be audit e d , record on the dat a she e t s the appro pri a t eaudit cylind er serial num b e r s , certified gas conc e n t r a tio n s and the dat e s ofanalysis. The following step s s hould be perfor m e d :1. Notify the appro pri a t e staff that the audit is rea dy to begin and to disre g a r d the CEM calibra tion alar m s .
  • 30. 2. Initiat e a Zero and Span check of the CEMS by ma n u ally switching gas e s on. Upon com pl e tio n, discon n e c t the "routin e oper a tion" calibra tion gas and conn e c t the appro p ri a t e audit gas cylinder s.3. Verify the audit cylinder conc e n t r a tio n value s as listed on the audit dat a she e t , and initiat e a calibra tion.4. Repe a t with all conc e n t r a ti o n s - zero, low and mid values , for thre e non cons e c u tiv e runs.5. The value s for the comp u t e r are ent e r e d on the CGA Audit Data Form.6. Disconn e c t the audit cylinder s and recon n e c t the routin e oper a tioncylind er s.7. Verify that the syst e m has bee n retur n e d to norm al oper a tion (alar m conditions).8. Advise the appro pri a t e staff that the audit is com pl e t e . Record compl e tion in the CEM log. Section No.: 7 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 5 of 57. 3 . 3 Dat a Red u c t i o n an d Analy s i s1. Obtain CGA Audit Dat a Form and ent e r dat a from the DAHS calibra tionreport.2. Calculat e the perc e n t differe n c e (% diff) for each value as follows: % diff = (aver a g e rea din g - known conc e n t r a tio n) / known conc e n t r a ti o n x 1003. Verify that the % diff does not exce e d 15% ( or applica bl e limit) for anydat a point.
  • 31. 4. Add any rem a r k s relating to the audit on the dat a she e t . If any audit value exc e e d s the acce p t a bl e limits, initiat e imm e di a t eappro pri a t e correc tion actions, as specified in the QA Plan. Upon com ple tionof the nec e s s a r y corrective actions, the CGA mus t be rep e a t e d . The resultsof the original audit, correc tive actions, and any rep e a t audits are report e d .7. 3 . 4 Rep or ti n g A report of the results from each CGA is prep a r e d for inclusion in thecurre n t Quart e rly Emission Report. The CGA report should use the followingoutline: I. Introduc tio n - briefly describ e the audit and purpo s e II. Results - give the dat e of the audit & a brief description of the results - describ e any com m e n t s from obs erv a tio n that may have affect theresults - pres e n t the res ults of rep e a t audits, if requir e d III. Suppor tin g Dat a -includ e the CGA Audit Data, Calibration Report and any othe r suppor tin g dat a ( i.e., vend or s gas cylinder certification report s). Section No.: 8 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 1 of 28. 0 QC PROCEDURES8. 1 INTRODUCTION Quality control checks may be define d as all thos e checks perfor m e d on a
  • 32. routin e basis such as syst e m insp ec tio n s, periodic calibra tion s and routin emaint e n a n c e . The proce d u r e discus s e d her e are pres e n t e d as docu m e n t e dwritt e n proc e d u r e s . Other proce d u r e s will be inher e n t in the use of emissiondat a for boiler oper a tio n s .8. 2 DAILY CALIBRATION CHECK Each CEMS is auto m a ti c ally challeng e d to a know stan d a r d once each 24hour period. The DAHS calculat e s the perc e n t differe n c e from ent er e dknown value s. The TITLE OF RESPO N SIBLE PERS ON will be respo n sibl efor verifying monitor respo n s e to be within specification s of 40 CFR 60,Appen dix F at a minimu m . Recalibra tion of the CEM will be perfor m e d ifdrift is indicat e d .8. 3 WEEKLY SYSTEMS AUDIT A weekly syst e m s audit will be perfor m e d and record e d in a boun dlogbook. A syst e m s audit may be perfor m e d at any time if oper a ti n gproble m s are obs erv e d during routin e checks of emission dat a on dailyzero/s p a n checks. This audit is a gen e r al appr ais al of the CEMS oper a ti n gpar a m e t e r s . The following checks will be record e d during the syst e m s auditand may be revis e d as oper a tin g exp e rie n c e dictat e s .1. Obtain multida y calibration report for previous 7 days for all CEMS. Check for tren d s in drift.2. Verify that the correc t span value s are ent e r e d into the com p u t e r .3. Insect the instru m e n t cabin e t for gen e r al cleanline s s and te m p e r a t u r e within limits of 68 to 86 degr e e s F. Check air conditioning filter for clea nline s s .4. Check tha t the gas cylinder pres s u r e s are abov e 250 psi.5. Exa min e opacity re mo t e pan el, not e any alar m s display e d and tha t rea din g s are consist e n t with monitor oper a tion. Section No.: 8 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7
  • 33. Page No.: 2 of 2 6. Check dilution air pres s u r e and corre s p o n di n g prob e vacuu m for any chan g e s . 7. Verify that scrub b e r s in the air syst e m are acce p t a bl e and indicating silica gel is blue. Verify that reg e n e r a t iv e dryer and absor b e r units are cycling every 30 secon d s . 8. Check NOx analyz er desicc a n t . 9. Check NOx analyz er sa m pl e vacuu m .10. Check SO2 analyz er sa m pl e vacu u m , sa m pl e flow and lamp voltag e .11. Check CO2 sa m pl e flow.12. Re- calibrat e monitors if nec e s s a r y .8. 4 QUARTERLY SYSTEMS AUDITAdministr a tiv e1. Check maint e n a n c e logs for tim ely and com pl e t e rep airs.Technic al (includ e all checks ass oci at e d with weekly syst e m s audit)1. Printer oper a tion al and legible, rea din g s consist e n t with proc e s sconditions .2. Compu t e r dat a table clean and are a is maint ai n e d .3. Monitor enclos ur e clean and are a well maint ain e d .4. Purge air blowers for opacity oper a tio n al and align m e n t of opacitymonitor is correct.
  • 34. Section No.: 9 Revision No.: 0 Date: Se p t e m b e r 10 , 19 9 7 Page No.: 1 of 2 9. 0 ROUTINE PREVENTIVE MAINTENANCE All maint e n a n c e of the CEMS can be classified into one of two are a s :Routine prev e n tiv e maint e n a n c e : A regularly sche d ul e d set of activities design e d to prev e n t proble m s before they occur.Non- routine prev e n tiv e maint e n a n c e : A set of activities is also design e d to prev e n t proble m s , but the nee d for it canno t be pre dict e d , so it is done on an as- nee d e d basis. For exa m pl e , if sa m pl e vacuu m on the NOx analyz er drops from its norm al rea din g, the pum p, gau g e or sa m pl e capillarie s should be replac e d or clea n e d . This would be consid e r e d non- routine prev e n tiv e maint e n a n c e . Non- routin e prev e n tiv e maint e n a n c e is not discus s e d in the QA/QC man u al bec a u s e it is neith e r practic al nor nec e s s a r y to dev elop writt e n proc e d u r e s for it. The routin e prev e n tiv e maint e n a n c e require d for the CEMS is listed in Table 9- 1. The TITLE OF THE RESPON SIBLE PERSO N is ultim a t ely respo n si ble for since all routin e prev e n tiv e maint e n a n c e is com pl e t e d on sche d ul e.
  • 35. Section No.: 9 Revision No.: 0 Date: Se p t e m b e r 10 , 19 9 7 Page No.: 2 of 2 TABLE 9- 1 RECOMMENDED ROUTINE PREVENTIVE MAINTENANCEOpa ci t y Quart e rl y 1. Clean blower pre- filter 2. Replac e blow er filter ele m e n t 3. Check optic align m e n t 4. Clean optics, set window check value S e m i - Ann u a l 1. Check ext er n al zero whe n boiler is off line 2. Scale syst e m (electro nic ally)SO2 Quart e rl y 1. Chang e Teflon inlet filterNOx We e k l y 1. Check drierite canist e r & chan g e if exp e n d e d Quart e rl y 1. Replac e Teflon inlet filterAir Sy s t e m Quart e rl y 1. Replac e reg e n t scrub b e r s Ann u a l 1. Replac e particulat e filtersProb e s Quart e rl y 1. Check conn e c tion s for leaks
  • 36. 2. Clean coars e scre e n and quartz wool plugCom p u t e r Sy s t e m (DAHS) We e k l y 1. Back- up the fixed disk Section No.: 10 Revision No.: 0 Date: Se p t e m b e r 10 , 19 9 7 Page No.: 1 of 2 10 . 0 CORRECTIVE ACTION AND REQUIRED NOTIFICATIONS When e v e r the CEMS is found to be "out- of- control" the dat a gen e r a t e d from the syst e m canno t be use d to show complia nc e with per mit limits or dat a capt ur e requir e m e n t s . Correc tive action must be perfor m e d as soon as possible after det e r mi nin g that the CEMS is not oper a tin g within 40 CFR 60 , Ap p e n d i x F. Correc tive action is define d as the resolution of proble m s tha t occur on a non- routin e basis. 10 . 1 SUGGESTED CORRECTIVE ACTION Refer e n c e s to specific troubl e s h o o tin g proc e d u r e s are listed in Table 10- 1. 10 . 2 REQUIRED NOTIFICATIONS Imm e di a t ely after learning the CEMS is non oper a tio n al, the following individu als mus t be notified:TITLE OF THE RESPON SIBLE PERSO NTITLE OF THE RESPON SIBLE PERSO NTITLE OF THE RESPON SIBLE PERSO N
  • 37. List th e s p e c i fi c re s p o n s i b i l i t i e s for e a c h p e r s o n . Section No.: 10 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 2 of 2TABLE 10- 1 REFERENCES TO TROUBLE-SHOOTING/CORRECTIVE ACTIONList th e ap p r o p r i a t e ref e r e n c e s to th e an al y z e r , pr o b e , DAHS, e t c .m a n u a l s wh e r e tr o u b l e s h o o t i n g pr o c e d u r e s ar e s p e c i f i e d .
  • 38. Section No.: 11 Revision No.: 0 Date: Se p t e m b e r10 , 19 9 7 Page No.: 1 of 111 . 0 REFERENCESList all ref e r e n c e s us e d to co m p i l e thi s QA Plan .
  • 39. Section No.: 12 Revision No.: 0 Date: S e p t e m b e r10 , 19 9 7 Page No.: 1 of 112 . ATTACHMENTS Inclu d e an y p e r t i n e n t infor m a t i o n su c h as: 1. Op e r a t i n g Per m i t 2. Ap pli c a b l e CFRs or por t i o n s of th e CFR. 3. Ap pli c a b l e an al y z e r , pr o b e , DAHS, e t c . m a n u a l s or por t i o n s ofth e m a n u a l s 4. Ap pli c a b l e St a t e Rul e s or por t i o n s of th e Rul e s 5. Exa m p l e s of au d i t an d cali b r a t i o n for m s 6. Exa m p l e s of op e r a t i o n an d m ai n t e n a n c e log s
  • 40. 7. Exa m p l e s of re p o r t i n g for m s8. Exa m p l e DAHS prin t o u t s

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