CEMS QA/QC Plan Template for Compliance

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 for
Continuous Emissions Monitoring Systems or CEMS. This QA/QC Plan meets the minimum
requirements of the Indiana State Rule 326 IAC 3-5-4 Standard Operating Procedures and
Chapter 20 of the Indiana Quality Assurance Manual.

This example QA/QC Plan may be used as a guide for the construction of your CEMS
QA/QC Plan. Please keep in mind that this example plan has the basic elements that comprise a
good QA/QC Plan but, it may not cover all the areas that are specific to your plant's CEMS. Be
sure to incorporate your specific operational knowledge, experience and applicable State and
Federal requirements into the QA/QC Plan for your company. If you have any questions please
call 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 Plan's text is
intended for areas in which company names, boiler numbers or other text can be
inserted. Text which is bold, underlined lower case italics is intended for areas
where additional text may be inserted into the Plan.

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

Section 1.0 Introd uc tio n
Section 1.1 Quality Assura n c e and Quality Control (QA / QC) -
Definition and Function
Section 1.2 Quality Assura nc e Policy, Goal, and Objective
Section 1.3 Distribution and Docu m e n t Control
Section 2.0 Orga niz a tion and Respo n si ble Individu als
Section 2.1 Com m u nic a tio n of Inform a tio n, Data and Report s
Section 2.2 Emission Data and Emission Report s
Section 2.3 QC Data and Report s
Section 2.4 QA Audit Data and Report s
Section 2.5 QA Results and QA Reports
Section 2.6 Emission Data and Emission Report s
Section 3.0 Description of Facility and CEMS
Section 3.1 Facility
Section 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 m
Section 4.0 Training
Section 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 Training
Section 5.0 Quality Control/Quality Assura n c e Activities
Section 5.1 Quality Control Activities
5.1.1 Calibration Gas e s
5.1.2 Calibration Check
5.1.3 Syst e m s Audit
Section 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 Testing
Section 5.3 Data Recordin g and Reportin g

TABLE OF CONTENTS

Section 5.4 Preve n tiv e Mainte n a n c e
Section 5.5 Repair Progra m
Section 5.6 Spar e Parts Invent ory
Section 5.7 Activity Matrix
Section 6.0 Docu m e n t a t i o n and Report s
Section 6.1 DAHS
Section 6.2 Emission Measur e m e n t Data Proce s sin g
Section 6.3 DAHS Report s
Section 6.4 Mainte n a n c e Record
Section 6.5 Audit Report s
Section 6.6 CGA Gas Certification
Section 7.0 Quality Assura n c e Proce d u r e s
Section 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 n
Section 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 Reporting
Section 8.0 QC Proce d u r e s
Section 8.2 Daily Calibration Check
Section 8.3 Weekly Syste m s Audit
Section 8.4 Quart e rly Syst e m s Audit
Section 9.0 Routine Preve n tiv e Mainte n a n c e
Section 10.0 Correc tive Action and Require d Notifications
Section 10.1 Sugg e s t e d Correctiv e Action
Section 10.2 Require d Notification s
Section 11.0 Refer e n c e s
Section 12.0 Attach m e n t s

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1. 0 INTRODUCTION

A Quality Assura n c e (QA) Plan is the basis for ass e s si n g and maint ai ning
of the qual ity of continu o u s emission monitoring dat a. This QA Plan has
bee n prep a r e d for the COMPANY oper a t o r s of Continuo u s Emission
Monitoring 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 pollution
conc e n t r a tio n s from boiler(s) No. BOILER NUMBER OR DESIGNATION
and stack opacity from boilers num b e r( s) BOILER NUMBER OR
DESIGNATION .

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 LOCATION
NOx TECO 42 42D- 1234 5- 269 1000 pp m Unit # 1- Stack A
CO 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 of
the OPERATING PERMIT, STATE RULE, FEDERAL REGULATION ,
AGREED ORDER, ETC . Thes e CEMS also provid e proc e s s dat a to aid in the
oper a tio n and the maint e n a n c e of the pollution control equip m e n t require d
at this facility. This quality assur a n c e plan was dev elo p e d from guide lines
develo 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 of
Air Quality (IDEM - OAQ) and the U. S Environ m e n t a l Protec tion Agency. All
docu m e n t s used in the dev elop m e n t of this quality ass ur a n c e plan are
liste 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 and
interr el a t e d functions . First, Quality Assura n c e will be define d as a syst e m of
gen 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 is
perfor min g ade q u a t e l y. Where a s , Quality Control is define d as a series of
specific 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 quality
control function..
QA Plans consist of prim arily two function s: (1) the QA function which is
the 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 a
quality. Thes e two functions com bin e d form a control loop. For inst a n c e ,

when accur a c y or precision (a QA function) is unacc e p t a b l e , QC functions
mus t incre a s e until the quality of the dat a is acce p t a bl e .

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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 on
occasion 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 party
sa m pl e and analysis for accur a c y and precision, com p a ris o n to know
calibra 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 Quality
Assura nc e Plan enco m p a s s e s both QA and QC function s and strives to
identify 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 NAME'S policy to efficiently oper a t e and maint ai n its
facilities and CEMS in accord a n c e with good oper a tin g practice s and all
applica ble local, stat e and feder al environ m e n t a l regul ation s . COMPAN Y
NAME 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 its
oper a tio n s are in com plianc e with its oper a tin g per mit. The COMPAN Y
NAME 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 s
are 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 and
acce 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 with
the 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

32 6 IAC 3- 1. 1 - 4

COMPAN Y NAME recog niz e s that the reliability and acc e p t a bility of
CEMS dat a is directly dep e n d e n t on satisfact ory com ple tion of all activities
stipulat e d in a well- define d QA plan. Accordingly, the objective of this QA
Plan is to define thos e activities nece s s a r y to guar a n t e e that CEMS dat a
quality is maint ain e d at acc e p t a bl e levels. The Plan also provid e s the
fram e w o rk for carrying out QA activities by addr e s sin g item s such as
docu m e n t a ti o n, training, correctiv e actions, and prev e n tiv e maint e n a n c e
activities.

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This Plan addr e s s e s oth er nec e s s a r y supp ort servic es and activities, such
as 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 are
requir 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 as
gre a t det ail as oth er more critical activities. Activities not fully discus s e d
may 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 e
ma 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 QA
Plan 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 al
exp 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 will
be forward e d to all appro p ri a t e parties . In the eve n t a major revision to the
QA 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 revision
nu 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 is
respo 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.

A copy of this QA Plan will be sent to the Indian a Depar t m e n t of
Environ m e n t a l Manag e m e n t Office of Air Quality (IDEM - OAQ) for their
review and com m e n t . All futur e chan g e s or revisions to the Plan will also be
forward e d to IDEM - OAQ.

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2. 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 s
in 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 d
op 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 t
op 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 the
effective com m u nic a tio n of the results from QA/QC activities to all affect e d
partie s. Clear chan n el s of com m u nic a tio n and respo n sibility mus t exist
within 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

the oper a tio n al stat u s of a CEMS syst e m . This Plan also provid e s for the
com 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 s
for 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 emission
report s. Therefor e, CEMs dat a must flow throu g h this position to ens ur e the
accur a t e and com pl e t e pre p a r a tio n of quart e rly report s. TITLE is
respo n sibl e for verifying tha t the dat a are reduc e d , validat e d , and report e d
prop e rly. Addition ally, as an inde p e n d e n t QA/QC check, TITLE will decid e if
the 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 d
boiler and control equip m e n t oper a tin g record s. This review of emission
dat a is used to identify periods of unus u al oper a tion, which may be
indicativ 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 to
the num e r o u s type s and the various levels of string e n c y involved in the s e
test s it is impra ctic al to discus s every possible direction of inform a tio n flow
or exch a n g e .

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Howev er, an exa m pl e of a QC inform a tio n exch a n g e would be the daily
zero/s p a n calibration check. The CEMS auto m a tic ally switch e s to sa m pling
known gas conc e n t r a ti o n s once every 24 hours and the s e value s are logg e d
to a com p u t e r dat a acquisition and han dling syst e m (DAHS). On a daily
basis, TITLE would review the me a s u r e d value s comp a r e d to the known
conc 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. If
value s are outsid e limits, the TITLE would proce e d to the instru m e n t to
compl e t e a visual insp ec tio n checklist. Norm ally, it the value s are confirm e d
to be outsid e the oper a ti n g limits a recalibr a tio n of the instru m e n t is
nec e s s a r y . After recalibr a tion, the visual checklist, the daily calibra tion
report and a description of corrective action would be sub mitt e d to the

TITLE for review. If any unus u al conditions continu e to be obs erv e d , the
TITLE 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 the
obs erv e d proble m . Upon com ple tion of the maint e n a n c e rep air requ e s t , a
det ailed description of the proble m and its’ resolution will be ent er e d in the
maint 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 d
in 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 opacity
Calibration Error (CE) audits. Thes e audits are perfor m e d in accord a n c e
with 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 a
periodic basis. The actu al perfor m a n c e of an audit may be conduc t e d by a
contr 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 final
audit report. This report det ails a com p a ris o n betw e e n results and
comp 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 QA
results and report s to all appro pria t e grou p s. TITLE is also resp o n si ble for
prep a r a tio n of the final QA report and its sub mit t al to the Indian a
Depa 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).

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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 a
is availa ble for review, eith er as a com p u t e riz e d dat a bas e or print e d
emission logs, and maint ain e d in a file for 24 mont h s . All quart e rly
complia nc e report s will be sub mit t e d to the IDEM - OAQ within 30 days of
the end of the quart e r as define d in the oper a tio n per mit.

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3. 0 DESCRIPTION OF FACILITY AND CEMS

3. 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 0
poun d s of ste a m per hour circulating fluidized bed, firing Indian a bitu mino u s
coal. Dry limes t o n e injection into the furnac e are a is use d to control sulfur
dioxide 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, for
ex 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 e
acquisition syst e m using a dilution prob e for moist ur e , gas e s and particula t e
control. 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 acquisition
handling syst e m (se e figure). Effluent com p o n e n t s monitor e d and
me a s u r e d include LIST THE MEASURED GASES AND/OR FLOW S . Opacity
is me a s u r e d using stack moun t e d in-situ devic es .

[DIAGRAM ]

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3. 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 position
the 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 e
location 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 g
of the sonic flow critical orifice. To minimize maint e n a n c e require m e n t s on
the s e filters, a high vacuu m (min. 15 inche s of Hg), low flow (1 to 5 cubic
feet per day) is utilized to reduc e the total am o u n t of
particulat e being expos e d to the filters. This efflue n t sa m pl e is draw n
throu g h the filters using the air educ a t o r. A dilution ratio of 1:250 is
achiev 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 the
prob e , analyz er and calibration gas delivery syst e m . The umbilical cord
consist s of a polyet h yl e n e line for dilution air, a Teflon line for the dilut e d
sa m pl e, a Teflon line for calibra tion gas e s , and a polyet h yl e n e line for
monitoring vacuu m at the sonic orifice. This tube bundle is wrapp e d in a
Mylar R (thin plastic liner) and enclos e d in a PVC (he a vy plastic) jacket for
prot 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 :

After tran s p o r t to the instru m e n t location, the dilute d sa m pl e is
distribut e d to the an alyz er s for det e r mi n a ti o n of the various polluta n t
conc 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 7
liters 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.

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3. 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 ) , for
ex 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 to
illu 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 of
th 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 monitor
and me a s u r e Oxides of Nitrog e n (NOx) emission s. This analyz er is a part of
an dilution extr a c tio n analysis syst e m , and receiv e s an effluen t sa m pl e that
has 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 reaction
produc e s a sm all am o u n t of light that is directly propor tion al to the am o u n t
of 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 e
pass 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 s
with O 3 . A
photo m ul tiplier tub e det e c t s this light produc e d by the che mic al reaction of
O 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 r
and retror eflect or), control unit and a DAHS collection syst e m . All
comp o n e n t s listed mak e up the COMS syst e m and are certified in conc ert
with each oth er thus providing a “CERTIFIED SYSTEM”. An exa m pl e of an

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 the
regula t o ry or per mit conditions ). The me a s u r e m e n t of a stack opacity is
acco m plish e d by passin g a bea m of visible light acros s the stack (throu g h
the efflue n t) and reflecting it back thus me a s u ri n g the perc e n t absorb a n c e
caus e d by the particula t e mat t e r in the effluen t. This an alyz er use s a
double- pas s me a s u r e m e n t techniq u e that allows easi er zero and spa n
calibra 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 of
th e CEMS .

3. 2 . 4 . 1 Air Filt er/ Dr y e r
3. 2 . 4 . 2 Pro gr a m m a b l e Tim er
3. 2 . 4 . 3 Diluti o n /C ali br a t i o n Contr ol

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3. 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 and
dilue nt dat a for subs e q u e n t calculation s and report prep a r a ti o n. DATA
gen e r a t e d by the syst e m includ e not only the sa m pl e dat a but monitor
oper a tio n al dat a such as alar m stat u s , calibra tion dat a, and routin e emission
report 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 TRAINING

4. 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 . It
provid 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

decision. Training is a fra m e w o rk abou t which require d activities are tau g h t
in 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 not
inte n d e d much to deliver det ailed or specific knowled g e but to provide an
gen 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. This
training 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 to
this facility’s oper a tion and consid e r e d beyon d any monitor vendor supplied
training. 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 s
to this QA/QC Plan. All employ e e s mus t at a minim u m beco m e familiar with
this 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 of
monitoring com p e t e n c y . All new hires are require d to att e n d QA plan
training progr a m s offer periodically. Addition ally all CEMS senior staff will
receiv 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 as
QA/QC chan g e s are ma d e .

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5. 0 QUALITY ASSURANCE /QUALITY CONTROL ACTIVITIES

5. 1 QUALITY ASSURANCE ACTIVITIES

Quality Assura n c e audits are perfor m e d on CEMS in order to verify the
precision and accur a c y of the dat a . QA audits also serv e to confirm
oper 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)

A RATA as describ e d in EPA’s, 40 CFR 60 Appen dix B, is a test design e d to
ass e s s the accur a cy of the CEMS monitors relative to the appro p ri a t e EPA
refer e n c e met h o d tes ts . Its prim ary use is in det e r mi nin g efflue n t
conc 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 e
Specification 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 staff
respo n sibl e for CEM maint e n a n c e and rep air. Norm ally a recalibr a tion is
appro 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 no
longe r “OUT OF CONTROL” and also reaffirms the effective n e s s of the
training progr a m on incre a s e d QC proce d u r e s . In order in ens ur e the
accur 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 and
the 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)

CGA's is a quart e rly audit test employ e d to show monitor linearity. The
test consist s of triplicat e non cons e c u tiv e injections of thre e (3) certified
protoc ol 1 gas e s covering zero (0), 20 to 30% and 50 to 60% of spa n for
each analyz er. The CGA is design e d to ass e s s calibra tion error, resp o n s e
time, 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 the
prob e so that the entire sa m pling train will be use d to dilut e and trans p o r t
the gas to the analyze r. A total of thre e non- cons e c u tiv e rea ding s are take n
for eac h upsc ale gas conc e n t r a tio n. The individu al gas e s are inject e d singly
and the monitor oper a t e d in the calibra tion mod e . Once a sta bl e reading is
obt ain e d , the respo n s e time s (minim u m 95% of known conc e n t r a tio n) and
CEMS instru m e n t resp o n s e s are record e d .

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5. 1 . 3 Opa ci t y Audit (Calibr a t i o n Error - CE)

Opacity monitor audits shall be don e accordin g to EPA’s 40 CFR 60
Appen dix B Perfor m a n c e Specification 1. Thre e sep a r a t e and certified
neutr al density filters are use d to challen g e the oper a tion of the opacity
monitors. A total of fiftee n (15) non- cons e c u tiv e reading s are take n, five for
each 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 is
perfor m e d to est a blish initial acc e p t a bility of the CEMS. It is perfor m e d in
accord a n c e with EPA’s 40 CFR 60 Appen dix B, (PST 1, 2, 3). Require d
Appen 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 EPA
proc e d u r e s

Should the PST not produc e acce p t a bl e results, correctiv e action is take n
and 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’s
perfor 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 t
monitor 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 a
handling and reportin g proce d u r e s . Quality control activities rely upon a
qualified and well- traine d staff.

Initial installation of any monitoring syst e m is carrie d out in strict
accord 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 s
also includ e d initial start- up, debu g gi n g , and inspe ction of the syst e m s to
ens 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 all
comp o n e n t s of the syst e m is maint ain e d by the TITLE OF RESPO N SIBLE
PERSO N . Thes e ma n u al s provid e com pl e t e description s of the syst e m
including the ory, installation, oper a tio n, troubl e shootin g, rep air and gen e r al
maint 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 h
the use of known conc e n t r a tio n zero and spa n gas e s of the applica bl e gas
species . 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

calibra t e d . Extern al zero is perfor m e d eith er during actu al or stimula t e d
clear stack conditions. Alignm e n t checks betw e e n the trans c eiv e r and
retror eflec t or are perfor m e d during any ext er n al zero adjust m e n t or any
routin e maint e n a n c e .

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5. 2 . 2 Calibr a ti o n Che c k

Dyna mic calibration checks are perfor m e d by challen gin g the monitors
once every 24 hours with a calibra tion gas of a known conc e n t r a tio n. A
progr a m m a b l e timer auto m a t ic ally initiat e s the precision check. This
syst 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 to
the DAHS, which auto m a t ic ally com p a r e s the value to the certified value s of
the 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 s
the applica bl e sta n d a r d , the DAHS initiat e s an instru m e n t "OUT OF
CONTROL" alar m.

During the calibra tion checks of the opacity monitors, the dat a syst e m
verifies the prop e r compl e tio n of the calibration cycle. Should any individu al
zero drift exce e d 2% of the instru m e n t spa n, or any calibration drift exce e d s
2% of the instru m e n t span, an alar m condition is indicat e d and correc tiv e
action 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 the
availability 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 the
following 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 by
aut 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 m

Technic al

- print er: oper a tion al, legible print, rea din g s consist e n t with the proc e s s
conditions
- 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 correct
conc e n t r a tio n rang e , abov e the 250 psi minim u m
pres 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 within
applica ble rang e s
- opacity monitor: align m e n t v e rifica tion, purg e air blowers oper a tio n al

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5. 3 DATA RECORDING AND REPORTING

Data 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 a
into 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 the
vendor' 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 d
as exp e ri e n c e dictat e s . Thes e proc e d u r e s may be modified to be more
specific for the inst allation. Preve n tiv e maint e n a n c e is sche d ul e d and
perfor 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

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 m
proble m , the TITLE will be notified directly and in writing. A nota tion of the
proble 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 al
oper a ti n g require m e n t s . Emerg e n c y parts are availa ble throu g h the vendor
on a next day basis. TITLE has the over all respo n si bility for maint ai nin g the
ade q u a c y of the spar e parts invent ory. The curre n t inven t ory is bas e d on
the vend or' s reco m m e n d e d list for 90% dat a availability, and is modified on
an as- require d basis.

5. 7 ACTIVITY MATRIX

An activity matrix sum m a rizing the various routin e QA/QC activities is
pres e n t e d in the table on pag e s 5 and 6. Daily activities will include checks
of daily zero and spa n value s and obs erv a tio n of routin e dat a from the
norm al oper a tion of the CEMS.

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Activity/
QA Checks Weekly Monthly Quarterly Annually

1. Calibration Gas X
Pressure

2. Sample Gas X
Pressure/Vacuum

3. Sample Gas X
Pressure/Flows-
Analyzer

4. NOx Analyzer X
Desiccant

5. Replace Filters X

Analyzers

6. Replace Filters/ X
Scrubbers Air
System

7. Replace/Clean X
Filters-Probe

8. Temperature X
Control Analyzer
Enclosure

9. AC Filter X
Cleaned

10. Clean Interior
of Enclosure/
Analyzer

11. Leak Check Gas
Connections

12. Clean Disc
Drive Head

13. Printer
Maintenance

14. System Audit X

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Activity/
QA Checks Weekly Monthly Quarterly Annually

15. Clean Optical
Surfaces
16. Check Air X
Hoses

17. Clean/Replace X
Filters

18. Check/Adjust X
Alignment

Activity/
QA Audit

1. CGA X

2. Opacity Audit X

3. RATA X

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6. 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 al
part of this QA Plan. This section describ e s report s and oth er record s that
provid 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 ry
me a n s of docu m e n t a ti o n us ed are:

(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/QC
docu 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 a
report s. During QA audits, the DAHS will be oper a t e d to collect dat a in a
norm al fashion, but will print all insta n t a n e o u s engin e e rin g units for a real
time 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, but
it also serv e s as the CEMs dat a acquisition and proce s sin g syst e m . Each of
the 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 t
subs 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 g
docu 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 e
ma n n e r .

Report s are used to notify individu als of proble m s relat e d to oper a tio n of
the CEMS. Compilation of the s e report s is inten d e d to assist in identifying
the 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 DAHS

De 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 a
si 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 of
infor m a t i o n an d pr o c e s s si g n a l s .

[DIAGRAM ]

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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 s
of 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 REPORTS

6. 3 . 1 Curre n t (Hourly ) Rep or t s

6. 3 . 2 Daily Rep or t s

6. 3 . 3 Alarm Rep or t s

6. 3 . 4 Quart e rl y Rep or t s

6. 4 MAINTENANCE RECORD

This record is maint ain e d throu g h TITLE. The TITLE ent er s description s
of routin e prev e n tiv e and maint e n a n c e actions perfor m e d on the monitoring
syst 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 log
books. This record also docu m e n t s the us e of spar e part s, and its periodic
review 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 e
part 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 in
a report. All supp ortin g dat a are kept on file by TITLE. Thes e audits serv e
as 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 Plan
mus t provide a gas conc e n t r a tio n certificat e for each cylinde r of gas
supplied. 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 .

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7. 0 QUALITY ASSURANCE PROCEDURES

7. 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 s
accur 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 t
value s obt ain e d from the CEMS to value s obt ain e d by EPA Refer e n c e Method
or approv e d altern a tiv e testin g met h o d . The res ults of the s e test s provide
verification of the continu e d comp a r a bility of the CEM dat a to, dat a
collect 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 e
test s are publish e d in EPA 40 CFR 60, Appen dix A, B and F [OR OTHER
APPLICABLE RULES OR REGULATION S ] .

7. 2 RATA PROCEDURES

7. 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 testing
prer 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 test
protoc ol form.

Verifications are ma d e tha t the boiler to test e d will not be und e r g oin g
sche d ul e d maint e n a n c e and that no oth er condition exists which would
preclud e testing the boiler emission s und er repr e s e n t a tiv e oper a tin g
conditions .

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 t
nec 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 dix
A and B proc e d u r e s .

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7. 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 RATA
testin g. Verify that the CEM oper a tin g conditions are norm al by conduc tin g
a syst e m s audit.

Notify TITLE OF RESPO N SIBLE PERSO N of testin g and requ e s t notification
should any condition arise that would result in less tha n a 50% sta ble load
during the testing.

Proce e d to the test location and verify the following for the stack testing
crew.
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 s

Verify availa bility of plant or pollution control equip m e n t oper a tin g dat a
requir e d for the report.

Upon com pl e tion of the testing, notify the TITLE that testing has bee n
compl 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 audit
sa m pl e s .

7. 2 . 3 Dat a Red u c t i o n an d Analy s i s

The results of the ma n u al Refer e n c e Method s , as part of the RATA, are
calculat 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 the
concurr e n t CEM dat a to calculat e relative accur a c y.

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7. 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 in
Perform a n c e Specification 2. In this proce d u r e , the res ults of the Refer e n c e
Method 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 Method
results 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 100

7. 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 the
curre n t Quart e rly Emis sion Report. The RATA report follows the following
outline.

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

- 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 report

7. 3 PROCEDURES FOR CGA

7. 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 pling
and the analysis sys te m s . Zero, low, and mid- rang e audit gas e s are
introdu c e d in lieu of the norm al calibra tion gas e s . The DAHS calibra tion
report is use d in stre s sin g calibra tion error.

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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 at
each monitoring location are show n in table xx. Audit dat a and
obs erv a tio n s , including conc e n t r a tio n s of gas e s actu ally use d during the
audit, 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 al

40 CFR Part 60, Appen dix F

7. 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 e
audit cylind er serial num b e r s , certified gas conc e n t r a tio n s and the dat e s of
analysis. 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 .

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 tion
cylind 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.

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7. 3 . 3 Dat a Red u c t i o n an d Analy s i s

1. Obtain CGA Audit Dat a Form and ent e r dat a from the DAHS calibra tion
report.

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
100

3. Verify that the % diff does not exce e d 15% ( or applica bl e limit) for any
dat a point.

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 e
appro pri a t e correc tion actions, as specified in the QA Plan. Upon com ple tion
of the nec e s s a r y corrective actions, the CGA mus t be rep e a t e d . The results
of 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 the
curre n t Quart e rly Emission Report. The CGA report should use the following
outline:

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 the
results
- 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).

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8. 0 QC PROCEDURES

8. 1 INTRODUCTION

Quality control checks may be define d as all thos e checks perfor m e d on a

routin e basis such as syst e m insp ec tio n s, periodic calibra tion s and routin e
maint 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 d
writt 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 emission
dat 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 24
hour period. The DAHS calculat e s the perc e n t differe n c e from ent er e d
known value s. The TITLE OF RESPO N SIBLE PERS ON will be respo n sibl e
for 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 if
drift 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 d
logbook. A syst e m s audit may be perfor m e d at any time if oper a ti n g
proble m s are obs erv e d during routin e checks of emission dat a on daily
zero/s p a n checks. This audit is a gen e r al appr ais al of the CEMS oper a ti n g
par a m e t e r s . The following checks will be record e d during the syst e m s audit
and 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.

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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 AUDIT

Administr a tiv e

1. 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 s
conditions .
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 opacity
monitor is correct.

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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.

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TABLE 9- 1 RECOMMENDED ROUTINE PREVENTIVE MAINTENANCE

Opa 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 filter

NOx
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 filter

Air 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 filters

Prob e s
Quart e rl y
1. Check conn e c tion s for leaks

2. Clean coars e scre e n and quartz wool plug

Com p u t e r Sy s t e m (DAHS)

We e k l y
1. Back- up the fixed disk

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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 N



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
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TABLE 10- 1 REFERENCES TO TROUBLE-SHOOTING/CORRECTIVE ACTION

List 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 .

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11 . 0 REFERENCES

List all ref e r e n c e s us e d to co m p i l e thi s QA Plan .

Section No.: 12
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12 . 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 of
th 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

7. Exa m p l e s of re p o r t i n g for m s

8. Exa m p l e DAHS prin t o u t s

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