EPA 450/4-92-010
TECHNICAL ASSISTANCE DOCUMENT
PERFORMANCE AUDIT PROCEDURES FOR OPACITY MONITORS
Prepared By
Keith R. Hazel
Steven J. Plaisances
James W. Peeler
Entropy Environmentalists, Inc.
Research Triangle Park, NC 27709
Contract No. 68-D1-0009
Work Assignment No. 38
Thomas J. Logan, Work Assignment Manager
Methods Research and Development Division
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
ATMOSPHERIC RESEARCH AND EXPOSURE ASSESSMENT LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
RESEARCH TRIANGLE PARK, NC 27711
MARCH 1992
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DISCLAIMER
The information in this document has been funded by the United
States Environmental Protection Agency under contract 68-D1-0009
It has been subjected to the Agency's peer and administrative
review, and it has been approved for publication as an EPA
document. Mention of trade names or commercial products does
not constitute endorsement or recommendation for use.
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ABSTRACT
This manual contains monitor-specific performance audit procedures and
data forms for use in conducting audits of installed continuous opacity
monitoring systems (COMS's). General auditing procedures and acceptance
criteria for various audit criteria are delineated. Practical considerations
and common problems encountered in conducting audits are discussed, and
recommendations are included to optimize the successful completion of
performance audits.
Performance audit procedures and field data forms were developed for the
following opacity monitors: (1) Lear Siegler Measurement Controls Corporation
Dynatron 1100M and MC2000; (2) Lear Siegler Measurement Controls Corporation
Model RM-41; (3) Lear Siegler Measurement Controls Corporation Model RM-4; (4)
Dynatron Model 1100; (5) Thermo Environmental Instruments, Inc. Model 400; (6)
Thermo Environmental Instruments, Inc. Model 1000A; (7) Thermo Environmental
Instruments, Inc. Model D-R280AV; (8) Enviroplan Model CEMOP-281; (9) United
Sciences, Inc. Model 500C; (10) Land Combustion Model 4500; and (11) DataTest
Models 900A and 900RM. The concise step-by-step format of the audit procedures
promotes a thorough evaluation of the quality of the monitoring data and the
reliability of the opacity monitoring program.
Generic audit procedures have been included for use in evaluating COMS's
with multiple transmissometers and combiner devices. In addition,
several approaches for evaluating the zero alignment or "clear-path" zero
response have been described. Although the zero alignment checks cannot
usually be conducted during a performance audit, the zero alignment procedures
have been included because this factor is fundamental to the accuracy of
opacity monitoring data.
m
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CONTENTS
Di scl aimer i i
Abstract ....."............... i i i
Figures ............ vi
1. Introduction 1_1
1.1 Background i.i
1.2 Use of This Manual 1-2
1.3 Approach and Limitations 1-4
2. General Audit Procedures 2-1
2.1 Practical Considerations 2-1
2.2 Pre-Audit Information 2-3
2.3 Performance Audit Procedures 2-8
3. Performance Audit Procedures for Lear Siegler Measurement Controls
Corporation Opacity Monitors 3_1
3.1 Lear Siegler - Dynatron 1100M and MC2000 CQ^S'3................... 3-1
3.2 Lear Siegler Model RM-41 Transmissometer and Model 611 Control
Unit , 3_|5
3.3 Lear Siegler Model RM-4 COMS...............'. .*'.'.'...[.'.'.'.'. \ [ V '. * .*."." ] 3^3
4. Performance Audit Procedures for the Dynatron Opacity Monitor. 4-1
4.1 Dynatron Model 1100 Transmissometer ".** 4.}
5. Performance Audit Procedures for Thermo Environmental Instruments, Inc.
Opacity Monitors 5^
5.1 Thermo Environmental Instruments Model 400 Transmissometer and
Model 500 Control Unit 5_j
5.2 Thermo Environmental Instruments Model ioOO/v!!!!!!!!!!!!!!!!."!!."!!! 5-12
5.3 Thermo Environmental Instruments Model D-R280AV (Duragj........... 5-18
6. Performance Audit Procedures for Enviroplan Opacity Monitor.. 6-1
6.1 Enviroplan Model CEMOP-281 (Durag) !!!!!!!! 6-1
7. Performance Audit Procedures for United Sciences, Inc. Opacity Monitor 7-1
7.1 United Sciences, Inc. Model 500C Opacity Monitor 7-1
8. Performance Audit Procedures for the Land Combustion Opacity Monitor 8-1
8.1 Land Combustion Model 4500 Opacity Monitor 8-1
9. Performance Audit Procedures for DataTest Monitors 9-1
9.1 DataTest Models 900A and 900RM i!!!!!!!!!."!!!!!! 9-1
10. Performance Audit Procedures for COMS with Combiners 10-1
10.1 Calculation of Stack-Exit Opacity for Combiner Systems 10-1
10.2 General Audit Procedures 10-4
11. Zero Alignment Checks H.j
11.1 Off-Stack Zero Alignment 11-1
11.2 On-Stack Zero Alignment .!!!!...!!.!!.!!. 11-2
11.3 Alternate Zero Alignment Approaches 11-3
(Continued)
• iv
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CONTENTS (continued)
Appendix A. Lear Siegler Measurement Controls Corporation -
Dynatron 1100M and NC2000 Data Forms
Appendix B. Lear Siegler Measurement Controls Corporation -
Model RM-41 Audit Data Forms
Appendix C. Lear Siegler Measurement Controls Corporation -
Model RM-4 Audit Data Forms
Appendix D. Dynatron Model 1100 Audit Data Forms
Appendix E. Thermo Environmental Instruments Model 400
Audit Data Forms
Appendix F. Thermo Environmental Instruments Model 1000A
Audit Data Forms
Appendix G. Thermo Environmental Instruments Model D-R280 AV
Audit Data Forms
Appendix H. Enviroplan Model CEMOP-281 Audit Data Forms
Appendix I. United Sciences, Inc. Model 500C Audit Data Forms
Appendix J. Land Combustion Model 4500 Audit Data Forms
Appendix K. DataTest Models 900A and 900RM Audit Data Forms
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LIST OF FIGURES
Figure Page
No. No.
2-1. Opacity Pre-Audit Data Form 2-4
3-1. Lear Siegler Measurement Controls Corporation Dynatron 1100M
Transmissometer . 3-2
3-2. Lear Siegler Measurement Controls Corporation Dynatron 1100M
Control Unit 3.3
3-3. Lear Siegler Measurement Controls Corporation MC2000
Transmissometer 3.5
3-4. Lear Siegler Measurement Controls Corporation RM-41
Transmissometer 3.15
3-5. Lear Siegler Measurement Controls Corporation RM-41
Control Unit (Model 611) 3.18
3-6. Lear Siegler Measurement Controls Corporation RM-41
Control Unit Circuit Board Arrangement 3-21
3-7. Lear Siegler Measurement Controls Corporation RM-41 Transceiver 3-26
3-8. Lear Siegler Measurement Controls Corporation RM-41 Junction
Box (J-Box) 3_28
3-9. Lear Siegler Measurement Controls Corporation RM-4
Transmissometer 3.34
4-1. Dynatron Model 1100 CEMS Components 4-2
5-1. Thermo Environmental Instruments Model 400 Transmissometer 5-2
5-2. Thermo Environmental Instruments Model 500 Control Unit 5-3
5-3. Thermo Environmental Instruments Model D-R280 AV Transmissometer 5-19
5-4. Thermo Environmental Instruments Model D-R280 AV Control Unit 5-20
5-5. Thermo Environmental Instruments Model D-R280 AV Junction
Box (J-Box) 5-25
6-1. Enviroplan CEMOP-281 Transmissometer 6-2
6-2. Enviroplan CEMOP-281 Control Unit 6-3
(continued)
VI
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LIST OF FIGURES (continued)
7-1. United Sciences, Inc Model 500C Transmissometer 7-2
7-2. United Sciences, Inc Model 500C Control Unit 7.4
7-3. United Sciences, Inc Model 500C Junction Box (J-Box) 7.9
8-1. Land Combustion Model 4500 Transmissometer g-2
8-2. Land Combustion Model 4500 Control Unit 3.4
8-3. Land Combustion Model 4500 Transceiver with Lamp Access
Cover Removed; exaggerated view of "AUTO COMP" Switch 8-12
11-1. Alternate Zero Alignment Procedure Using Zero Alignment Jig 11-5
vii
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SECTION 1
INTRODUCTION
1.1 BACKGROUND
In 1975, the U. S. Environmental Protection Agency (EPA) first promulgated
specific effluent monitoring requirements for several source categories
subject to the Standards of Performance for New Stationary Sources. Affected
sources were required to install, operate, and maintain systems for continuous
monitoring of effluent opacity. At the same time, EPA also promulgated
similar provisions necessitating revisions to State Implementation Plans to
include opacity monitoring requirements for selected source categories. Since
that time, Federal, state, and local air pollution control agencies have
expanded the applications of continuous opacity monitoring systems (COMS's) by
adopting monitoring requirements for additional source categories, by
requiring monitoring in operating permits, and through the use of other
source-specific mechanisms. In most cases, the source owner or operator must
periodically report data related to excess emissions and monitor performance
to the appropriate control agency. Excess emissions data are generally used
as an indication of: (1) whether proper operation and maintenance practices
for process and control equipment are being used; (2) the degree of compliance
with applicable opacity standards; (3) particulate emission levels; and (4)
the need for an inspection of the source.
Regardless of the particular monitoring requirements or the control agency's
use of the data, issues affecting the quality of the COMS data are of concern
to both the control agency and source representatives. In almost all cases,
the source owner or operator is required to demonstrate that the COMS complies
with Performance Specification 1 of Appendix B, 40 CFR 60. This demonstration
(referred to as a performance specification test) is usually completed shortly
after the COMS becomes operational and serves to ensure that the monitoring
system is properly installed and capable of providing reliable data.
EPA regulations, as well as most state and local regulations, include
minimum operating procedures that the source owner or operator must follow
after completing the initial performance specification test. Typically,
source operators are required to check the calibration of the COMS at two
points at least once daily. These checks are usually performed at zero
percent opacity and at an upscale point called the span check. For sources
subject to EPA requirements in 40 CFR 60, cleaning of the optical surfaces
exposed to the effluent stream and adjustment of the monitor are required if
the zero or span check responses exceed two times the 24-hour drift limits in
Performance Specification 1. Most state and local regulations are similar.
Except for the zero and span check requirements, EPA and most state and local
monitoring regulations do not require the source operator to conduct tests or
otherwise periodically assess the quality of the opacity monitoring data.
However, most monitoring regulations require the source owner or operator to
properly operate and maintain the COMS, to keep records of all adjustments and
repairs to the monitoring system, and to submit periodic reports to the
control agency (i.e., quarterly excess emissions reports).
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A performance audit provides a relatively simple and quick method of
obtaining an objective evaluation of opacity monitor performance. Audits may
be conducted to assess the quality of the data provided by the COMS and/or to
identify operation and maintenance problems that may impact the reliability of
opacity monitoring results. A performance audit provides a quantitative
evaluation of monitor performance in terms of the accuracy and precision of
the data provided. Since it is not feasible to perform a relative accuracy
test by obtaining Independent effluent measurements for comparison with the
measurements provided by an installed opacity monitor, a series of checks of
the individual monitoring system components 1s conducted. Based on the
results of these checks, an assessment of the performance of the entire
monitoring system can be made.
Audits of COMS's may be conducted by either the control agency or
source personnel. The control agency may conduct performance audits at
«!!/«!!! K-S? ?Cte? so!Jrces or at sources wnere opacity monitoring problems
and/or high levels of excess emissions are indicated in quarterly excess
rm,t^«nK r?ports- S°ui:ce Personnel may conduct performance audits on a
rnnrlrnc •* M ***$.'* * ^u^ty assuran« program, or when specific
concerns arise regarding the validity of the opacity monitoring data.
1.2 USE OF THIS MANUAL
pr?r1de* Detailed procedures for conducting performance
i1- Up2ates and rePlaces the information and procedures
JEli^S?^1' "Pe^°™ance Audit Procedures for Opacity
60°/8-87-°25» April 1987). The revised procedures include
m°n1t°rS "* addre" Changes 1n ""temporary monUoHng
this l^iPhr!fnKteam/h?Uld,perforin the aud1t; however, the procedures in
norLn ^ K 6 K66? des^ned so th« «««t *™ *>* conducted by a single
?np*nor?S *? a bw1c, understanding of monitor operation. Relatively
«^nTS^i^$on!!? "5 C0nduct aud1ts after m1n1mal f1eld training by
carefully following the audit instructions. '••"ing oy
Section 2 of this manual discusses practical problems and
considerations in conducting audits and the gathering of preliminary
information prior to the audit. Section 2 also presents I discussion of
general opacity monitor audit procedures and the evaluation of audit results.
3,!j!rou9h 2 Provlde monitor-specific information and
mnntn K Udlt Pro<;edures for the most commonly encountered opacity
monitors. These procedures can often be applied to slightly different
0f ^h%^e,°r mon1tor for ^1ch the> we^ w?itien? or to a
-HH S ldenJ1fl?d bv »rt than one make or model number! Table 1-1
InH^ 5s/ ?K1Ck reference to helP the auditor match the type of monitor
audited to the appropriate document subsection. Provided in the
appendices to this document are monitor-specific data forms (coded to
"th the step-by-step instructions). Use of these data forms will
Slt0rJ?"ric°ir?1ng a11 °f the necessa^ information and in
the audit results.
1-2
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Section 10 describes performance audit procedures for use in
evaluating COMS's that include multiple duct mounted transmissometers
and a combiner device for computing the equivalent combined stack-exit
?S2c/ y'i£ generic approach is presented for conducting audits of
cons s with combiners. These procedures require that the auditor understand
the monitor-specific audit procedures for COMS's with a sinale
transmissometer. *
thn J!f!J°n n4j!1scusses several approaches for checking the zero alignment of
the opacity monitoring system. The zero alignment checks cannot usually be
tho ?«! VUnngA!!erfonnan?e audit; these procedures are included because of
$ata 2er° al1gnment to the ^curacy of the opacity monitoring
«i ay f1nd some of the d^cussions in Sections 1
?K at °yerwhelmin9 at «rst. Review of these materials after working
p ^nT1 •°r"SpeCi!1c 1nronnation for at least <»* monitor should 9
e confuS1on regarding the basic approach and terminology
1.3 APPROACH AND LIMITATIONS
COMS performance audits involve a series of checks of monitor ina svstpm
(1) Monitor Component Analysis
fScanre!?cL1^IBade to/er1fy the accuracy of the path length correction
factor used to convert measurements obtained at the monitoring location
to the equivalent opacity observed at the stack exit. Ideally two
esS|abfiSahrinn0tnh1derteK:1(a)trhether the pr°Per di»ensions were used in
vafte of Jh! ^thP?!H ]^9th co:rection '«tor, and (b) whether the
value of the path length correction factor used by the monitor is
1* t(?e "l"1>ted «1ue. Note that in som^ ?ns?In«s,
ay prevent addressin9 these
i"JJe«tOP«."« the COM3 control unit are checked to
whether various monitor parameters are operatinq within
SEilErJ1"1*4',. "SUa11yr these 11m1*s are established by the mon tor
manufacturer; however, for some monitors, the user may select
activation limits for the fault circuits.
™^n™»-,, * ^ . cnecks are performed in accordance with the
recommendation of the monitor manufacturer to determine the ooerationai
status of the monitor. These checks are performed™sing the ?on?rols
and meters of the monitoring system. The use of external electronic
test equipment is generally beyond the scope of a perfSrman« audii
1-4
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• The responses of the COMS to the daily zero (low range) and span check
is evaluated using both the control unit panel meter and the permanent
data recorder.
(2) Transmissometer Maintenance Analysis
• The optical alignment of the transmissometer (transceiver and
reflector) is checked using the alignment sight of the monitor. The
results of this check are considered to be indicative of the mechanical
stability of the monitor mounting and the adequacy of on-stack
component maintenance activities.
• The dust accumulation on the optical surfaces of the transmissometer
is checked to determine the status of the purge air system and the
adequacy of the frequency of lens cleaning. This determination is
based on the difference in the opacity read before and after
cleaning of the optical surfaces exposed to the effluent stream. The
results of this check may be adversely affected by fluctuations in the
effluent opacity.
(3) Calibration Error Analysis
• The linearity of the COMS is determined relative to a series of neutral
density filters which have opacity values above and below the emissions
standard. For most monitors, this test is performed using an audit
device that simulates the instrument clear path zero setting and allows
insertion of the filters into the light path. For other monitors, the
calibration error determination is accomplished by evaluating the COMS
response to the superposition of audit filters and the effluent
opacity. In either case, calibrated neutral density filters are
inserted into the light path of the transmissometer and the
corresponding response of the monitoring system is determined from the
permanent data recorder.
The purpose of the performance audit is to provide a basis for
evaluating the accuracy and precision of the monitoring data; however, the
audit procedures do not provide a single result which is representative of the
overall performance of the monitor. Instead, the series of steps described
above serves to identify problems which detract from the accuracy of the
opacity measurements. In the absence of such problems, the opacity
measurements are assumed to be accurate.
The results of the calibration error check of an installed COMS do not
provide a measure of the absolute accuracy of the monitoring data collected
prior to the audit for two reasons. First, the presence of the effluent
opacity during the audit prohibits detection of any offset or error in the
clear-path zero response of the monitor. A determination of the absolute
accuracy of a COMS can only be accomplished by combining the results of a
performance audit with the results of an independent zero alignment check
(e.g., determination of the degree of agreement between the simulated zero
response and the true zero response of the monitor under clear-path
conditions). Normally, the zero alignment check is beyond the scope of a
performance audit (see Section 11).
1-5
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Second, since the transmissometer optics are cleaned prior to conducting
the calibration error test, the results of the check do not include any
measurement bias due to accumulation of particulate material on the optical
windows of the transmissometer. To estimate the accuracy of the opacity
measurements prior to the audit, superposition of the results of the
calibration error check and the dust accumulation checks would be necessary.
Consideration of zero and span errors are not necessary, provided that no
adjustments to the monitor are made during the audit.
1-6
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SECTION 2
GENERAL AUDIT PROCEDURES
This section provides an overview of continuous opacity monitoring system
(COMS) performance audit procedures as a supplement to the monitor-specific
procedures presented in Sections 3 through 9. Practical considerations
affecting COMS performance evaluation programs are addressed in Section 2.1.
Information that should be acquired before conducting the audit is identified
in Section 2.2. A discussion of general audit procedures, acceptance limits
for various audit criteria, and the evaluation of audit results is provided in
Section 2.3.
2.1 PRACTICAL CONSIDERATIONS
Several practical considerations are addressed in this section because
questions regarding these matters arise frequently.
Human Resources - Performance audits may be conducted by one person or by
a team of at least two people. If one person performs the audit, a sufficient
period of time must be allowed to elapse during each action taken at the
transmissometer location (e.g., cleaning of windows, insertion of filters,
etc.) to allow the monitoring system to obtain and clearly record the resulting
response. This period should be approximately two minutes for monitors
recording instantaneous opacity data on a strip chart recorder. For a COMS
*?a Kr?C°irds onl?uinte9rated opacity data, this period must be, at a minimum,
onl9,m ntl^r J 2V*1" tht !nte9ration P^iod. This ensures that at least
JSt rorSrSc ^1* f^*9? 1$ ™*™ fW MCh St6P °f th* 3Ud1t' F°r a
that records only 6-minute averages, a minimum of 13 minutes must elaose
«? actlon that the auditor performs. Conducting an audit under these
«?«» J"S ?°?ld rT1reua Slngle aud1tor to rema1n a* the ^nitoring
ch^i] K !•* le!Su flve hours- S1nce th1s 1s Dually impractical, the audit
should be performed by two people in cases where the COMS cannot record
instantaneous or short term data averages. A second problem with having one
person conduct COMS audits is that the auditor has no real-time feedback to
indicate when specific steps in the audit should be repeated because of
^nvMr T?i £S;K °?ly af*6r th! au?U 1s comPlet* can the auditor ascertain
if any or all of the transmissometer location checks need to be repeated.
Using a team of at least two people (one at the monitoring location and
one at the control unit/data recording location) greatly reduces the time
required to complete the necessary steps at the monitoring location and
eliminates the above mentioned feedback problems (assuming that effective
communication between the two locations is established). The person at the
control unit does not have to be trained in auditing monitors because recording
the monitor responses and advising the auditor to continue with the next step
is all that is required. In many cases, a single control agency representative
can perform the audit in an effective manner, provided that a source
representative is willing to relay the COMS responses from the control unit and
data recording device to the auditor. Source personnel are usually willing to
provide this assistance. However, control agency representatives who plan to
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conduct audits in this manner should request the assistance of plant personnel
in advance of the audit to ensure that personnel are available and willing to
perform specific activities. The auditor should also ensure that the plant
representative determines the monitor responses from the appropriate data
recording device and that the data are interpreted and recorded correctly.
Communication - Communication between the monitoring location and the
control unit/data recorder location is essential when audits are conducted
using the team approach. Some power plants have hard-wired communication lines
between the two locations that can be used by the auditor. In some cases,
plant personnel will loan radios to the audit team or will operate radios for
the auditors. However, the availability of such equipment at power plants and
other stationary sources is generally very limited. Control agency auditors
should not make assumptions concerning the availability or use of such
equipment; they should discuss the need for communications equipment with plant
personnel in advance or provide their own.
Communication between various locations at stationary sources using short
wave radios is often severely restricted or impossible because of electrical
interference and shielding problems. The use of FM radios is preferred. It Is
imperative that non-plant personnel obtain clearance to use radio equipment:
prior to its use at any stationary snurrpIn some cases use or even
possession of radios ID the plant control room is prohibited, since these
radios may interfere with instrumentation or control signals necessary to
significant * Safely' The consequence of unauthorized use of radios can be
Computer System Operations - Most modern plants are equipped with
computerized data acquisition systems. The operation and control of
computerized systems may be complex, and the output format may be confusing
when first encountered Control agency personnel who are conducting 9
Snl^r™"0!!/"?1*5 snoul? not expect to ful1* understand how such systems
nSa™ S'SrftSS"'1 sn?u™ be ^quested to enter the control commands
necessary to facilitate acquisition of the appropriate output. If the Agency
auditor is going to record monitor responses, an adequate explanation of the
D%°rLUnn^°dUe\P±ShOUJH * °Ea1ilid' * the a"d1tor should ^u™t tnVlource
personnel determine the monitor responses from the computer output for each
Step Or LnG audit.
., Equipment Damage Liability - Auditing of COMS's creates a situation where
tnere is a remote chance that the monitoring equipment could be damaged.
Control agency personnel should determine their agency's policy with respect to
abilUy J" adVan?e °f the audit- In *'• event that relevanrpo'icy
assumP*lon °f liability, control agency personnel should adopt a
ap2™CJ and nar6.^311^ Plan* personnel perform the audit under
of th<
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initial meeting with representatives of the concerned organizations in order to
describe the audit procedures, discuss possible actions resulting from the
audit, and to answer questions. Also, the auditor must be aware, in advance,
of restrictions resulting from union limitations and from other plant specific
rules enforced on the job site. For example, the auditor may not be allowed to
press buttons or even touch the monitor controls. In addition, break, meal,
and quitting times may be rigidly enforced, thereby restricting the auditor's
access to plant equipment and personnel.
Preserving Objectivity - Regardless of whether control agency personnel or
source representatives conduct the audit, it will be advantageous to all
parties if several simple steps are taken to preserve the objectivity of the
auditors. The reference values for the zero (or low range) and span checks of
the monitor should be determined prior to initiating the zero or span checks
Also, the calculated values of the neutral density filters should not be
divulged to the person recording the monitor responses for the calibration
error test until after the test is completed.
2.2 PRE-AUDIT INFORMATION
The successful completion of an opacity audit requires certain information
about the source, the monitor, and the data recording system. In the case of a
control agency, this information can usually be obtained from source files
CK E K aUdl*°!; reache? the test Slte« Durin9 the aud1t> the information
should be verified and updated as necessary. If the auditor cannot acquire
information on the source from existing files, he/she should utilize the
opacity audit data form (Figure 2-1) to compile the necessary information prior
^ I ^H1?9 uhe axdlt' Thls 'form should become Part of the maintained and
updated data base for the particular source. The information categories on
this form are described as follows:
Ie!ls the auditor at a ^ance the when, what, where, and
,
who of the audit without having to search through the data form.
Source Identification: This information identifies the particular facility to
be audited. The corporate name, the plant or station name, the mailing
address, the appropriate telephone numbers, and the principal plant contact
should be listed.
Corporate Contact: Many source organizations have corporate personnel charged
with overseeing environmental activities at the satellite facilities The
corporate contact is often a valuable source of information when setting up an
au2-*' JnSrCOr?ora£e contact generally wishes to be notified of any plans to
audit a COM3 under his/her oversight and should be given access to the COM3
audit results. The names, addresses, and telephone numbers of the involved
corporate environmental personnel should be listed on the pre-audit data form.
Additional Contacts: Source personnel concerned with monitor operation,
maintenance, calibration, servicing, or data reduction should be identified as
they are encountered. This information will aid the auditor in becoming
acquainted with the source's monitoring program. It may also be necessary to
contact some of these individuals to answer specific questions as they arise.
2-3
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OPACITY PRE-AUDFT DATA FORM
CBmCAL
PERSON TO CONTACT UPON ARRIVAL
AT (GATE OFFICE. ETC.): _
MONITOR TYPE: _
SOURCE NAME: _
FINAL AUDIT DATE
THE,
UNIT*.
SOURCE PEKTIFICATTOM
CORPORATION:
PLANT OR STATION NAME:
PRINCIPLE CONTACT:
PLANT MAILING ADDRESS:
TELEPHONE NO.:
PLANT TELEPHONE NO.:
CORPORATE eOMTAfTT
NAME
TITLE
MAILING ADDRESS:
TELEPHONE NO.:
SOURCE DAT A
UNIT*
FUEL
ADPfTlQNAL
1. NAME
AFFILIATION:
TELEPHONE NO.:
2. NAME
AFFILIATION:
TELEPHONE NO.:
3. NAME
AFFILIATION:
TELEPHONE NO.:
OUTPUT (MW): (FROM PERMIT)
AIR POaUTION CONTROL EQUIPMENT:
TYPICAL EFFLUENT OPACITY:
AVAILABILITY OF COMMUNICATIONS (RADIO. TELEPHONE. ETC.) BETWEEN MONITOR LOCATION AND CONTROL ROOM:
AVAILABILITY OF PERSONNEL TO TAKE READINGS FROM OPACITY DATA RECORDER DURING AUDIT:
Figure 2-1. Opacity Audit Data Form.
2-4
4406 0/91
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OPAcmr pRE-Auorr DATA FORM (CONTINUED)
HQNTTOR LOCATION
MONITOR LOCATION (STACK / DUCT):
DISTANCE FROM NEAREST FLOW OBSTRUCTION:
HEIGHT (IN FEET): (TOMONrTOR)
(UPSTREAM).
(TOTAL STACK)
ACCESS TO SAMPLING LOCATION (LADDER. STAIRS, HOIST. ELEVATOR):,
STACK/DUCT INSIDE DIAMETER: (AT MONITOR LOCATION)—
((DOWNSTREAM)
(STACK EXIT)
MONITOR DATA
MANUFACTURER / MODEL NO.:
MONITOR PRESET STACK EXIT CORRECTION FACTOR (BY MONITOR MANUFACTURER):
MONITOR ZERO AND SPAN VALUES (BASED ON MOST RECENT CALIBRATION): (ZERO).
COMBINER SYSTEM IN USE?
(SPAN)
DATA RECORDING / LOGGING SYSTEM:
DATA FORMAT USED IN REPORTING TO A.O. AGENCY (6-MIN / DAILY AVGS.)^
AVAILABILITY OF INSTANTANEOUS MONITOR OUTPUT RECORD (METER. STRIPCHART. OR COMPUTER^.
RECENT REPAIRS / MODIFICATIONS / CALIBRATIONS:
SOURCE EMPLOYEE MOST FAMILIAR WITH THE MONITORNG SYSTEM
COMMENTS
LOCATION SCHPUftT|C
PPACTTY DATA SYSTEM senc^TKT
Figure 2-1. (continued)
2-5
4406 8/91
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Source Data: Information about the unit (output capacity, type of fuel,
installed pollution control equipment, and typical effluent opacity) is
included to provide a basis for a description of the plant. The output
capacity should be taken from the most recent permit. It should be recorded in
the units specified in the permit. Since communications between the opacity
data recorder and transmissometer locations are vital in facilitating the
completion of an audit, the auditor should note if the source can supply
communications equipment (radios, telephone, etc.) and/or an employee to take
readings from the opacity data recorder during the transmissometer portion of
the audit.
Monitor Location: The monitor location should be specified with respect to
height and distances from upstream and downstream flow disturbances. Enough
information should be gathered to produce a schematic showing the location of
the monitor within the effluent handling system. The most critical dimensions
to be acquired are the stack exit inside diameter and the stack inside diameter
(or duct width) at the transmissometer location. These values are used to
calculate the stack exit correlation factor and should be known with an
accuracy of ±1.0 inch. The form of access to the monitor location (ladder,
stairs, elevator, etc.) should be known so that the auditor can budget his or
her time if a lengthy climb is anticipated.
Monitor Data; The monitor should be identified by manufacturer and model
number. If possible, the stack exit correlation factor, as well as zero and
span values, should be identified either prior to or at the outset of the
*J ,?,!"".the 2ero and *Pan values may be renamed during the routine clear-
path calibration procedures, these values should be verified prior to each
audit.
The presence of a combiner system should be identified prior to the audit
because specialized audit procedures are required for such systems.
The data recording/logging system should be identified and categorized as
to stnpcnart, circular chart, and/or computer. Frequently, sources employ a
combination of stripchart and computer data systems, with both instantaneous
and six-minute averaged opacity data being recorded. If the source records
only six-minute averaged data, the auditor should request that source personnel
be available to reset the data acquisition system (DAS) or control unit
integration periods to produce instantaneous opacity data for the duration of
the calibration error analysis. The auditor should also note the averaging
format of data reported to the control agency.
The auditor should inquire about any recent repairs, modifications, or
calibrations of the monitor. This information will allow the auditor to
anticipate problems that may be encountered.
In addition, the auditor should obtain the name of the source person most
knowledgeable about the operation and maintenance of the monitor so that this
person can be consulted for additional information.
Comments: General comments about the source or monitor that will facilitate
the audit should be entered in this section of the form.
2-6
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Monitor Location Schematic: The auditor should sketch the effluent system,
including the heights and distances associated with the monitor location, along
with upstream and downstream flow disturbances. The schematic should include
the Inside diameter of the stack at the stack exit and the inside diameter of
the stack or duct at the transmissometer location.
Opacity Data System Schematic; The auditor should produce a schematic
depicting the data transfer from the transmissometer to the control unit and
the opacity data recorder. The format of the data (e.g., double pass
transmittance, instantaneous path opacity, six minute averaged opacity) should
be indicated at each stage of data collection, and the COMS components should
be described (e.g., transmissometer, control unit, stripchart recorder,
computer, printer, etc.).
2.3 PERFORMANCE AUDIT PROCEDURES
The following discussions define the specific parameters that are
evaluated during a performance audit, describe how these parameters are
?!anHI '/!Jd-present ac«Ptance criteria for each item. Detailed information
is presented in areas where problems are frequently encountered.
Opacity monitor performance audits provide an accurate and reliable
indication of monitor performance through a simple and quick field test
procedure. Specialized equipment necessary for a typical audit includes a
^rI;SpeClf15 refl?Ct°!;rraud1t W>* «tenalS for cloning the optical
fllSS 6A??S6f JK the effl!Jent>.a"d a "t of three calibrated neutral density
Thl !MHO/ K°fiihe/eq!!lred e1uil»*nt can be transported in a small suitcase.
IiLcoc cV*°UlK alsokhav? safet* equipment, including a hard hat, safety
glasses, safety shoes, hearing protection, and any specialized equipment
required by the plant or particular working environment. e"ulPmen*
of thmonnn are Or9?n1"d sequentially according to the location
?h. EL? ? 2 Jng y?tem comP°nents (mov1"9 from the control unit location, to
the installed transmissometer, and then back to the control unit) so that a
single individual can conduct the audit. As previously described, in many
Sf LI VS ^Vanta9eous for multiple personnel to be involved in conducting
audit rr^oJ^a9enral ^P^cedures and acceptable limits for the various
audit criteria are described below.
2.3.1 Stack Exit Correlation Frrnr
mnrHtl^lc*11?' the,crosf '**** °Ptical Path Ien9th of the installed opacity
monitor is not equal to the diameter of the stack exit. To obtain a stack
exit opacity value, the measured opacity at the monitor location is corrected
IA i? ??U fondltlons through the use of a path length correction factor.
Ideally, the stack exit correlation error is the percent error of the path-
length correction factor used by the COMS relative to the correct path lenqth
correction factor calculated from actual stack or duct dimensions. The stack
exit correlation error should not exceed ±2 percent.
-------
In some cases, 1t 1s possible to measure the path length correction factor
set within the COMS control unit. As an example, pressing the stack taper
display button inside the Thermo Environmental Instruments Model 500 control
unit will display the path length correction factor on the digital front panel
meter of the unit. For the Lear Siegler RM41 opacity monitor, the path length
correction factor can be determined by removing the opacity circuit board from
the control unit and measuring the resistance of the R6 potentiometer using a
digital voltmeter or equivalent device. The value of the correction factor is
then calculated as the resistance across R6 divided by 400.
Removal of circuit boards and/or performance of internal electronic checks
should only be performed by qualified personnel. It is recommended that these
types of procedures not be attempted by control agency representatives.
Diagnostic procedures of this type are generally beyond the scope of the audit
and involve the use of equipment that may be unfamiliar to the control agency
auditor. Where applicable, procedures that involve access to the internal
electronics of the COMS are included as options in the monitor-specific
sections of this document.
2.3.2 Fault Lamp Indicators
The control unit of a typical opacity monitor has several fault lamps that
warn of monitor system malfunctions. These fault lamps are indicative of a
variety of conditions, depending on the manufacturer. Most units use fault
lamps to monitor the intensity of the optical beam, the quantity of dust on
monitor optical surfaces, and the status of internal circuitry that maintains
monitor calibration. In general, the monitor parameter indicated by a fault
lamp is out-of-specification" if the fault lamp is Illuminated. However,
monitor system malfunctions cannot be detected by fault lamps if the fault
indicator circuitry is malfunctioning or 1f there is a problem with the lamp
(i.e., missing or burned out bulb).
Many contemporary computerized data handling systems are capable of
performing a variety of self-.diagnostic tests and of displaying "error
messages," "flags," or COMS malfunctions/faults in the permanent data record.
The availability of error message outputs is dependent on both the type of
monitor and the particular software that are used. In almost all cases, the
explanation of error messages is either self-evident or can be adequately
explained by the personnel responsible for COMS operation.
2.3.3 Auxiliary Electronic Checks
Some COMS's provide access to various electronic signals or circuits which
are indicative of the monitor operational status. The output of these
diagnostic signals is usually accessed through manipulation of the monitor
control unit or data handling system. Such signals are inherently monitor-
specific and tend to reflect parameters which the manufacturer identifies as
critical to the accuracy of monitor calibration or operation. Examples of
auxiliary electronics checks are the Lear Siegler RM-41 reference signal and
the Dynatron Model 1100 lamp voltage, both of which are critical parameters in
the operation of the respective monitors. Monitor-specific procedures for the
evaluation of these parameters are provided in Sections 3 through 9 of this
manual.
2-9
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the stack exit inside diameter Is usually not possible, and blueprints showing
construction details are often not readily available at the source. The
problem associated with determining the monitor path length and stack exit
dimensions can be minimized by requesting the information in advance so that
source personnel have time to locate the appropriate documentation. The
flange-to-flange separation distance of the transceiver and reflector
components (the actual distance that separates the transceiver and the
retroreflector when they are mounted on the stack) should also be requested
This information helps to identify the majority of problems that are likely to
be encountered in the calculation of path length correction factors because the
most common mistake is the use of the flange-to-flange separation distance in
place of the stack or duct inside diameter. (The flange-to-flange separation
distance is always greater than the internal diameter of the stack or duct at
the monitoring location, and is used in establishing the proper path lenath for
SfH-StaC-' Clear-Path calibrations of thl opacity mon??or. Unless
d dlmen?10?? are obviously in error, the dimensions provided by
l t°-1d be "Sed t? calculate the path length correction factor.
e1uatlons are Provnded in the monitor-specific sections of this
The auditor must attempt to determine the value of the path lenath
tKdi?nrfaCt°K thKi \S U5ed by the COMS' Two ^Proaches may be "lid: (1)
the auditor may be able to determine the value of the correction factor preset
by the manufacturer, or (2 in some cases, the auditor may be able to directfv
measure the path length correction factor set within the COMS. <""-ectly
s sometimen»+* factor Preset by the manufacturer
Un1t or Included in the documentation
H°Wev?r' th1s '"formation is sometimes unava liable
v"alue was usJ"^ th*"' J 1$ not P°"ib1e to determine Aether the
K 1 ! ? 5ed by the monltor manufacturer. If the correction factor
the stack exiteTor~1atideSCribed be1°W' ,the aud1t reP°rt Shou1d "d?cate that
rnr™^ * * correlation error was not determined, and the path length
aud'H calculation31"13*^ ** the aUd1t°r $h°Uld be Used 1n «" «">«auent
will roL?r?r assoc^ated with th? value °f the path length correction factor
for the low mid anHeMnK°' ^^^ ?11S 1n th§ •8ln ^^erences obtained
tor the low, mid, and high range calibration error checks. (In the absence of
other problems, errors in the path length correction factor will result in
™rhe!fSh??eeiT!!rS "$+ ^creasing opacity.) When the audit results indicate
such a bias, the auditor can, as a troubleshooting technique, calculate a path
length correction factor that would provide a mean difference of zero for the
to recalculitAth. In! !UH^°rKCan then ??? th1s path Ien9*th correction factor
10 recalculate the low and high range calibration error check results. If the
systematic bias in the calibration error results is removed, it is likely that
factor NntrthatH!K!!0n^Kr ™ ^ to *? ?rror in the Path Ien9tn correction
factor. Note that when other problems with the monitor are found (e.g zero
offset, excessive span error, misalignment, etc.), use of the above calculation
procedure to evaluate errors in the path length correction factor becomes
significantly more complicated, if not impossible. Therefore, it is strongly
recommended that the other problems be resolved prior to determining lf?he
path length correction factor is incorrect.
2-8
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2.3.7 Monitor Alignment Error
The optical alignment of the transmissometer is critical in maintaining
accurate opacity measurements. Misalignment of the measurement beam can cause
erroneously high opacity readings because a significant portion of the
measurement beam is not returned to the measurement detector. Most opacity
monitor manufacturers include provisions for an optical alignment check either
as a standard feature or as an option. Monitor alignment errors are typically
observed as an off-center light beam when looking into the monitor's alignment
Sight.
2-3.8 Optical Surface Dust Accumulation
The amount of dust found on the optical surfaces of the transmissometer is
quant! fied by recording the effluent opacity before and after each exit window
is cleaned. The optical surface dust accumulation is excessive If, after
cleaning the optical surfaces, the total reduction in apparent opacity (1 e
opacity". transce1ver and reflector dust accumulation) exceeds 4 percent
resu^s of th1« check may be adversely affected by fluctuations in the
obtnth«P^^°Ver the time period re"uired to Clean the "it windows and
obtain the opacity measurements. The auditor should use caution when usina
u»? '!!^S °Pa?1ty measure"*nt* to represent the effluent opScUy; in Some
thP !ina«!r 9e ValU8S ?ay pr?v1de more representative results. In add tionTif
irt,,! i? * are Ver*. Clean when the audn 1s conducted, the auditor may
actually increase the paniculate matter on the optica surfaces rather than
decrease it. The auditor should use the following procedures:
(a) For monitors with zero reflectors (e.g., Lear Siealer RM-4 RM-41
Enviroplan CEMOP 281, etc ), the audi!or shou!d cfean the reflexive
side of the zero mirror when cleaning the transceiver window. If the
SM 1$ «Ou1PPed w1th automatic zero compensation, whenever
possible, the zero compensation should be reset after cleaning the
thasS?r™[ ±d?T a?" aS.a1" 4fter cleani"9 the zero refleaSr. If
this is not practical, the zero compensation should be reset after
cleaning both the transceiver and zero reflector windows. Resetting
™ ^H!° ""P6"53^0" between cleaning the optical surfaces provides
an independent indication of whether dust has accumulated on each of
«!«n!£IC!S\ Sln" the bias 1ntroduce
-------
2.3.4 Panel Meter Checks
of tho rnnt™? n *[* T1PP?lc)th " "J^1"9 Ol" d1SUa1 P3"*1 meter <"> the
?rancr.?»r ?L^I 5I?8 COMS*S tpt a1so e1uiPPed «1th an analog meter at the
St^n^ ^ 'hi -I*1"6 ?!ters may * useful as a ref*rence "hen making
adjustments to the monitor. The accuracy of the panel meter may be checked,
and a panel meter correction factor can be calculated for each type of
measurement which can be displayed on the panel meter (I.e., opacity and
?K denS* y f°r ""?* ""Itors and Input current signals for some monitors)
IS thf «0m-^r/OTTeCtT faftor$ are the ratl0 of th« Pane1 meter responses
to the specified values for the opacity filter, input signal, or optical
* percent (ratios
Hot.J^ S3"!1 meter correcti°n factors (scale factors) should only be
determ ned when source personnel use the panel meter to check or make
nZi ! mo? Adjustments to the COMS. It is not necessary to diterafte the
Serfo™^ hact°rs for Paralneters that are not used to assess monitor
performance by source personnel .
2.3.5 Zero and Span Errors
a as-
reouired when'th^"^^^""^^ ^J™ re9ul»«on, adjustment thCOMS i
required when the drift exceeds ±4X opacity. For sources subject to state or
]pn»IJ?qUlrenlen*S' the ac«Ptan« limits for zero and span err"s are
generally conS1stent with the applicable federal regulations.
2-3.6 Zero Compensation Limit
Some COHS's are equipped with a circuit or other means of automatically
adjusting the monitor calibration to compensate for drift in the monitor's
response to the simulated zero opacity condition. This automatic adjustment
lurf'acnr^1?:! 1S deSl9"el t0 aCCOUnt for dust 'ccumuS on the Sea
+0 ma nn wMrh r SC6-Ver Jhe accePtable limit for zero compensation is
th. i • °?'/hlcl^ 1S e3uiva1e»t to ±4X opacity. This value 1s consistent with
the limitation imposed by EPA regulations contained in 40 CFR 60 K I (d)(l":
"For continuous monitoring systems measuring opacity of emissions the
DerforinTth"5 tXpO$!!d t0 ^ effluent »««•» «h«" "e cleaned pri or to
KI^T,?9 J? and span drift adjustments except that for systems
when9thP ™a i%"r° adjusjllents- T"6 optical surfaces shall be cleaned
when the cumulative automatic zero compensation exceeds 4 percent opacity
2-10
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occurs, the auditor should reclean the optical surfaces
and recheck the effluent opacity.
(c) For all monitors, an apparent increase in the effluent opacity
after cleaning an optical surface results in a negative quantity of
accumulated dust on that optical surface. Presuming that the auditor
has recleaned the optics and rechecked the effluent opacity this
nonsensical result can be attributed to variations in the effluent
opacity. The negative result should be ignored; "negligible" dust
accumulation should be stated in the report; and 'zero- rather than
the actual negative value should be used in calculating the total
quantity of dust deposited on optical surfaces.
2.3.9 Calibration Error Checks
To perform the calibration error check, the response of the COMS to the
va°?uery?iUeS °f ^T calibrated neutral density filters is deterged
Vf the neutral density ™ters are corrected to stack °"enninea-
S *V6anS ?f the path le"9th correction factor used by the COMS )
m0nit0rS' !tis Checlc 1s Permed using an audit device thJt simulates
e~
c
T ''
« the calculated
checkl:6 f°11ow1n9 add1ti°"al procedures are applicable to calibration error
(a) For all checks performed using a reflective audit device the device
is installed on the COMS and adjusted to provide a zero response
(0-2% opacity). Each of the three filters is placed in the 1 iqht oath
five times and the response of the COMS to each filter is taken frSm
the appropriate data recording device. The calibration error resuHs
will be adversely affected if the zero value provided by the audit
mbrat±aT,KUrin9-+the.COUrSe °f the 15 "I'" -""surements
arfl,,rj- ? i monitoring location or accidentally bumping the iris
adjustment lever of the audit device can cause such a change; ttest
situations occur quite frequently.) Therefore, at a minimum the zero
tn^rJ^tf by the ?ud1t device should be recheckeS rt ™e end of
and -a~?«J °? error1test: If the difference between the "post test"
3n?i™ t "f K"^ ^alues 1s 9reater than one Per«"t opacity, the
SrJI!i, *t '^^^."PMted. It is recommended that the auditor
recheck the audit device zero value after each set of three filter
measurements to ensure that the zero value is stable. If the zero has
dnrf^dtKy more.thaVQ« Percent opacity, discard the data coll ec?ed
during the previous 3-filter test run, reset the zero to the "oretest"
value, and continue the calibration error test. This practice^'lows
2-12
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the auditor to discover a zero drift problem earlier and reduces the
number of measurements that must be repeated.
(b) For COMS's that do not allow the installation of an audit device, the
calibration error check is performed by superimposing a series of
three calibrated audit filters onto the effluent opacity (the
incremental calibration error procedure). The calculation procedure
requires that the average of "before' and "after" effluent opacity
readings be mathematically combined with the filter value 1n order to
determine the expected or "correct" response. Thus, variations in the
effluent opacity during each filter measurement will affect the
accuracy and precision of the calibration error test results Short
term effluent opacity spikes present the greatest problem. Therefore
each instantaneous effluent opacity measurement and each filter '
measurement must be obtained as quickly as possible. Two-way
communication between the monitoring location and the control unit
location is required in this situation. When using this procedure it
is advantageous for the auditor to watch the panel meter for about'lS
minutes before starting the test in order to recognize repeating
patterns of opacity fluctuations such as those caused by activation of
the rappers in the last stage of an electrostatic precipitator.
When a run of responses to the audit filters deviate from the mean by
more than 1 to 2 percent opacity, the 3-filter run in question should
-Lfor!- !«; -T~ ru"~r f1lter read1ng should also be repeated if the
before and "after effluent opacity measurements vary by more than 2
to 3 percent opacity. It is usually possible to get five reasonable
measurements of each filter within seven attempts? The decision to
When great difficulty is encountered in conducting the test, it is
appropriate to relax the calibration error specification. It is
?»?££! f K t1 Whe!ie diffifcult* 1* encountered, the confidence
interval be ignored and the ±3 percent opacity limit be applied only
to the mean difference between the expected and actual monitor
responses.
(c) For all monitors, the acquisition of a minimum of 15 filter responses
using 6-minute averages (as are recorded at many stationary sources)
is far too time consuming to be practical. Therefore, it is
recommended that the calibration error check responses be determined
from the permanent data recorder based on instantaneous measurements
or short term averages (e.g., 1-minute averages) where possible. If
the Permanent data recorder cannot display short term measurements,
the calibration error measurements can be obtained from the control
unit panel meter or by use of a temporary output device such as a
digital volt meter (DVM). To do this, two or more people must perform
the audit and communications between the control unit/data recorder
location and the transmissometer location are required. This
procedure is generally adequate for determining the accuracy and
precision of the opacity monitor. An additional check involving only
one 6-minute average response for each of the three audit filters is
2-13
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adequate to determine whether the 6-minute averaging equipment is
operating properly.
(d) Care must be exercised when handling the neutral density filters
utilized in the calibration error check. Any contamination, such as
fingerprints, dust, or moisture, can cause a positive bias in the
audit results. If any visible foreign matter is present on the audit
filters, the filters should be cleaned using lens paper and lens
cleaner. The filters should be rechecked before.each use to ensure
that no foreign matter has accumulated in the interim. The filters
should be recalibrated every six months or any time the auditor
suspects that the filter has been damaged.
2-14
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SECTION 3
3.1 LEAR SIE6LER MEASUREMENT CONTROLS - DYNATRON 1100M AND
MC2000 OPACITY MONITORS
n 1988, Lear Siegler Measurement Controls Corporation acquired the Model
muc .continuous opacity monitoring system (COMS) from Dynatron, Inc The
COMS is currently identified as the Lear Siegler Measurement cSntroU
Corporation (LSMCC) Dynatron 1100M, and is essentially identical to the 1100M
thp ovrln^nn * ^^"i ^r S^er also ™rtets the MC2000 COMS. With
the exception of the calibration mechanism, the MC2000 COMS is also identical
to the Dynatron 1100M. The audit procedures presented in this section S tn
the Dynatron 1100M, the LSMCC Dynatron 1100M, and the LSMCC MC2000 PP *
3.1.1 COMS Description
Measurement Controls Corporation Dynatron 1100M COMS
ssrs'
=taf i
fiber optics to the reference photodetector (see
~
to
acoreout Tn
.S f 1^9*?^ rSL^ J^JlTtS^R^ftffi*1"
sources. One of the light sources is filtered through a loileJel neutral
density fliter (< 10% OP) to produce the internal ze?o response The other
i%«i!iiTci?iKar" upscaie neutrai densn> ^ ^ ^
?h±^S fr°!? a«uraulatin9 condensed stack gas moisture; and (3) H min mUes
thermal conduction from the stack to the instrument. A standard instS Tation
air;Pur?in9 ^sterns for the transceiver and retrorefl ector
^
es and performs several self diagnostic functions (see Figure 3-2 ° mi°n
un ^ ^City V?lu!$ are disP]a>ed °" the digital frint panll meter of the
unit and can be output as an analog signal to a data recording device. Several
3-1
-------
MEASUREMENT AND
REFERENCE
Figure 3-1. Lear Siegler Measurement Controls Corporation Dynatron 1100M
Transmissometer
3-2
-------
lANlVWAMNmO
Opacity Monitor
Figure 3-2. Lear Siegler Measurement Controls Corporation Dynatron 1100M
Control Unit
3-3
-------
indicator lamps on the front panel of the control unit provide information
regarding the status of the COMS. Under normal operation, the "CLEAR" lamp
will be illuminated. The "ALARM" and "EARLY WARNING" lamps will illuminate if
effluent opacity levels exceed a predetermined value set within the control
unit. The "AUTO CAL" lamp will illuminate when the COMS has entered the
automatic calibration cycle, and the "WINDOW" lamp will illuminate if the dirty
window detector in the transceiver housing detects excessive dust accumulation
on the transceiver protective optics. The "FAULT DIAGNOSTICS" lamp will
illuminate if any one of a number of system faults are detected. Inside the
control unit are several switches that can be manipulated to output specific
fault information and to initiate a manual zero and upscale calibration
routine.
With the exception of the calibration mechanism, the LSMCC MC2000 is
essentially identical to the LSMCC 1100M. During the zero calibration check, a
servomotor swings a zero mirror into the path of the measurement beam. The
zero mirror intercepts the measurement beam and returns it directly to the
measurement detector. During the span calibration cycle, a span filter is
placed into the measurement beam with the zero mirror in place. Figure 3-3
presents a schematic of the transmissometer.
The 1100M and MC2000 opacity monitors measure the amount of light
transmitted through the effluent from the transceiver to the retroref lector and
back again. The COMS uses this double-pass transmittance to calculate the
optical density of the effluent at the monitor location, or the "path"
optical density. In order to provide stack exit opacity data, the path optical
density must be corrected to stack exit conditions. The correction factor is
calculated as the ratio of the stack exit inside diameter to the measurement
path length of the monitor (two times the inside diameter of the stack or duct
at the transmissometer location). Dynatron referred to this correction factor
as the M factor. Lear Siegler has traditionally referred to this factor as
the optical path length ratio" (OPLR), and the Lear Siegler Dynatron 1100M
manual refers to this factor as the "stack exit correlation ratio." The terms
M factor, OPLR, and stack exit correlation ratio are interchangeable; they all
refer to the same number. The term "stack exit correlation ratio" will be used
throughout the following audit procedures. The equations below illustrate the
relationship between the stack exit correlation ratio, path optical density,
and stack exit opacity.
SECR - - - Stack Exit Correlation Ratio
where: L, - stack exit inside diameter (ft)
L, - measurement path length (ft) - two times the
stack inside diameter (or the duct width) at
the monitor location
3-4
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TRANSCEIVER
Reference Box
Reference Beam
Beamsplitter
Zero
Reflector
PASSIVE
REFLECTOR
Calibration Motor
Light Source Reducing Lens
wMttwr cover *y*t»m •nclosures
with heel shield mounting brackets
Figure 3-3. Lear Siegler Measurement Controls Corporation MC2000 Transmissometer.
3-5
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OP, -i.io- xioo
where: OP, - stack exit opacity (%)
00 - transmlssometer optical density (path)
3.1.2 Performance Audit Procedures
Preliminary Data
2.
S^K1? h?us/?clc f?1t 1nside d1ameter and the transmissometer measurement
path length (two times the stack or duct inside diameter or width at the
S^fffJSSRSJS1?0!* and record these values 1n blanks r.3 9 he
on the 1100M/MC2000 Performance Audit Data Sheet.
Note. Effluent handling system dimensions may be acquired from the
following sources listed in descending order of reliability- (1)
physical measurements, (2) construction drawings, (3) opacity
pe0rsotn0n^rr«o]lect0?on0sr.Cert1fiCat10n d°CUIMSntS' a"d (4) SOUrce
e the stack exit correlation ratio (SECR) (divide the value in
by the value in blank 21. Record the result in blanks
3. Record the source-cited SECR in blank 4.
1s preset by the "^"^cturer using information
Tr-t^Adar«2i» 5s ^.TLrj- by
routme operation and should only be attempted by Jual If led source
b?anSkn3ekou id ho%KECR ,1S n0t dete"»ln^ directly? ?neva?uf recorded in
filanJLi should be the value source personnel agree should be set inside
the monitor. Typically, this value is cited from monitor installation
data, monitor certification data, or COM3 service reports?
4. Obtain the reference zero and span calibration values Record these
values in blank 5 and blank 6. respectively.
" oerdeTdu^^^
and span values recorded in blank 5 and blank 6 should be the reference
values recorded during the most recent cielf^pTth calibration of the COMS.
5. Go to the data acquisition system (DAS) location and Inspect the ooacitv
data recorder (strip chart or computer) to ensure proper operation
d^nVthLPaPer WUh ^ aUdU°r'S name' «"»'StlS.. pf-trSit.
3-6
-------
Fault Lamp Checks
The following section describes the fault lamps found on the front of the
COMS control unit. Unless otherwise noted, the audit analysis can continue
with illuminated fault lamps, provided that the source has been informed of the
fault conditions.
6. Record the status (ON or OFF) of the WINDOW fault lamp in blank 7.
Note: An illuminated WINDOW fault lamp indicates that the quantity of
dust on the transceiver optics has exceeded the limit set within the
control unit. If the WINDOW fault lamp is illuminated, the monitor output
may be biased high by dust on the transmissometer optics, and the auditor
should pay particular attention to cleaning the protective window during
subsequent audit steps.
7. Record the status (ON or OFF) of the FAULT DIAGNOSTICS lamp in blank 8.
Note: An illuminated FAULT DIAGNOSTICS lamp indicates that one or more
nfSrJnc??™*!0118 l?av?11beei? detected by the control unit. If the FAULT
DIAGNOSTICS lamp is illuminated, specific fault information can be output
to the front panel meter in the form of a reason code by turning the
digital thumbwheel inside the control unit to position 14 Before
rnllc1^1?? th« audit, source personnel should determine the cause of the
roue i i!" Ju aud1tor snould discuss the cause and magnitude of the
COMS fault with source personnel to determine if the audit can continue.
Zero/Span Check
8. Unlock the two front panel knobs and pull the control unit forward until
the zero/span switch is accessible. (Be careful not to pull the inner
unit out too far or it may fall out of the outer, chassis.)
9. Initiate the zero calibration mode by moving the zero/span switch to the
zero position.
10. Record the zero value displayed on the panel meter in blank 9.
11. Record the zero value displayed on the data recorder in blank 10.
Note: During the zero calibration check of the 1100M, the measurement lamp
is turned off and the zero light source is turned on. During the zero
calibration check of the MC2000, a zero mirror is moved into the path of
the measurement beam by a servomotor. The zero mechanism of each analyzer
is designed to present the transceiver with a simulated clear-path zero
The daily zero check does not test the actual clear-path zero, nor does'it
provide an indication of cross-stack parameters such as the optical
alignment of the transmissometer or drift in the reflectance of the
retroreflector. The actual clear-path zero can only be checked during
clear-stack or off-stack calibration of the COMS.
3-7
-------
12. Initiate the upscale calibration mode by moving the zero/span switch to
the span position.
13. Record the span value displayed on the control panel meter In blank 11.
14. Record the span value displayed on the data recorder in blank 12.
Note: During the span calibration check of the 1100M, the measurement lamp
is turned off and the span light source is turned on. During the span
calibration check of the MC2000, a servomotor moves a span filter into the
path of the measurement beam while the zero mirror 1s in place.
15. Return the zero/span switch to the center position. Close the control
umt and secure the latches.
16. Go to the transmissometer location.
Retroref lector Dust Accumulation Check
17. Record the effluent opacity prior to cleaning the retroref lector
protective window in blank 13.
Note: The acquisition of real-time monitor response data requires that
there be communication between the auditor at the transmissometer
location and an assistant at the opacity data recorder location.
18' 6' 1nspect' clean' and rePlace the retroref 1 ector protective
19. Record the post cleaning effluent opacity 1n blank 1*.
Go to the transceiver location. -
Transceiver Dust Accumulation Cherk
20. Record the pre-cleaning effluent opacity in blank 15.
21. Remove, inspect, clean, and replace the transceiver protective window.
22. Record the post-cleaning effluent opacity 1n blank 16.
Optical Alignment Check
mecnan1snK *m be encountered when
enrunH n t™l»J»*»«t«
-------
23. (A) Determine if the monitor is equipped with an alignment scope style
alignment mechanism. If it is, follow the procedures listed below. If it
is not, go to step 24.
(B) Activate the target light by turning on the "Target Light" toggle
switch on top of the lamp power supply.
(C) Look through the alignment sight and observe whether the beam image
is centered on the alignment reticle.
(D) Record whether the image is centered (YES or NO) in blank 17.
(E) Draw the orientation of the alignment image in the circle provided on
the COMS audit data form.
(F) Turn the "target light" toggle switch off.
(G) Go to Step 25.
V. ~ "' """ IIIW"' "Wl '•* «HU|HHCU WILII a tnrougn tne lens (MLl
a I innmanr mo *• Kiwi »•> t j: .: A. j _ .e_i T J_L • ... .._ » /
(A) Determine if the monitor is equipped with a "through the lens (TTL)B
alignment mechanism. If it.is, follow the procedures listed below If i
is not equipped with an alignment mechanism, omit the alignment analysis
and go to Step 25.
(B) Activate the TTL alignment mechanism by turning on the "lamp steady"
toggle switch on top of the lamp power supply.
(C) Look through the alignment port on the right hand side of the
transceiver and observe whether the beam image is centered on the
alignment reticle. The alignment port is located just above the
transceiver cable connectors.
(D) Record whether the image is centered (YES or NO) in blank 17.
+11 r™?Vl!e ?rientation of the alignment image in the circle provided on
the COMS data form.
(F) Turn the "lamp steady" toggle switch off.
Note: The optical alignment has no effect on the internal checks
of the instrument, or on the calibration error test; however, if the
optical alignment is not correct, the stack opacity data will be biased
high since a portion of the measurement beam will be misdirected before it
is returned to the measurement detector.
Calibration Error Check
The calibration error check is performed using three neutral density
filters and an audit device called an audit jig. When installed on the
transmissometer, the audit jig intercepts the measurement light beam
before it crosses the stack or duct and returns it directly to the
measurement detector. Performing the calibration error check on-stack
3-9
-------
27.
using the audit jig and filters determines the linearity of the Instrument
response relative to the current clear-path zero setting. This
)I C*SCk d°?s "1 dete™ne th« accuracy of the Instrument
°r*th! ftatus of an> cross-stack parameters. A true
error test Is performed by moving the on-stack components to a
amb1ent ™
In
25. Remove the transceiver dirty window detector on the left forward
*in*« ?h 5? '"""elver. Install the audit J1g by Inserting It
IrL,^ he.d1rty wind0*' detector port (with the 1r1s opening facing
toward the light source) and tightening the thumb screws.
26. Remove the transceiver protective window.
Adjust the audit J1g Iris to produce a 1-2% opacity value on the
Mttlng. re" Th1S adjustment Slmulates the f1n" that
and record the
29. Remove the transceiver protective window.
30' BSS iS6 ?an"d1Lf1^er S6r1al numbers «- °P-^y values in
> 1f
32. Record the jig zero value from the opacity data recorder.
Note: The acquisition of monitor responses from the data recorder
Sio'n aCnTaUnn1aCat^°? b,etW^Vh5 aSd1tor at the transmi slSmeter
location and an assistant at the data recorder location.
33. Insert the low range neutral density filter into the monitor.
34. Wait approximately two minutes or until a clear value has been
recorded and displayed on the opacity data recorder.
3-10
-------
Note: The audit data should be taken from a data recording/reporting
device that presents instantaneous opacity (or opacity data with the
shortest available integration period).
35. Record the COMS response to the low range neutral density
filter.
36. Remove the low range filter from the monitor and insert the mid
range neutral density filter.
37. Wait approximately two minutes and record the COMS response.
38. Remove the mid range filter and insert the high range filter.
39. Wait approximately two minutes and record the COMS response.
40. Remove the high range filter, wait approximately two minutes, and
record the jig zero value.
Note: If the final jig zero value differs from the initial value by
more than 1% opacity, the jig zero should be adjusted to agree with
the initial value and the three-filter run (i.e., low, mid, and
high) should be repeated.
41. Repeat steps 33 through 40 until a total of five opacity readings are
obtained for each neutral density filter.
42. If six-minute integrated opacity data are recorded, repeat steps
32 through 40 once more, changing the waiting periods to 13 minutes.
43. Record the six-minute integrated data, if available.
44. When the calibration error check is complete, remove the audit jig,
replace the dirty window detector and the protective window, and
close the transceiver protective housing.
45. Return to the control unit location.
46. Obtain a copy of the audit data from the data recorder.
47. Transcribe the calibration error data from the data recorder to blanks 22
through 47 of the audit data sheet and complete the audit data
calculations.
3-11
-------
3.1.3 Interpretation of Audit Results
n * Th1?,!Sct1on 1s des19ned to help the auditor interpret the Lear Siealer
Dynatron 1100M and MC2000 perfonnance'audlt results. A general dlfcuss on of
performance audit results 1s presented 1n Section 2 of this manual
Stack Exit Correlatlnn Error Check
The path length correction error in blank 48 should be within +2X Thi«
error exponentially affects the opacity readings, resulting in over- or'
Fault Lamp Analysis
that the monitor
sreitc c
Control Unit Panel Meter Error
3-12
-------
Internal Zero and Span Check
The 1100M style transmissometer internal zero is typically set to indicate
2-10% opacity. This is because the monitor will not indicate negative opacity
values. A zero error (blank 501 greater than 4% opacity is usually due to
electronic drift or data recorder electronic/mechanical offset. For the MC2000
dust accumulation on the optical surfaces may also be a source of zero error
The condition should be accompanied by an illuminated window fault lamp
Instrument span error (blank 52) may be caused by the same problems that cause
zero errors and may be identified in a similar fashion.
If the zero and span errors are due to a data recorder offset, both errors
will be in the same direction and will be of the same magnitude.
Transmissometer Dust Accumulation Check
j« AT5e results ?f the dust accumulation check (blank 55) should not exceed
4%. A dust accumulation value of more than 4% opacity indicates that the
airflow of the purge system and/or the cleaning frequency of the optical
i^tfn"5,^6 ^equate. When determining the optical surface dust accumu-
lation the auditor should note whether the effluent opacity is reasonably
if til &Thint±2% °PJc1?y> **« and tft«* cleaning the optical surfaces.
Optical Alignment Check
When the transceiver and retroreflector are misaligned, a portion of the
measurement beam that should be returned to the measurement detector is
misdirected, resulting in a positive bias in the data reported by the COMS. One
" °f
t _ . is vibration which may cause the on-
c«n rnco nf t0 ?.lft 'J1?1*1* on *he Instrument mounting flanges. Another
common cause of misalignment is thermal expansion and contraction of the
Shn J£6 on*h!ch the transmissometer is mounted. If the COMS is being audited
± nn ho""1* 1S °ff; ine Ic5!d SJadc)' the resu1ts of the Alignment analysis
may not be representative of the alignment of the instrument when the stack or
duct is at normal operating temperature.
Calibration Error Check
Calibration error results (blanks 65. 66. and 67) in excess of +3% are
indicative of a non-linear or miscalibrated instrument. However, the'absolute
calibration accuracy of the monitor can be determined only when the instrument
clear-path zero setting is known. If the zero and span data are out-of-
specification, the calibration error data will often be biased in the same
direction as the zero and span errors. Even if the zero and span errors
indicate that the COMS is calibrated properly, the monitor may still be
inaccurate due to error in the clear-path zero adjustment. The optimum
calibration procedure involves using neutral density filters during a
clear-stack or off-stack calibration. This procedure would establish the
3-13
-------
™nrctri ^ ?"-aCCUracy a?d 1inear1ty of the COMS. If this procedures is
r™ti« ik it is reasonable to assume that the clear-path zero is set
correctly, the monitor's calibration can be set on-stack using either the
neutral density filters or the Internal zero and span values
3-14
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3.2 LEAR SIEGLER MEASUREMENT CONTROLS CORPORATION
MODEL RM-41 TRANSMISSOMETER AND MODEL 611 CONTROL UNIT
The RM-41 was Lear Siegler's primary opacity monitor prior to the
acquisition of the Dynatron 1100M. The RM-41 opacity monitors were installed
when Lear Siegler Measurement Controls Corporation was called Lear Siegler, Inc
(LSI), and are generally identified as the LSI RM-41.
3.2.1 COMS Description
The RM-41 continuous opacity monitoring system (COMS) consists of three
major components: the transmissometer, the air-purging and shutter system, and
tne Model 611 control unit. The transmissometer component consists of a
transceiver unit mounted on one side of a stack or duct and a retroref lector
unit mounted on .the opposite side. The transceiver unit contains a light
source, a photodiode detector, and the optical, mechanical, and electronic
components used in monitor operation and calibration. The output signal from
.
c?nn^a?KCrver (double-Pass> uncorrected transmittance) is processed into a
signal that represents single-pass stack exit opacity by the COMS control unit.
111u?Jrit« *»» general arrangement of the RM-41 transceiver
^ units°" the stack- The RM-41 uses a modulated, dual -beam
hpH-H +Te- L1lht em1tted b* the "9ht sour« in the transceiver
head is modulated by a perforated rotating disc to make the instrument
insensitive to ambient light. The light is then split into reference and
Th«eam| which u^T on, a single P^todiode detector in a time-shared
•* ^^ beam *™** directly to the detector to produce the
t™2Si' / 6 m"s"rem!nt beam Bosses the stack (through the effluent)
the retroref lector, which returns the beam to the detector producing the
?ntafnrerent I19!*1'. T° W^te for variations in component stability (lamp
Irl nroH;jJeKtr0rnC Jttb] 1t^ etc-), the reference and measurement signals
are processed by an automatic gain control (AGC) circuit that drives the
reference signal toward a constant value and stabilizes instrument output.
The air purging system serves a threefold purpose: (1) it provides an air
window to keep exposed optical surfaces clean; (2) it protects the optical
surfaces from condensation of stack gas moisture; and (3) it minimizes thermal
L0±£°".fr0m the StaC.k t0 the inst™™t. A standard installltlon has
separate air-purging systems for the transceiver and retroref lector units Each
™
k ++ In fhLeve5t of a Partial or a complete failure of the purge air system
oDtUlaerSurfaf^dna%han JPt1«»).*«t«Mt1cmy provide protection^? thfexpSsed
optical surfaces of the transceiver and retroref lector. Whenever the purge
airflow decreases below a predetermined rate (due to blower motor failure, a
hi?H?nn th K\a 5r°ken hos^ or st^ ^er failure), the servo mechanism
holding the shutter open is deactivated by an airflow sensor installed in the
hose connecting the air-purge blower to the instrument mounting flange. Under
stack power failure conditions, the shutters are reset automatically upon
restoration of power to the blowers. However, each solenoid may have to be
reset manually under high negative or high positive stack pressure conditions
3-15
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Figure 3-4. Lear Siegler Measurement Controls Corporation RM-41 Transmissometer
3-16
-------
The control unit (Figure 3-5) converts the transceiver output to stack exit
opacity, controls the daily automatic calibration cycles, and performs several
self diagnostic functions. Many control units contain an optional integrator
circuit card which compiles the opacity data into discrete data averages. The
integration period (typically six minutes) is set by manipulating a rotary switch
on the integrator circuit card. This function will probably not be used at
facilities employing a computer to reduce and record opacity data since the
computer can perform the integration.
The opacity monitor measures the amount of light transmitted through the
effluent from the transceiver to the retroreflector and back again. The
control unit uses this double-pass transmittance to calculate the optical
density of the effluent at the monitor location, or the "path" optical
density. In order to provide stack exit opacity data, the path optical density
must be corrected to stack exit conditions. The correction factor is calculated
as the ratio of the stack exit inside diameter to the measurement path length
(two times the inside diameter of the stack or duct at the transmissometer
ocation). This ratio is called the "optical path length ratio (OPLR)" when used
in reference to the RM-41. This value is set within the control unit circuitry?
and the correction is automatically applied to the path optical density
measurements The following equations illustrate the relationship between the
OPLR, path optical density, and stack exit opacity.
k
OPLR - . optical path length ratio
*-t
L, • stack exit inside diameter (ft)
LT - measurement path length (ft) - two times the
effluent depth at the transmissometer location
OP, - (l - 10-(°PLR)(°D)] xlOO
where: OP, • stack exit opacity (%)
OD - transmissometer optical density (path)
3.2.2 Performance Audit Procedures
Preliminary Data
1. Obtain the stack exit inside diameter and transmissometer measure-
ment path length (two times the stack or duct inside diameter
or width at the transmissometer location) and record these values in
blanks 1 and 2 of the Lear Siegler RM-41 Performance Audit Data Sheet
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order of reliability:
3-17
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RM-41 VISIBLE EMISSION MONITORING SYSTEM
AM NM-41 O^TICAt
PUft«f MMM MMITT
-- "
Figure 3-5. Lear Siegler Measurement Controls Corporation RM-41 Control Unit (Model 611)
3-18
-------
(1) physical measurements, (2) construction drawings, (3) opacity
monitor installation/certification documents, and (4) source
personnel recollections.
2. Calculate the OPLR (divide the value in blank 1 by the value in
blank 2). Record the result in blank 3.
3. Record the source-cited OPLR value in blank 4.
Note: The OPLR is preset by the manufacturer using information supplied bv
the source. The value recorded in blank 4 should be the value that source
personnel agree should be set inside the monitor. Typically, this value is
cited from monitor installation data, monitor certification data, or COMS
service reports.
4' ?nth^nth? reI6K?nCf fer° and s?ar\ Calibrat1°" values. Record these values
in DianK 5 and blank 6. respectively.
S*?^.7!!"?* Va1U6S ar5 Set dur1"9 mon1tor calibration and may not be equal
«rn ™H " re"rded at installation and/or certification. Records of the
fh^iHK sPan/?lues "suiting from the most recent monitor calibration
should be kept by source personnel. If source personnel cannot site an
e^rel ^Sla^T"^^; the ^"Z aSSlgned $Pan "a?ue should be
entered in blank 6. The factory assigned span filter value is calculated
usmg data collected during the audit and the following formula :
Span value - ( 1- [ 10 ' (OPLR) (0.0.)]) x 10Q
where:
>
Span value - the factory assigned span filter value in
percent opacity
OPLR - the optical path length ratio from blank 14a
O.D. - the span filter value in optical density read
from the serial number data plate on the bottom of
the transceiver unit (blank 291.
5. Inspect the opacity data recorder (strip chart or computer) to
ensure proper operation. Annotate the data record with the
auditor s name, affiliation plant, unit, date, and time.
Fault Lamp Checks
c- i™6!/!!1]0?]?9 steps descn'be the fault lamp analysis for the Lear
Siegler Model 611 control unit. Unless otherwise noted, the audit
can continue with illuminated fault lamps, provided that the source
has been informed of the fault conditions.
3-19
-------
6. Record the status (ON or OFF) of the FILTER fault lamp In blank 7.
Note: An Illuminated FILTER fault lamp Indicates a reduction or loss of
purge air flow to the transceiver and/or retroreflector. This fault does
not preclude the completion of the audit; however, source personnel should
be notified of this condition immediately. Loss of purge air can damage the
on-stack COMS components.
7. Record the status (ON or OFF) of the SHUTTER fault lamp in blank 8.
Note: An illuminated SHUTTER fault lamp indicates that one or both of the
protective shutters has closed, blocking the optical path and preventing
measurement of effluent opacity. The performance audit can continue,
however this fault condition precludes performance of cross-stack audit
analyses relating to the retroreflector and transceiver window checks.
8. Record the status (ON or OFF) of the REF fault lamp in blank 9.
Note: An illuminated REF fault lamp indicates that the reference signal
is out-of-specification. This condition may be due to a fault in
the automatic gain control (AGC) circuit or to a fault in the associated
transceiver electronics (e.g., low line voltage, burned-out or improperly
installed lamp, etc.).
9. Record the status (ON or OFF) of the WINDOW fault lamp in blank 10.
Note: An illuminated WINDOW fault lamp indicates that the zero
compensation exceeds the maximum preset limit of 4% opacity. The zero
compensation circuit electronically corrects the monitor's opacity
responses for dust accumulation on the transceiver optics (both the
primary lens and the zero mirror). Exceeding the zero compensation
limit may bias the opacity measurement data as well as the zero and span
calibration values.
10. Record the status (ON or OFF) of the OVER RANGE fault lamp in
Oj^ fl H IN 11 .
Note: An illuminated OVER RANGE fault lamp indicates that the
optical density of the effluent exceeds the range selected on the
optical density circuit board. This condition will affect the recorded
opacity data.
Control Unit Adjustments and Checks
Note: The following checks should be performed only by source personnel or
by a qualified auditor with the approval of source personnel.
11. Open the control unit and remove the main power fuse.
12. Locate and pull the CAL TIMER circuit board inside the control unit
(see Figure 3-6). Record the position of the SI switch in blank 12.
3-20
-------
S/N
CALTfcCR r
POS M*S c
1 t c
22 c
« • C
5 24 C
OPT C
SIGNAL
ore
CALT1
POWER
C
E
c
c
g
c
E
c
E
MER & REG
SUPPLY W/AUTC
RESPONSE
FAST A
T»
SLOW f
DENSITY
PQB
1
2
3
4
S
RANGE
008
ait
046
ate
IM
^^ «
VR
> ZERO
r
i
E
c
c
c
E
OPTI
DENS
1
•iB^
X3
OPACITY
FOB
1
2
3
4
8
%
10
20
30
SO
too
RESPONSE
SLOW t
til
. E
RBE
C
E
c
E
E
OPLR (R6)l *
•^w
Al
GAL
STY
r/a-MEAaJ
1
OPA(
MWM LEVEL!
ALARM^
SET PONT ^R14C
MJGH LEVEL HR34C
ALARM I
DELAY I C
LOW LEVEL!
ALARM 1
SET FONT f—«9g[
LOWLEVELK-R25E
ALARM 1
DELAY I C
3TY AL/
•900COOI
"" SPARE
Figure 3-6.
Measurement Controls Corporation RM-41 Control Unit Circuit Boarc
3-21
-------
13. Rotate the SI switch to the sixth position, 1f necessary, and reinstall
the board.
Note: This adjustment deactivates the automatic calibration timer to
prevent the initiation of a calibration cycle during the audit. Damage to
the zero mirror mechanism may result if the mechanism is activated during
the calibration error portion of the audit.
14. Locate and pull the OPTICAL DENSITY circuit board (see Figure 3-6) Record
the position of the SI switch 1n blank 13.
15. Rotate the SI switch to the fifth position, 1f necessary, and reinstall the
board.
Note: This adjustment expands the optical density measurement
range to Its maximum to ensure that upscale audit filters can be read
during the calibration error test.
(see F1gure 3'6)- Record the posnion
the'board6 " SWUCh *° the f1fth P°s1t1on> 1f necessary, and reinstall
tri - Sl9nal frtm the contro1 un't to the
data recorder at the maximum value of 0 to 100* opacity.
18. Optional OPLR check: Measure the resistance across the R6
Potentiometer in OHMS. Divide this value by 400 and enter the
" " " ""
fuse and close the
2°' Ch0rl9lnal P°Sltion of the contro1 Un1t HEASUREMENT switch
Reference Signal
21. Turn the MEASUREMENT switch to the REF position.
22. Record the mill i amp current value displayed on the 0-30 scale of the
control unit panel meter 1n blank 16.
»f«n* ,should be With1n the
r?«Sr?J-/ ?+?*?% Value, Outs1de the 9reen band «">y Indicate
malfunction of the AGC circuit or the measurement lamp.
23. Turn the Measurement switch to the "100X OP" position.
3-22
-------
Zero Check
24. Press the Operate button on the control panel to initiate the zero mode.
CAL
Note: The green OPERATE light should go out when the zero mirror has
??n5djnu°. *!* °Ptical Path- The yellow CAL light and the green
ZERO light should become illuminated.
25. Record the zero value displayed on the panel meter in blank 17.
26. Record the zero value displayed on the data recorder in blank 18.
Note: During the zero calibration check, the zero mirror is moved into the
path of the measurement beam by a servomotor. The zero mechanism is
designed to present the transceiver with a simulated clear-path condition
I5U ^ y "r°cn?ck does ™t test the actual clear-path zero, nor does it
provide a check of cross-stack parameters such as the optical alignment of
the transimssometer or drift in the reflectance of the retroref lector The
actual clear-path zero can only be checked during clear-stack or off-stack
* 10nf the C°MS In add1t1on to siting the Instrument clekr"-
28*
n h ,*K -
path zero, the zero mechanism allows the amount of dust on the transceiver
optics (primary lens and zero mirror) to be quantified by the zero
compensation circuitry.
Zero Compensation Check
27. Turn the MEASUREMENT switch to the COMP position.
bS ^ife!3 "mPensat1on value On optical density) displayed on the
bottom scale of the control panel meter in blank 19.
ro^ The Jransc?ivfr lamP output is split into two beams: (1) the
m thpCL«a!!! whl£h Produces the reference signal within the monitor, and
l?irnr sc ?n rKmenti^am/hlch passes throu9h tne effluent. When the zero
?hl ?«n • C? lbrate P°sltion' the measurement beam passes through
Lrk to theiV6r °PtlCS; ftrikes the 2ero mirror> and is reflected directly
back to the measurement detector. The signal produced by the measurement
beam is compared with the signal produced by the reference beam; the
nf tUrUS! e? I *? !ignals is assumed to be due to the attenuation
of the measurement beam by dust on the transceiver optics and zero mirror
The monitor automatically compensates for the difference. The zero
.
Panel met- -presents this difference
29. Turn the MEASUREMENT switch to the 100% OPACITY position.
Span Check
30. Press the ZERO button to initiate the span mode.
SPAN
3-23
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31. Record the span value displayed on the control unit panel meter 1n
blank 20 (0-100% Op scale).
32. Record the span value displayed on the data recorder in blank 21.
Note: During the span calibration check, a servomotor moves a span filter
into the path of the measurement beam while the zero mirror is in place.
The span mechanism 1s designed to provide an indication of the upscale
accuracy of the COMS relative to the simulated clear-path zero.
33. Press the OPERATE/CAL button to return the monitor to the stack
opacity measurement mode. Go to the transmissometer location.
Note: The OPERATE AND CAL lamps will light to Indicate movement of
the zero mirror. The OPERATE/CAL button should not be pressed when
both the OPERATE and CAL lamps are Illuminated because the zero mirror
may stop before it has cleared the path of the measurement beam.
Retroreflector Dust Accumulation Check
34. Record the effluent opacity prior to cleaning the retroreflector
optics in blank 22.
35. Open the retroreflector housing, Inspect and clean the
retroreflector optics, and close the housing.
36. Record the post cleaning effluent opacity in blank 23.
Go to the transceiver location.
Transceiver Dust Accumulation Check
37. Record the pre-cleaning effluent opacity in blank 24.
38. Open the transceiver, inspect and clean the optics (primary lens and
zero mirror), and close the transceiver head.
39. Record the post-cleaning effluent opacity in blank 25.
Note: After the transmissometer optics have been cleaned, the zero
compensation must be reset so that it will not continue to
compensate for dust that is no longer present. This operation must
be conducted at the control unit and may involve the assistance of
source personnel.
40. Press the OPERATE button on the control unit.
CAL
41. Turn the MEASUREMENT switch to the COMP position.
42. Record the post cleaning zero compensation value in blank 26.
3-24
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43. Press the OPERATE button.
CAL
44. Turn the MEASUREMENT switch to the 100% opacity position.
Automatic Gain Control Check
45. Determine whether the green AGC LED (Figure 3-6) on the
transceiver is illuminated. Enter the AGC LED status TON or OFF)
in blank 27. '
Optical Alignment Check
46. Remove the protective cover on the transceiver mode switch located
on the bottom right-hand side of the transceiver (see Figure 3-7).
47. Turn the switch one position counter-clockwise until ALIGN can be
seen through the switch window.
48. Determine the alignment of the transmissometer by looking through the
9 P?rt (*1gure 3"7) and observing whether the beam image is in the
ar target.
49. Record whether the image is centered inside the circular target (YES
or NO) in blank 28. * v
50. Draw the orientation of the beam image in the circle provided on the data
; ™e optical alignment has no effect on the Eternal checks of the
instrument or on the calibration error test; however, if the optical
nortJnn'Vth"01 COIT8Ct» t|» stack opacity data. will be biased high since a
portion of the measurement beam will be misdirected before it is returned to
the measurement detector.
51. Turn the transceiver mode switch clockwise until OPERATE appears in
the window. Replace the mode switch protective cover.
Span Filter Check
52. Record the instrument span filter optical density value in blank 29. Record
the output current value in blank 30. These values are written on the serial
number dataplate on the underside of the transceiver
3-25
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CAPTIVE.SCREWS (3) ALIGNMENT BULL'S EYE WINDOW
FAILSAFE SHUTTER ASSY
LAMP ACCESS DOOR
FLANGE MOUNTING BOLT (3)
GUIDE RELEASE LATCH (4)
MODE SWITCH
WIRING CABLE TO
"J" BOX
\
MEASUREMENT CLEAR ADJUSTMENT
MEASUREMENT OPAQUE ADJUSTMENT
SERIAL I LABEL
Figure 3-7. Lear Siegler Measurement Controls Corporation RM-41 Transceiver,
3-26
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Calibration Error Check
The calibration error check is performed using three neutral density
filters and an audit device called an audit jig. When installed on the
transmissometer, the audit jig intercepts the measurement light beam and returns
it directly to the measurement detector. Performing the calibration error check
on-stack using the audit jig and filters determines the linearity of the
instrument response relative to the current clear-path zero setting. This
clwr^ih^ITn/^ *°?S "°* determ1ne the ?«uracy of the actual instrument
arror'tfcJ " * the status of any cross-stack parameters. A true calibration
error test is performed by moving the on-stack components to a location with
are'^i^Pd^n^hl^'i111^1"9^^6 $? ' $* ^°?er path ler)9th and Alignments
are attained, and then placing the calibration filters in the measurement beam
pa zn .
53. Install the audit jig by sliding it onto the transceiver projection
lens barrel.
54'
n°V11de °n until U 1s flush with the
mrrnr u tlten n0t t0 PUSh U 39ainst the Zero
mirror or to pinch the wires serving the zero mirror motor.
J1? 1nJ.to produce a 19'20 ** outP"t current on
COMS
Note: The junction box meter is located in a gray box mounted near the
transceiver unit. The meter allows the auditor to get the jig zero
value near the zero value on the data recorder. Thi final j g zero
adjustments should be based on readings from the data recorde?. The
rn °* °^C^ Sln« the audit
n Correction equations can account for an offset in the jig
zero. A jig zero value in the range of 0-2% opacity is acceptable.
55. Record the audit filter serial numbers and opacity values in
Planks 31. 32. and 33.
56. Remove the filters from their protective covers; inspect, and if
necessary, clean them. K
57. Record the jig zero value from the data recorder.
Note: The acquisition of monitor responses from the data recorder
requires communication between the auditor at the transmissometer
location and an assistant at the data recorder location.
58. Insert the low range neutral density filter into the audit jig.
3-27
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Figure 3-8. Lear Siegler Measurement Controls Corporation RM-41 Junction Box (J-Box)
3-28
-------
59. Wait approximately two minutes or until a stable value has been
recorded and displayed on the data recorder.
Note: The audit data should be taken from a data recording/reporting
device that presents instantaneous opacity (or opacity data with the
shortest available integration period).
60. Record the COMS response to the low range neutral density filter.
COM3 response to the mid
63.
audit jig and insert the hi
64.
the
65' rlclrd the ^^rorn9^!^1^1 "Jl1 aPProximately two minutes, and
record the jig zero value from the opacity data recorder.
from the initial value bv
!•.... j
66. rxeyeat steps DO tnrough 65 until a total of five opacity
C7 T £ ' *
*7 ^X"miwU« 1nte9rated opacity data are recorded, repeat steos
57 through 65 once more, changing the waiting periods to 13 mtnutes
68. Record the six-minute integrated data.
69'
Ca11?ra^on -error che(* " complete, remove the audit jig
b°X> and close the
Zero Compensation Check
71. Turn the MEASUREMENT switch to the COMP position
3-29
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72. Record in blank 34 the zero compensation value (in optical density) from
the bottom scale (-0.02 to +0.05 O.D.) of the control unit panel meter.
73. Return the monitor to the operate mode by pressing the OPERATE/CAL
button.
Control Unit Adjustment Reset
74. Return the CAL TIMER, OPTICAL DENSITY and OPACITY board SI switches,
and the MEASUREMENT switch to their original positions as recorded
in blanks 12. 13, 14. and 15.
75. Obtain a copy of the audit data from the data recorder.
76. Transcribe the calibration error responses from the data record into
blanks 35 through 60 and complete the audit data calculations.
3.2.3 Interpretation Of Audit Results
nu This section is designed to help the auditor interpret the Lear Siegler
RM-41 performance audit results. A general discussion of performance audit
results is presented in Section 2 of this manual.
Stack Exit Correlation Error
The path length correction errors in blanks 61 and 6? should be within +2%
This error exponentially affects the opacity readings, resulting in over- or"
?U nSfS1**^?11 °f th? S£ack ex1t °Pac1tv- The "ost common error in computing
the OPLR is the use of the flange-to-flange distance in place of the stack or
duct inside diameter at the monitor location. This error will result in
under-estimation of the stack exit opacity and can be identified by comparing
the monitor optical path length to the flange-to-flange distance. The flange-
to- flange distance should be greater by approximately, two to four feet.
Fault Lamp Analysis
Fault lamps are typically associated with parameters that the monitor
manufacturer feels are critical to COMS function and to the collection of valid
opacity data. The parameters associated with each of the Model 611 control unit
fault lamps is discussed in the audit procedures. With the exception of lamps
that warn of elevated opacity levels (alarm or warning lamps), an illuminated
fault lamp indicates that the COMS is not functioning properly.
Control Panel Meter Error (Optional)
The accuracy of the control panel meter is important at sources using the
meter during monitor adjustment and calibration. The accuracy of the control
unit panel meter is determined by comparing the zero and span reference values
to the panel meter output recorded during the COMS calibration check. Errors in
the control panel meter should not affect the opacity data reported by the
3-30
-------
monitoring system unless the control panel meter is used to adjust the
calibration of the COMS. The percent error values associated with the control
panel meter are found in blanks 64 and 66. At sources using the panel meter
data, the panel meter should be adjusted so that the error is less than 2%
Since the control panel meter error is calculated using the span filter, any
change in the specified values for the span filter will cause an erroneous
assessment of the control panel meter errors. The span filter value may change
due to aging, replacement, etc. Each time the monitor is thoroughly calibrated
the internal span filter should be renamed and new specified values for the
optical density and output current should be recorded and used in all subsequent
adjustments.
Reference Signal Error Check
The reference signal is an indicator of the status of the automatic gain
control circuit, the measurement lamp, the photodiode detector, and/or the
preamplifier. A reference signal error (blank 63) greater than 10% is
indicative of a malfunction in one of these component systems. Since the
reference signal is critical to maintaining the accuracy of the transmissometer
Cea
Internal Zero and Span Check
prrnrc "!? should •* set to Indicate 0% opacity. A zero
error (blank 65) greater than 4% opacity is usually due to excessive dust
JS3±-1/n °K the ?ptiSal surfac"' ^ctronic drift? or data recorder
electronic/mechanical offset. Excessive dust on the optical surfaces sufficient
rln S%- S19niricant "re ^ror will be accompanied by an elevated zlro
tSSlSr.Urt^lS11^ i"Uinil?ated WINDOW ?ault li- A malfunction of the
reference ^1!?*™* resu]tln9 ™ » zero error should be accompanied by a
^m! nrnhifl?^ ? ^ Instrument span error (blank 67) may be caused by the
same problems that cause zero errors and may be identified in a similar fashion
A span error may also be caused by an inaccurately named span fi Her value!
uHii if *he *ero and span errors are due to a data recorder offset, both errors
will be in the same direction and will be of the same magnitude.
Zero Compensation Check
The amount of zero compensation needed to compensate for dust on the
SlcSrSnsJtv^f oSHmpd "?H eX"ed 4% °pacity' «PP«x1-«tely equivalent to an
28 anJ 7n i yi2 ;°18* The 2ero compensation values recorded in blanks 68.
fhlOFind^r ?pnt°h teXC6ed ±
-------
conditions), the Internal zero will also have been adjusted to read 0% opacity.
This will offset the zero in the negative direction. Under these conditions,
the internal zero and the zero compensation circuit should be readjusted after
the optics are cleaned. '
Optical Alignment Check
When the transceiver and retroreflector are misaligned, a portion of the
measurement beam that should be returned to the measurement detector is
misdirected, resulting in a positive bias in the data reported by the COMS. One
of the most common causes of misalignment is vibration which may cause the on-
stack components to shift slightly on the instrument mounting flanges. Another
common cause of misalignment is thermal expansion and contraction of the
structure on which the transmissometer is mounted. If the COMS is being audited
while the unit is off-line (cold stack), the results of the alignment analysis
may not be representative of the alignment of the instrument when the stack or
duct is at normal operating temperature.
Transmissometer Dust Accumulation Check
nnar Jv8 TU^ °f the, *"?* accumulation check (blank 73) should not exceed 4%
a?rf nw'nAhUSt accumuljtion value of more than 4% opacity indicates that the
airflow of the purge system and/or the cleaning frequency of the optical
' "
Uonth-^ srfacdust mu-
lation, the auditor should note whether the effluent opacity is reasonably
th! I Iff rUJ1n ** °P?C1^> ™*™ and after cleaning tSe opt ca™su?f tees. If
* ^ tt» ±2%, the dust accumulation
Calibration Error Check
lMtlf,v (t)1a"ks 83- a« '•" ««) in excess of +3% are
h«t?«n »°»-li"«r or mlscallbrated Instrument. However, th! absolute
lr-lllh «™Ura&™ the»°n1t°r can be determined only when the instrument
cnHf?«tta indicate
Irrnr ?n t?^ ,i cilibrattd properly, the monitor may still be Inaccurate due to
?^i " clear-path zero adjustment. The optimum calibration procedure
«^«t%^in9Th-Utra1 drs1ty fllter3 dur1n9 * d«r-stack or off "stack COMS
calibrate. This procedure would establish both the absolute calibration
accuracy and linearity of the COMS. If this procedure is impract caT and it is
aSKUme ?hat the 51eai-P>th zero is set correctly, the monitor's
filters or the
3-32
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3.3 LEAR SIEGLER MEASUREMENT CONTROLS CORPORATION MODEL RM-4 OPACITY COMS
+k DIh?,RM"^WaLL!ar S1e9ler's primary opacity monitor before being updated to
the RM-41. The RM-4 opacity monitors were installed when Lear Siegler
Measurement Controls Corporation was called Lear Siegler, Inc. (LSI) and are
generally identified as the LSI RM-4.
3.3.1 COMSDescriotion
The RM-4 continuous opacity monitoring system (COMS) consists of three
comP°nenJs: the transmissometer, the air-purging and shutter system, and
the remote control and data acquisition system. The transmissometer cons sts of
unit m«nnt»HrnUnth mounted °" °"e sid* °f the stack or duct and a retroref lector
™,,Lo ed. ?n^h! °PP°slte Sld«- The transceiver unit contains a light
r«I f Photodiode detector, and the optical, mechanical, and electronic
components used in monitor operation and calibration. The output signal from
tt»t transceiver (single-pass, optical density) is transmitted to the contro?
il]ustrates the general arrangement of the transceiver and
n h"-tS °n "»*«*• The KM'* ««s » modulated, dua beam
«lit ?n?0qrofp.p19ht 631tted "y the il9ht source in ihe transceiver
* reerence and measurement beams before being modulated bv a
the 1sjht beams "^es the Instrument
omtnh,
^ + amblejt 1^t- Tl)e reference beam travels directly to the
UCe Si9na1' The «««^«nt beam
tavel cr«S nsh ' e ««««n eam
returnl thl bL» L J^ M*hT9Vhe •J"'""*) to th« retroref lector which
rom^f ,+ < the detector to produce the measurement signal . To
compensate for component instability (lamp Intensity, electronic nstabi 11 ty
Pr°""ed by an »«tmatc gain
the reference Slgnal toward a constant
air
^
the t™sci1v.r and retro?eflecaor unUs Each
'
In the event of partial or complete failure of the purge air
, ,
?: s-^rrj sa.y.sras'j: ssst, "Hr
instruBent mounting flange. Under stack power failure c^diU^sTth8 shutters
are reset automatically upon restoration of power to the blowe?s? However each
ItleT.''4 manUal1y ^ ^ "^ " ^ """«
3-33
-------
t«fleecor Unit
Figure 3-9. Lear Siegler Measurement Controls Corporation RM-4 Transmissometer
3-34
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The converter control unit converts the transceiver output to stack exit
opacity, controls the daily calibration cycles, and can be used to perform
several self diagnostic functions. The converter has a calibration mode switch,
fault lamps, and a measurement parameter and scaling switch. The measurement
and mode switches allow the automatic gain control (AGC) current, the zero
value, and the span value to be checked. A potentiometer mounted on the
converter front panel permits the adjustment of the optical density zero value
to compensate for minor dust accumulation on transceiver optics.
•
The opacity monitor measures the amount of light transmitted through the
effluent from the transceiver to the retroref lector and back again. The
transceiver calculates the optical density of the effluent at the monitor
location, or the "path" optical density. In order to provide stack exit opacity
data, the path optical density must be corrected to stack exit conditions. The
correction factor is calculated as the ratio of the stack exit inside diameter
to the measurement path length of the monitor (two times the inside diameter of
the stack or duct at the transmissometer location). This ratio is called the
"optical path length ratio" (OPLR) when used in reference to the RM-4. The
following equations illustrate the relationship between the OPLR, path optical
density, and stack exit opacity.
L,
OPLR - - - optical path length ratio
^
where: Lx - stack exit inside diameter (ft)
L, - measurement path length (ft) - two times the
stack inside diameter (or duct width)
at the transmissometer location >
OP. -|l - 10 -(OPLR) (00)] X10Q
where: OPX « stack exit opacity (%)
OD - transmissometer optical density (path)
3.3.2 Performance Audit Procedures
Preliminary Data
1. Obtain the stack exit inside diameter and the transmissometer path length
(two times the stack or duct inside diameter or width at the transmis-
someter location) and record these values in blank 1 and blank 2 of the
RM-4 audit data sheet. -
Note: Effluent handling dimensions may be acquired from the following
sources listed in descending order of reliability: (1) physical
measurements, (2) construction drawings, (3) opacity monitor installation
or certification documents, and (4) source personnel recollections.
3-35
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2. Calculate the OPLR (divide the value 1n blank 1 by the value In
blank 21. Record the result 1n blank 3.
3. Record the source-cited OPLR value 1n blank 4.
Note: The OPLR 1s preset by the manufacturer using Information supplied by
the source. The value recorded In blank 4 should be the value source
personnel agree should be set Inside the monitor. Typically, this value
is cited from monitor installation data, monitor certification data, or
from COMS service reports.
4. Obtain the reference values that the monitor should measure for the daily
zero and span calibrations. Record these values in blank 5 and blank 6.
respectively.
Note: These values are set during monitor calibration, and may not be
equal to values recorded at installation and/or certification. Records of
the zero and span values resulting from the most recent clear-path
calibration should be kept by source personnel. If source personnel
cannot cite an updated span reference value, the factory assigned span
value should be entered in blank 6. The factory assigned filter value is
calculated using data collected during the audit and the following
formula:
Span value - (1- [ 10 -
-------
6. Record the status (ON or OFF) of the FAULT fault lamp In blank 7.
Note: An Illuminated FAULT fault lamp Indicates that the transceiver AGC
current has fallen below 10 milliamps. This condition indicates a
malfunction of the measurement lamp, a chopper motor failure, or a fault
in the reference signal circuitry. This fault should be repaired before
the audit is continued.
7. Record the status (ON or OFF) of the OVER RANGE faulflamp in blank 8.
Note: An illuminated OVER RANGE fault lamp indicates that the optical
density of the effluent exceeds the range selected on the optical density
circuit board, which in turn affects the recorded opacity data If this
fault lamp remains illuminated for an extended period of time, switch to a
higher optical density range.
Control Unit Configuration Check
8' Sdinhb1ank99na1 P°Slti°n °f ^ MEASUREMENT Sw1tc" °" the control unit
Zero Check
9. Turn the MEASUREMENT switch to the 20% OPACITY position.
10' tnTzert U2SeE.SWltCh °n *"* C0ntro1 P8ne1 t0 the ZERO position to 1nitiate
11. Record the zero value displayed on the panel meter in blank 10.
12. Record the zero value displayed on the opacity data recorder in blank 11.
thh the "r0 "Iibra^°" check, the zero mirror is moved into the
path of the measurement beam by a servomotor. The zero mechanism is
designed to present the transceiver with a simulated clear-pa?h condition
I™ A y «r°chSck does not test the actual clear-path zero, nor does it
provide a check of cross-stack parameters such as the optical alignment of
the transmissometer or drift in the reflectance of the retroreflector
Sck'callbrat^o'nTthe61"?^" "ly ** ^^ d"r1n9 c1e""stack » '<*<-
Span Check
13.. Turn the MEASUREMENT switch to the 100% OPACITY position.
14. Turn the MODE switch to the CALIBRATE position.
15. Record in blank 12 the span value displayed on the control
pane meter (0-100% Op scale). Record the span value displayed on the
opacity data recorder in blank 13.
3-37
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16. Turn the MEASUREMENT switch to the OPACITY INPUT position (optional).
17. Record the control panel meter value displayed on the 0-20 mill lamp scale
1n blank 14.
18. Return the MEASUREMENT switch to the 100% OPACITY position.
19. Return the mode switch to the OPERATE position.
Note: During the span calibration check, a servomotor moves a span filter
into the path of the measurement beam while the zero mirror is in place.
The span mechanism is designed to provide an indication of the upscale
accuracy of the COMS relative to the simulated clear-path zero.
20. Go to the transmissometer location.
Retroreflector Dust Accumulation Check
21. Record the effluent opacity prior to cleaning the retroref1ector optics in
blank 15. Y
22. Open the retroreflector housing, inspect and clean the retroreflector
optics, and close the housing.
.23. Record the post-cleaning effluent opacity in blank 16.
Go to the transceiver location.
Transceiver Dust Accumulation Check
24. Record the pre-cleaning opacity 1n blank 17.
25. Open the receiver head, Inspect and clean the optics (primary lens and
zero mirror), and close the transceiver head.
26. Record the post-cleaning effluent opacity 1n blank 18.
Note: After the transmissometer optics have been cleaned, the zero offset
adjustment must be reset manually so that it will not continue to
compensate for dust that is no longer present. This operation must be
conducted at the control unit. To do this, place the mode switch in the
ZERO position and the measurement switch in the 20% OPACITY position.
Adjust the OFFSET potentiometer on the front of the control unit until
zero is read on the data recorder. Return the Mode and Measurement
switches to their original positions.
Fault/Test Check
27. Press the transceiver Fault/Test momentary-action switch and record the
mill lamp value displayed on the transceiver mil11 amp meter (0-20 mA) in
blank 19.
3-38
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Note: This combination indicator and momentary- act ion switch serves two
related functions: (1) when the current associated with the AGO circuit
falls below 10 milliamperes, the FAULT indicator becomes illuminated.
This condition will occur only if the light source burns out, the chopper
motor falls out of synchronous speed, or some other fault condition occurs
that causes the reference signal to fall below a preset level, and (2) a
fau t indication (closure) is transmitted on lead 6 to the remote control
SSflETS; Jfhen^he n™entary-action switch is pressed, the milliamp
meter indicates the current associated with the AGC circuit. This current
should be between 11 and 16 milliamperes. current
Optical Alignment Check
28'
oh!!™-"6 tuM?0ni'*2r ?lia-nraent DV Coking through the viewing port and
observing whether the beam image is in the circular target.
1$ centered 1nside the circular target (YES OR NO)
3°* fo™.the °rientation of the Deam 1ma9e in the circle provided on the data
Note: The optical alignment has no effect on the internal checks of the
lllaSS011 °? the Cal1bratio" e™ test; however? ?f the optical
alignment is not correct, the stack opacity data will be biased hi ah
retnuCrnedPt°nrttH0n °f thi •»•"«* beam will be misdirected be?or 9it is
returned to the measurement detector.
Span Filter Data
vaiue
Calibration Error C
filtprh^alf!br;!i-?nHerr0r chf?kJs Performed ^ing three neutral density
niters and an audit device called an audit jig. When installed on the
["sr^th^
.,*
-------
Note: The audit device will not slide on until it is flush with the
monitor. Care should be taken not to push it against the zero mirror
reflector or to pinch the wires serving the zero mirror motor.
33. Adjust the audit jig iris to produce a 2.0 mA output current on the front
panel meter. This simulates the clear-path zero setting of the COMS.
Note: This allows the auditor to obtain a jig zero value near the zero
value on the opacity data recorder. The final jig zero adjustments should
be based on readings from the data recorder. The jig zero does not have
to be exactly 0% opacity since the audit filter correction equations can
account for an offset in the jig zero. A jig zero value in the range of
0-2% opacity is acceptable.
34. Record the audit filter serial numbers and opacity values in blanks 22,
23. and 24. *•
35. Remove the filters from their protective covers, inspect, and, if
necessary, clean them.
36. Record the jig zero value from the opacity data recorder.
Note: The acquisition of monitor responses from the opacity data recorder
requires communication between the auditor at the transmissometer location
and an assistant at the data recorder location.
37. Insert the low range neutral density filter into the audit jig.
38. Wait approximately two minutes or until a clear value has been recorded
and displayed on the data recorder.
Note: The audit data should be taken from a data recording/reporting
device that presents instantaneous opacity (or opacity data with the
shortest available integration period).
39. Record the COMS response to the low range neutral density filter.
40. Remove the low range filter from the audit device and insert the mid-
range neutral density filter.
41. Wait approximately two minutes and record the COMS response to the mid
range neutral density filter.
42. Remove the mid-range filter from the audit jig and insert the high range
filter.
43. Wait approximately two minutes and record the COMS response to the high
range neutral density filter.
44. Remove the high range filter, wait approximately two minutes, and record
the jig zero value.
3-40
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Note: If the final jig zero value differs from the initial value by more
than 1% opacity, the jig zero should be adjusted to agree with the initial
value and the three-filter run (i.e., low, mid, and high) should be
repeated .
45. Repeat steps 37 through 44 until a total of five opacity readings are
obtained for each neutral density filter.
46. If six-minute integrated opacity data are recorded, repeat steps 36
tnrough 44 once more, changing the waiting periods to 13 minutes.
47. Record the six-minute integrated data.
Note: In order to acquire valid six-minute averaged opacity data, each
filter must remain in the jig for at least two consecutive six-minute
thl1^?; The f'rst ?e!:iod w111 be invalid because ^ was in progress when
the filter was inserted. A waiting period of 13 minutes is recommended
48. When the calibration error check is complete, remove the audit jig close
the transceiver panel cover, and close the transceiver head?
Zero Current Check (Optional)
Note: This is an optional check to evaluate the zero signal from the
transceiver which is unaffected by the zero offset circuitry The offset
potentiometer on the front of the converter unit is used to comoensate for
minor variations in the instrument zero due to lens dusting. P
49' ?hiU3a«
-------
underestimation of the stack exit opacity. The most common error In computing
the OPLR is the use of the flange-to-flange distance in place of the stack or
duct inside diameter at the monitor location. This error will result in under-
estimation of the stack exit opacity and can be identified by comparing the
monitor optical path length to the flange-to-flange distance. The flange-to-
flange distance should be greater by approximately two to four feet.
Fault Lamp Analysis
•
Fault lamps are typically associated with parameters that the monitor
manufacturer feels are critical to COMS function and to the collection of valid
opacity data. The FAULT fault lamp will become illuminated if the current
associated with the automatic gain control (AGC) circuit is out-of-
specification. The most likely causes of an AGC fault are a burned out
measurement light source, a chopper motor failure, or a fault in the AGC
circuitry. Source personnel should repair the fault before continuing the
audit. The OVER RANGE fault lamp Indicates that the opacity monitor is being
presented with opacity values that exceed the range setting of the instrument.
Although an over range condition will adversely affect the opacity data, it is
not necessarily indicative of a COMS malfunction. An over range condition can
be corrected by resetting the instrument range.
Control Panel Meter Error (Optional)
The accuracy of the control panel meter is important at sources using the
meter during monitor adjustment and calibration. The accuracy of the control
unit panel meter is determined by comparing the zero and span reference values
to the panel meter output recorded during the COMS calibration check. Errors in
the control panel meter should not affect the opacity data reported by the
monitoring system unless the control panel meter 1s used to adjust the
calibration of the COMS. At sources using the panel meter b!ata, the panel meter
should be adjusted so that the error is less than 2%. Since the control panel
meter error is calculated using the zero and span values, any change in these
values will cause an erroneous assessment of the control panel meter errors.
The span filter value may change due to aging, replacement, etc. Each time the
monitor is thoroughly calibrated, the internal zero and span values should be
renamed and the new values should be recorded and used in all subsequent
adjustments.
Internal Zero and Span Check
The RM-4 internal zero (blank 54) should be set to indicate 0% opacity. A
zero greater than 4% opacity is usually due to excessive dust accumulation on
the optical surfaces, electronic drift, or data recorder electronic/mechanical
offset. Excessive dust on the optical surfaces sufficient to cause a
significant zero error may also be indicated by an elevated zero offset reading.
If the zero and span errors are due to a data recorder offset, both errors
will be in the same direction and be of the same magnitude.
3-42
-------
Optical Alignment Cheek
When the transceiver and retroreflector are misaligned, a portion of the
measurement beam that should be returned to the measurement detector is
«J til6™ ?' resultln9 in a positive bias in the data reported by the COMS. One
of the most common causes of misalignment is vibration which may cause the on-
stack components to shift slightly on the instrument mounting flange! Another
s?™?,,^6 tT^9?1"6"1 ^s then"al exP»«ion and contraction of {he
!h«f *[ on.which the transmissometer is mounted. If the CONS is being audited
while the unit is off-line cold stack), the results of the alignment analvss
may not be representative of the alignment of the instrument whin the sUck or
duct is at normal operating temperature.
Transmissometer Dust Accumulation Check
onarit! T 5 *S ^ dust »««™ulat1on check (blank 601 .should not exceed 4%
a?rf1ow'of thUSt accumu1at1on value »f ^re than 4X opacity indicates that the
airflow of the purge system and/or the cleaning frequency of the optical
eSthar%,1,HateqUaie-1,When dete"»1n1"9 the optical surface dust accL-
, ^aUdl^r should note whethe'- the effluent opacity is reasonably
i^ihln*±2% °Pacity) before and after cleaning the opt cal surfaces
Calibration Error
d?rect on as th^^rn Hatl°n err°r data w111 often be biased <» the same
u$1n9 either the neutra1
3-43
-------
-------
SECTION 4
PERFORMANCE AUDIT PROCEDURES FOR THE DYNATRON OPACITY MONITOR
4.1 DYNATRON MODEL 1100 TRANSMISSOMETER
Model iinoM hv MHO • u?9rad*d the Model 1100 visible emissions monitor
i Model 1100M by redesigning the control unit and adding an alignment
to the transceiver component on the stack. In 1988, Lear Siegler
ement Controls Corporation acquired the 1100M from Dynatron, Inc Audit
Dvn^trnne?innM tb* ^^ 1100M Ind the Lear Siegler Measurement Controls
Dynatron 1100M are included in Section 3 of this document. ^rois
4.1.1 COMS Description
rnnc « Mo*el U°° continuous opacity monitoring system (COMS)
svctlf JH ^ m?J°r comP°nent^ the transmissometer, the air- purging
system, and the control unit. The transmissometer component consists of a
transceiver unit mounted on one side of a stack or duct and a
vsr^j
?Ee±ire fT taccum"lati"9 on the protective windows; and (3) Umfn1m*zes 9
thermal conduction from the stack to the instrument. A standard instal
has separate air-purging systems for the transceiver and retroref ector
. P^«"/»«lt lamps warn of monitor malfSons. Asel ector
?f the,.settln9 of the automatic calibration frequency, and a zlro/soan
rontrn! T ^e mon tor to be put into a manual calibration mode ThT
control unit can provide both instantaneous and integrated stack «u opacity
4-1
-------
LIGHT SOURCE
AND PHOTO
ELECTRIC
DETECTOR
AIR PURGE
SYSTEM
STACK OUTLET
L
J
LIGHT IEAM
r
SMOKE OR OUST
REFLECTOR
AIR PURGE
SYSTEM
•ASIC MONITORING SYSTEM
WEATHER
COVERS
QUICK
DISCONNECT
CABLE KITS
FIELD
INSTALLATION
SUPERVISION
DIGITAL
DISPLAY
ANALOG
DISPLAY
DATA
RECORDER
EPA
ZERO
SPAN
CHECK
STRIP
CHART
RECORDER
REMOTE
OPERATOR
STATIONS
STACK
EXIT
OUTPUT
CORRELATOR
OPTIONAL ACCESSORIES
Figure 4-1. Dynatron Model 1100 OEMS Components
4-2
-------
The Dynatron opacity monitor measures the amount of light transmitted
through the effluent from the transceiver to the retroref lector and back
again. The monitor uses this double-pass transmittance to calculate the
optical density of the effluent at the monitor location, or the "path"
optical density. In order to provide stack exit opacity data, the path optical
rSr«MSt ?K corr"ted ,to stack exit conditions. The correction facto? is
IK atelaV5? ratl
-------
3. Record the source-cited M Factor value 1n blank 4.
Note: The N Factor 1s preset by the manufacturer using Information
supplied by the source. The value recorded 1n blank 4 should be the value
source personnel agree should be set Inside the monitor. Typically, this
value 1s cited from monitor Installation data, monitor certification data,
or from COMS service reports.
4. Obtain the reference zero and span calibration values. Record these
values 1n blank 5 and blank 6. respectively.
Note: The reference zero and span calibration values may not be the same
as the values recorded during Instrument Installation and/or certifica-
tion. The zero and span values recorded In blank 5 and blank 6 should be
the reference values recorded during the most recent clear-path
calibration of the COMS.
5. Inspect the opacity data recorder (strip chart or computer) to ensure
proper operation. Annotate the paper with the auditor's name,
affiliation, plant, unit, date, and time.
Fault Lamp Checks
The following steps describe the fault lamps analysis for the Dynatron
Model 1100 control unit. Unless otherwise noted, the audit analysis can
continue with illuminated fault lamps, provided that the source has been
informed of the fault conditions.
6. Record the status (ON or OFF) of the LAMP fault lamp 1n blank 7.
Note: An illuminated LAMP fault lamp Indicates that the intensity of the
measurement lamp is outside of a specific range. This fault is a
conservative indicator of possible fluctuations 1n the lamp voltage.
Because the LAMP fault lamp 1s obscured by the control unit cover frame,
it is frequently overlooked during cursory inspections. Source personnel
should determine the severity of this fault before the audit is continued.
7. Record the status (ON or OFF) of the WINDOW fault lamp in blank 8.
Note: An illuminated WINDOW fault lamp indicates that the quantity of
dust on the transceiver optics has exceeded the limit preset within the
control unit. The opacity data may be biased high by excessive dust on
the optics and the auditor should pay particular attention to cleaning the
protective window during subsequent audit steps.
8. Record the status (ON or OFF) of the AIR FLOW lamp in blank 9.
Note: An illuminated AIR FLOW fault lamp indicates a reduction in the
flow of purge air to either the transceiver or retroreflector. This
condition could jeopardize both the cleanliness of the transmissometer
optics and the continued operation of the COMS as a result of
4-4
-------
exposure to hot, corrosive stack gas. Plant personnel should be
notified of this condition immediately.
9* 5?52rd,th? or|9inal Position of the AUTOMATIC CALIBRATION TIME (CYCLE
TIME) knob on the control unit panel in blank 10.
M?e:* II!6 *UTOMATIC CALIBRATION TIME (CYCLE TIME) knob is used to
adjust the frequency of calibration cycles.
10.
11. Record the original position of the METER DISPLAY knob on the control
panel in blank 11.
Note: The METER DISPLAY knob controls the pane] meter output. Stack exit
Ca",,be ^tp^ in percent opac1ty or 1n ""<*« <>f optical
12. Turn the METER DISPLAY knob to the opacity position, if necessary.
Zero Span
13. Press the zero/span switch.
Note: The green zero light should go on during the zero period and the
? be 1U dr1"9 the Span per"d The "onnor
fronl zero to span after approximately three
" the Span m°de' the "">""" reverts
14. Record the zero value displayed on the panel meter in blank 12.
15. Record the zero value displayed on the data recorder in blank 13.
zer? 1s sil»»1ated by the transceiver internal zero
rri* measurelBent "*t »urct is turned off and a zero light
r££V KUTd °?:. Assum1n9 that the clear-path zero setting s
correct, checking this simulated zero value provides an indication of the
accuracy of the monitor's calibration. It does not, however provide
*2?o12tt1^02r0thSr0$tS-$t?Ck,piriliet'rs' SUch " the Sl'cPer r-Jath
zero setting or the optical alignment of the transmissometer.
16. Record the span value displayed on the control panel meter in blank 14.
17. Record the span value displayed on the data recorder in blank IS.
Note: During the span portion of the calibration cycle, the measurement
III* 1^" 1$ turned °*Vnd the span """t sour« is illuminated? Th
span light source passes through a neutral density filter to provide an
upscale check of the monitor's accuracy with respect to its zero seu'ng
4-5
-------
18. Go to the transmissometer location.
Note: The acquisition of real-time monitor response data requires that
there be communication between the auditor at the transmissometer location
and an assistant at the opacity data recorder location.
Retroref1ector Dust Accumulation Check
19. Record the effluent opacity prior to cleaning the retroreflector
protective window in blank 16.
20. Remove, inspect, clean, and replace the retroreflector protective
window.
21. Record the post-cleaning effluent opacity in blank 17. Go to the
transceiver location.
Transceiver Dust Accumulation Check
22. Record the pre-cleaning effluent opacity in blank 18.
23. Remove, inspect, clean, and replace the transceiver protective window.
24. Record the post-cleaning effluent opacity in blank 19.
0
Optical Alignment Check
25. If an alignment tube is available, determine the monitor alignment by
looking through the tube and observing whether the image of the
measurement beam is centered around the retroreflector port on the
opposite side of the stack or duct. Always wear safety glasses when
performing this step of the audit.
Note: The Dynatron Model 1100 does not have a built-in alignment check
system. Many sources have installed sighting tubes near the transceiver
to observe the orientation of the measurement beam with respect to the
retroreflector port in the stack or duct. Frequently, these sighting
tubes are blocked with accumulated particulate. The auditor should note
such a condition, if found.
26. Record in blank 20 whether the beam image is centered around the
retroreflector port (YES or NO).
27. Draw the orientation of the retroreflector port in the circle provided on
the CONS audit data form.
Note: Instrument optical alignment has no effect on the internal checks
of the instrument or on the calibration check using the audit jig;
however, if the optical alignment is not correct, the stack opacity data
will be biased high since a portion of the measurement beam will be
misdirected before it is returned to the measurement detector.
4-6
-------
Calibration frror Check fJlo Procedure)
The calibration error check is performed using three neutral density
filters and an audit device called an audit jig. When installed on the
b3SE1S05ttrt ^ aUd1Vig ]»tfrcipt. ">e measurement light beSm
before it crosses the stack or duct and returns it directly to the
measurement detector. Performing the calibration error check on-stack
using the audit jig and filters determines the linearity of the instrument
response relative to the current clear-path zero setting. Thif «libra-
tion error check does not determine the accuracy of the actua c"ar-oath
0r,tl?e StaSus of "V cross-stack parameters A true P
"k-1S,per!?nned by mov1n9 the on-stack components to a
-rainilnal amt>1ent Opac1ty' mak1n9 sure that the proper path
P
"* n
If the audit jig is not available, or if the jig cannot be installed in
3tt
th! trans«'ve«- Protective "ndow 2f tte effluent
^^
28. Remove the transceiver dirty window detector on the left forward side nf
29. Remove the transceiver protective window.
30. Adjust the audit jig iris to produce a 1-2% opacity value on the
opacity data recorder. This adjustment simulStesVSSs0"
. s ausment simultess] ear- path zero
' '
th.t
31 • 1 W1ndow and record
32. Remove the transceiver protective window.
4-7
-------
33. Record the audit filter serial numbers and opacity values in
blanks 22. 23. and 24.
34. Remove the filters from their protective covers, inspect, and, if
necessary, clean them.
35. Record the jig zero value from the opacity data recorder.
Note: The acquisition of monitor response from the data recorder
requires communication between the auditor at the transmissometer
location and an assistant at the data recorder location.
36. Insert the low range neutral density filter Into the monitor.
37. Wait approximately two minutes or until a clear value has been
recorded and displayed on the opacity data recorder.
Note: The audit data should be taken from a data recording/reporting
device that presents Instantaneous opacity (or opacity data with the
shortest available Integration period).
38. Record the COMS response to the low range neutral density
filter. J
39. Remove the low range filter from the monitor and Insert the mid
range neutral density filter.
40. Wait approximately two minutes and record the COMS response to the mid
range neutral density filter.
41. Remove the mid range filter and Insert the high range filter.
42. Wait approximately two minutes and record the COMS response to the high
range neutral density filter. y
43. Remove the high range filter, wait approximately two minutes, and
record the jig zero value.
Note: If the final jig zero value differs from the Initial value by
more than 1% opacity, the jig zero should be adjusted to agree with
the initial value and the three-filter run (i.e., low, mid, and
high) should be repeated.
44. Repeat steps 36 through 43 until a total of five opacity readings are
obtained for each neutral density filter.
45. If six-minute integrated opacity data are recorded, repeat steps
35 through 43 once more, changing the waiting periods to 13 minutes.
46. Record the six-minute integrated data, if available.
4-8
-------
47. When the calibration error check is complete, remove the audit jig,
replace the dirty window detector and the protective window, and
close the transceiver protective housing.
48. Return to the control unit location.
49 ' {r."5™i!&DirJ$T' Jh? A"TOMATIC CALIBRATION (CYCLE) TIMER and
the METER DISPLAY knob to the positions recorded in blanks 10 and 11
50. Obtain a copy of the audit data from the data recorder.
51. Transcribe the calibration error data from the data recorder to
blanks 25 through SO and complete the audit data calculations.
Calibration Error Check (Incremental Procedure!
np-tth u address« o^er Dynatron monitors
Pernnt the «« of the audit jig. The incremental calibration
rh. « "Performed by substituting neutral density filters in plaw
The «uIE 2™?H ?ro^tive Wlndow wnhout inserting an audit devi«
UD»> l«Si! « / "de a" assumed Pr°t«tive window opacity value of
2K?«I I *J (
-------
1-32. Walt approximately two minutes and record the filter opacity value
Indicated on the opacity data recorder.
1-33. Remove the low range audit filter and replace the transceiver
protective window.
1-34. Walt approximately two minutes and record the Indicated effluent
opacity value.
1-35. Remove the transceiver protective window and Insert the mid range
audit filter.
1-36. Wait approximately two minutes and record the indicated filter
opacity value.
1-37. Remove the mid range filter and replace the transceiver protective
window.
1-38. Wait approximately two minutes and record the indicated effluent
opacity.
1-39. Remove the transceiver protective window and insert the high range
audit filter.
1-40. Wait approximately two minutes and record the indicated filter opacity
value.
1-41. Remove the high range audit filter.
1-42. Replace the transceiver protective window.
1-43. Wait approximately two minutes and record the indicated effluent opacity.
1-44. Repeat steps 1-31 through 1-43 until a total of five
opacity readings 1s obtained for each neutral density filter.
1-45. If six-minute integrated opacity data are recorded, repeat steps
1-30 through 1-43, changing the waiting periods to 13
minutes.
1-46. Record the six-minute integrated data, if available.
1-47. Replace the transceiver measurement window for the last time.
Ensure that the transceiver protective window is properly installed
and close the transceiver housing.
1-48. Return to the control unit location.
1-49. If necessary, return the AUTOMATIC CALIBRATION (CYCLE) TIMER and the
METER DISPLAY to the positions recorded in blanks 10 and 11.
respectively.
1-50. Obtain a copy of the audit data from the opacity data recorder.
4-10
-------
1-51. Transcribe the calibration error response data from the opacity data
T!!™V? 3U?-i da*a Sheet b^"ks 1-24 thmuoh T.SI and complete the
incremental calibration error calculations.
4.1.3 Interpretation of Audit Results
if ^^ to neJP the auditor interpret the Dynatron 1100
°
Stack Exit Correlation Error Check
The path length correction error in blank 51 should be within +
Opac1ty --^iirresultim in
The •0$t
n
^^
should be greater by approximately two to four flet.9
Fault Lamp Analysis
Control Panel Meter Error
monitoring system unless the control panel meter is used toldiust th»
; i s ^rirat-*r.rjat,rs,!!j5,?5K
span values, any change in the specified values for thi zero or swn wil? «
an erroneous assessment of the control panel meter errors Each til til
srff'.ss'Sft t «a' j-j'.re^'
4-11
-------
Internal Zero and Span Check
The Dynatron Model 1100 internal zero 1s typically set to indicate
2-10% opacity since the monitor will not indicate negative opacity values. A
zero error (blank 53) greater than 4% opacity is usually due to mi sealibration
of the instrument or data recorder electronic/mechanical offset. Instrument
span error (blank 551 may be caused by the same problems that cause zero errors.
In addition, a span error may be caused by an improperly named span reference
value.
If the zero and span errors are due to a data recorder offset, both errors
will be in the same direction and will be of the same magnitude.
Transmissometer Dust Accumulation Check
The results of the dust accumulation check (blank 58) should not exceed
4%. A dust accumulation value of more than 4% opacity indicates that the
airflow of the purge system and/or the cleaning frequency of the optical
surfaces are inadequate. When determining the optical surface dust accumu-
lation, the auditor should note whether the effluent opacity is reasonably
stable (within ±2% opacity) before and after cleaning the optical surfaces. If
the effluent opacity is fluctuating by more than +2%, the dust accumulation
analysis should be omitted.
Optical Alignment Check
When the transceiver and retroreflector are misaligned, a portion of the
measurement beam that should be returned to the measurement detector is
misdirected, resulting in a positive bias in the data reported by the COMS. One
of the most common causes of misalignment 1s vibration which may cause the on-
stack components to shift slightly on the Instrument mounting flanges. Another
common cause of misalignment is thermal expansion and contraction of the
structure on which the transmissometer 1s mounted. If the COMS is being audited
while the unit is off-line (cold stack), the results of the alignment analysis
may not be representative of the alignment of the Instrument when the stack or
duct is at normal operating temperature.
Calibration Error Check
Calibration error results (blanks 68. 69. and 70) or blanks 1-89. 1-90.
Iiil) in excess of ±3% are indicative of a non-linear or miscalibrated
instrument. However, the absolute calibration accuracy of the monitor can be
determined only when the instrument clear-path zero setting is known. If the
zero and span data are out of specification, the calibration error data will
often be biased in the same direction as the zero and span errors. Even if the
zero and span data indicate that the COMS 1s calibrated properly, the monitor
may still be inaccurate due to error in the clear-path zero adjustment. The
optimum calibration procedure involves using neutral density filters during
clear-stack or off-stack COMS calibration. This procedure would establish both
the absolute calibration accuracy and linearity of the COMS. If this procedure
is impractical, and it is reasonable to assume that the clear-path zero is set
correctly, the monitor's calibration can be set on-stack using either the
neutral density filters or the internal zero and span values.
4-12
-------
SECTION 5
PERFORMANCE AUDIT PROCEDURES FOR
THERMO ENVIRONMENTAL INSTRUMENTS, INC. OPACITY MONITORS
was originally marketed by the Contraves
400 in 1984 Environmental Instruments, Inc. acquired the Model
5.1.1 COMS Description
The Thermo Environmental Instruments Model 400 continuous opacity
monitoring system (COMS) consists of three major components: the *
transmissometer, the air-purging system, and the Model 500 control unit The
a s?ackSormdlet SV"""? C0n5,1sts °f * transce1ver unit mounted on one si*of
^M^^n^1^^^^011 Unit mou!:ted on the opposite side. The
a ngnt source, a photodiode detector, and the
electronic components used in monitor operation and
1llu$trat?« th* general arrangement of the transceiver and
h ™^
r^
ix?tub;Pe;cp?'bhoerrSratance) is pr°«"ed ^
-t
separate air purging systems for the transceiver and rrt««fl actor "nits.
The Model 500 digital control unit (Figure 5-2) converts the double-Da**
transmittance output from the transceiver to single-pass linear optical
density The control unit then applies the stack taper ratio (STR) to the
signal to correct the COMS output to stack exit opacity. (The STR is expressed
dUptPr^t°thf the $t*Ck 6Xlt 1?s1de d1ameter to the »ttck or duct InsSr
diameter at the transmissometer location.) The STR setting can be checked bv
TSr^9 * hWiJCh in?1ide thS contro1 unit' The »»tro? Sit also con?a?ns
data lvlrln°JX -h ??mpl " ^he above Opac1t> data and calculates a discrete
data average (typically six minutes). This function may not be used at
faculties employing a computer to reduce and record opacity data because the
computer can perform the integration. Note that the Model 500 control unit has
a lamp test button that lights all fault and control lamps.
5-1
-------
FLANGE TO FLANGE
DISTANCE
__ STACK EXIT _
DIAMETER
MOUNTING
F-LATE
OPTICAL
INSIDE
DIAMETER
MOUNTING POINT
[MS/230 VAC
If
1100 W
Figure 5-1. Thermo Environmental Instruments Model 400 Transmissometer
5-2
-------
EXCESSIVE
6 MIN. AV6.
OPACITY
EXCESSIVE
INSTANTANEOUS
OPACITY
EXCESSIVE
ZERO/SPAN
ERROR
CANCEL MANUAL
CALIBRATION OR
ACKNOWLEDGE -
MALFUNCTION
TEST ALL .
CONTROL UNIT
• LAMP BULBS
PROCESSING
TRANSMISSOMETER
SIGNAL
MOOa 500
TRANSMISSOMETER
REMOTE DISPLAY
000
EXIT PATH AV6.
O
OJ).
O
CAL
FAIL
ALARM
•1
ALARM
•2
POWER/DATA
INTERRUPTION
CAL
ZERO
STACK
POWER
FAIL
PURGE
FAIL
CAL
SPAN
LAMP
FAIL
WIN-
DOW
DIRTY
NORMAL
LAMP
TEST
RESET
O
INSUFFICIENT EXCESSIVE
AIR ZERO
FLOW COMPENSATION
INOPERATIVE
LIGHT
SOURCE
Figure 5-2. Thermo Environmental Instruments Model 500 Control Unit
5-3
-------
The Model 400 opacity monitor measures the amount of light transmitted
through the effluent from the transceiver to the retroreflector and back again
The control unit uses this transmittance to calculate the optical density of
the effluent at the monitor location, or the "path" optical density. In order
to provide stack exit opacity data, the path optical density must be corrected
to stack exit conditions. The correction factor is expressed as the ratio of
the stack exit inside diameter to the inside diameter of the stack or duct at
the monitor location. This ratio is called the stack taper ratio (STR) by
Thermo Environmental Instruments. The following equations illustrate the
relationship between the STR, path optical density, and stack exit opacity
STR - stack taper ratio
L, - stack exit inside diameter (ft)
It - the stack or duct inside diameter at
the monitor location (ft)
OP, -h - 10 -(SIR) (00)] xloo
where: OPX - stack exit opacity (%)
OD - transmissometer optical density (path)
5.1.2 Performance Audit Procedures
Preliminary Data
1- ?**?£!! +he St*Ck **ll 1fs1de d1ameter ™d the stack or duct inside diameter
IL Thprlnnpni"0inetei: J0?1"0"- "•"* thist values in blanks 1 and ? of
Sheet Environment*l Instruments Model 400 Performance Audit Data
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order of reliability: (1) physical
""^iS^S^dS^^^ir1^" (3) opacity monit°r i"«t5
or certification documents, and (4) source personnel recollections.
3. Record the source-cited STR value in blank 4.
Note: The STR is preset by the manufacturer using information supplied by
the source. The value recorded in blank 4 should be the value source
personnel agree should be set inside the monitor. Typically, this value is
cited from monitor installation data, monitor certification data, or from
5-4
-------
reP°rts- The STR "•> be displayed on the front panel meter of
E1* ^ Pre«]"9 pushbutton 5/K on the linerizer/integrator PC
personnel "" operation should only be attempted by qualified
values
Note: The reference zero and span calibration values may not be the same as
the values recorded during instrument installation and/or certification
The zero and span values recorded in blank 5 and blanks should be the
the COM" Va recorded duri"9 tne most recent cUaT^ath calibration of
5. Inspect the opacity data recorder (strip chart or computer) to ensure
SIS.*1" ™
Fault Lamp Checks
The following steps describe the fault lamps analysis for the Model 500
•
6. Record the status (ON or OFF) of the CAL FAIL lamp in blank 7.
1anp 1nd1cates that the ««» recent automatic
7. Record the status (ON or OFF) of the DIRTY WINDOW fault lamp in blank 8
r
This fault condition can jeopardize the quality of the monitoring data
8. Record the status (ON or OFF) of the PURGE AIR fault lamp in blank 9.
Note: An illuminated PURGE AIR fault lamp indicates that the transceiver
1s reduced- ™s *
9. Record the status (ON or OFF) of the STACK POWER fault lamp in blank 10.
?hlet./n !11uin1nated STACK POWER fault lamp indicates a loss of power to
the transmissometer. Power must be restored before the audit can continue
5-5
-------
10. Record the status (ON or OFF) of the LAMP FAILURE fault lamp In blank 11.
Note: An Illuminated LAMP FAILURE fault lamp indicates that the measurement
beam intensity is insufficient to make accurate cross-stack measurements.
This fault will jeopardize the quality of the monitoring data and should be
corrected immediately. If the measurement lamp is replaced, the audit
should be postponed for several hours to permit equilibration of the
measurement system.
11. Record the status (ON or OFF) of the ALARM fault lamp in Blank 12.
Note: An illuminated ALARM fault lamp indicates that the opacity of the
effluent exceeds a value selected by the source. This fault has no effect
on the accuracy of the monitoring data or on the completion of the audit.
12. Press the CAL ZERO switch on the control panel to initiate the zero
mode.
Note: The green NORMAL light should go out when the zero mode is
initiated. The yellow CAL light and the green ZERO light should remain
iIluminated.
13. Record the zero value displayed on the panel meter in blank 13.
14. Record the zero value displayed on the data recorder in blank 14.
Note: During the zero calibration check, the COMS outputs the signal
produced by reading the zero segment of the calibration wheel. The zero
mechanism is designed to present the transceiver with a simulated clear-
path condition. The daily zero check does not test the actual clear-path
zero, nor does it provide an indication of cross-stack parameters such as
the optical alignment of the transmissometer or drift in the reflectance of
ciM^EE 1 £• Jh? •W c]ear'Path zer° «n only be checked during
clear-stack or off-stack calibration of the COMS.
15. Press the CAL SPAN switch to initiate the span mode.
16. Record the span value displayed on the control panel meter in blank 15
Record the span value displayed on the data recorder in blank 16. Go to
the transceiver location.
Note: During the span calibration check, the COMS outputs the signal
produced by reading the span segment of the calibration wheel. The
calibration jechanism is designed to provide an indication of the upscale
accuracy of the COMS.
Retroreflector Dust Accumulation Check
17. Record the effluent opacity prior to cleaning the retroreflector optics in
blank 17.
5-6
-------
18. Open the retroref lector, inspect and clean retroref 1 ector optics, and close
the retroref lector.
19. Record the post-cleaning effluent opacity in blank 18.
Transceiver Dust Accumulation Check
20. Record the pre-cleaning effluent opacity in blank 19.
21. Open the transceiver, turn off the chopper motor switch, stop the chopper
clean the transceiver exit window, turn on the chopper motor switch, and '
close the transceiver.
Note: The chopper motor is stopped by turning off the toggle switch in the
MlLe^^£tl™1W ""^ '-1' "
22. Record the post-cleaning effluent opacity in blank 20.
Optical Alignment Check
b* look™9 through the viewing port on the
tc °SerVln9 Whether the """ lBla'e Ts'centeredon
24. Record whether the image is centered on the target (YES or NO) in blank 21.
"' dUa ^Or1entation of the beam image in the circle provided on the audit
Note: The optical alignment has no effect on the internal checks of the
instrument or on the calibration error test. However, if the optical
S ZS™ 'I ?S* C0rrect> the stack °Pac1t> dat* will be biafedhgh since
beam "m be m1sdirected
Calibration Error Check
The calibration error check is performed using three neutral densitv
tr nsem!saonltaeraU?hp ^f8.?'1!6? an aud1t *^ »•« 1 "stal Ted n'the
rl?urnl i? S^I;^ ,audHt J1Q 1ntercePts the measurement light beam and
returns it directly to the measurement detector. Performing the calibra-
tion error check on-stack using the audit jig and filters determines the
zlrTritH^n th?hnst™Knt response relative^ to the currenTcTeTpath
zero setting This calibration error check does not determine the accuracy
of the actual instrument clear-path zero, or the status of any cross- stick
parameters. A true calibration error test is performed by mSvi^g the
on-stack components to a location with minimal ambient opacity, making sure
5-7
-------
that the proper path length and alignments are attained, and then placing
the calibration filters in the measurement beam path.
Note: Thermo Environmental Instruments supplies a monitor-specific audit
jig with each monitoring system. If available, the audit jig supplied with
the CONS should be used during the audit because it is preadjusted to
simulate the correct clear-path zero value when installed on the
transceiver unit. If a monitor-specific device is not available, the
auditor should supply a similar device with an adjustable iris. Following
installation of this audit device, the iris should be adjusted to produce a
jig zero value of 0-2% opacity on the opacity data recorder.
26. Stop the chopper and install the audit jig by placing it over the primary
lens and tightening the attached set screw.
Note: The audit device is not properly installed until it is flush with
the monitor. Be certain that the chopper will not contact the audit jig
when the monitor is put back into operation. Do not bend or otherwise
damage the chopper blades.
27. Restart the chopper and allow the transceiver 2-3 minutes to warm-up.
Note: The jig zero value should be based on readings from the data recorder
The jig zero does not have to be exactly 0% opacity since the audit filter
correction equations can account for an offset in the jig zero. A jig zero
value in the range of 0-2% opacity is acceptable.
28. Record the audit filter serial numbers and opacity values in blanks 22.
23i and 24. 1
29. Remove the filters from their protective covers, inspect, and, if necessary,
clean them.
30. Record the jig zero value from the data recorder.
Note: The acquisition of monitor responses from the data recorder requires
communication between the auditor at the transmissometer location and an
assistant at the data recorder location.
31. Insert the low range neutral density filter into the audit jig.
32. Wait approximately two.minutes or until a clear value has been recorded and
displayed on the data recorder.
Note: The audit data should be taken from a data recording/reporting device
that presents instantaneous opacity (or opacity data with the shortest
available integration period).
33. Record the COMS response to the low range neutral density filter.
34. Remove the low range filter from the audit device and insert the mid range
neutral density filter. *
5-8
-------
. to the mid
36'
flter e m ra"9e er fr°m the 3Ud1t jl9 and insert the hi9h ra"9e
rtCOPd the COMS resp°nse to the h19h «nge
, and record the
th?»f1n*i jl9 zero Va1ue <»ffers from the initial value by more
'™
39. rvcuedL SLBDS ji rnrnnriM ifi nn+
-------
monitor optical path length to the flange-to-flange distance. The flange-to-
flange distance should be greater by approximately two to four feet.
Fault Lamp Analysis
Fault lamps are typically associated with parameters that the monitor
manufacturer feels are critical to COMS function and to the collection of valid
opacity data. The parameters associated with each of the Model 500 control unit
fault lamps is discussed in the audit procedures. With the exception of lamps
that warn of elevated opacity levels (alarm or warning lamps), an illuminated
fault lamp indicates that the COMS is not functioning properly.
Internal Zero and Span Check
,ui Ihf jnternal zero should be set to indicate 0% opacity. A zero error
(blank 53) greater than 4% opacity is usually caused by mi sealibration or
malfunction of one or more COMS components, or by data recorder electronic/
mechanical offset. Instrument span error (blank 55) may be caused by the same
problems that cause zero errors. A span error may also be caused by an
inaccurately named calibration wheel span segment.
u^n lf *he +uer° andJ?Pan errors are d"e to a data recorder offset, both errors
will be in the same direction and will be of the same magnitude.
Transmissometer Dust Accumulation Check
H,,cf III6 resu]*s of Jne du*t accumulation check should not exceed 4% opacity A
dust accumulation value of more than 4% opacity may indicate that the airflow of
i£dE2Vyi^ aUd{°r !h? Clean1ng f^quency of the optical surfaces are
!hnn?3 not: F?! ^f™^!?9 the Opt1cal surface dust ^cumulation, the auditor
should note whether the effluent opacity is reasonably stable (with n "» opacity)
before and after the cleaning of the optical surfaces! If the effluent opa?itJ li
fluctuating by more than ±2%, the dust accumulation analysis should S oSlttid*
Optical Alignment Check
When the transceiver and retroref1ector are misaligned, a portion of the
measurement beam that should be returned to the measurement detecTor is
misdirected, resulting in a positive bias in the data reported by the COMS. One
of the most common causes of misalignment is vibration which may cause the on-
stack components to shift slightly on the instrument mounting flanges. Another
onT!MrKatUKe ?f misal^""'fnt ** thti»l expansion and contraction of the structure
on which the transmissometer.is mounted. If the COMS is being audited while the
™™?2:lin%(Xld ??IckKthS results of the aH9nment analysis may no? be
representative of the alignment of the instrument when the stack or duct is at
normal operating temperature.
Calibration Error Check
Calibration error results (blanks 68. 69. and 701 in excess of +3% are
indicative of a non-linear or miscalibrated instrument. However, the
absolute calibration accuracy of the monitor can be determined only when the
5-10
-------
instrument clear-path zero setting is known. If the zero and span are out-of-
specification, the calibration error data will often be biased in the same
ftlf^rXc^' Ze?Vn2 5pan err?rs' Even 1f the zero and sPan data indicate
that the COMS is calibrated properly, the monitor may still be inaccurate due to
error in the clear-path zero adjustment. The optimum calibration procedure
involves using neutral density filters during clear-stack or off-stack COMS
calibration. This procedure would establish both the absolute calibration
accuracy and linearity of the COMS. If this procedure is impractical, and it is
reasonab e to assume that the clear-path zero is set correctly, the monitor's
calibration can be set using either the neutral density filters or the internal
zero ano span vaIues.
5-11
-------
5.2 THERMO ENVIRONMENTAL INSTRUMENTS MODEL 1000A
The audit procedures presented in this section apply to the Thermo
Environmental Instruments Model 1000A and to the Environmental Data Corporation
(EDC) Model 1000A.
5.2.1 COMS Description
The Thermo Environmental Instruments Model 1000A continuous opacity
monitoring system (COMS) consists of three major components: the transmissometer
the air-purging system, and the data acquisition system. The transmissometer '
component consists of a transceiver unit mounted on one side of a stack or duct
and a retroref 1 ector unit mounted on the opposite side. The transceiver unit
contains a light source, a photodiode detector, and the optical, mechanical, and
electronic components used in monitor operation and calibration. The output
signal from the transceiver (double-pass, uncorrected transmittance) is
transmitted to a control unit or directly to an opacity data recorder. The
transceiver zero and span signals are monitored continuously and are
electronically compensated through a gain control circuit to ensure that the
61"31" consJanV ?ince the electronic gain compensation affects the zero,
HaSUr*me« S+9?al amP11tude equally, variations in measurement lamp
do not affect the measurement signal.
Th? a!r pur*91n9 system serves a threefold purpose: (1) 1t provides an air
sufaces frn^^S05^0^10!1 futicis clean' <2> 1t Pr°tects *he op??cal
surfaces from condensation of stack gas moisture, and (3) it minimizes thermal
conduction from the stack to the instrument. A standard insta lit on has ™pa
hl.TbfiSr'JSrflSl^Jj! V"ICi1vir and retroreflector units ^Eachs^e
nas a blower that floods the Instrument mounting flange with filtered ambient air.
efflJnt JS^tH T1t0r ™*sur*s *he amount of light transmitted through the
Sm ?? H K?he tranfceiver to the retroref lector and back again. The monitor
efnupnt Jr±eI?%SK tran??1ttance to calculate the optical density of the
effluent stream at the monitor location, or the -path" optical density In
corroctL^o0" t6 ,Sta
-------
OP, -ll - 10-
Pe«o"nel recollections. Note that the
of the lnside diameter °f the
2
Correction factor (divide the value i
Record the result i
3. Record the source-cited optical path length correction factor in blank 4.
optical path length correction factor 1s preset bv the
b^nnk%CtsUhr0eulriUSin9tKnf0r?ati0n SUppl1ed b* the source, the valul recorded in
^^S^SSSH^MS."-
values. Record these values
refere,n« zer° and span calibration values may not be the same as
«« recorded duri"9 Instrument installation and/or certification The
va[UPrl^aH HaiU" re^rded 1n b1ank 5 and blank 6 should be the reference
values recorded during the most recent clear-pltTcTlibration of the COMS
Monitoring System
r ' s
wise, this check must be performed at the transmissometer location
5-13
-------
5. Inspect the opacity data recorder (strip chart or computer) to ensure
proper operation. Annotate the data record with the auditor's name,
affiliation, plant, unit, date, and time.
Zero/Span Check
6. If the source has installed a switch to initiate the internal zero and span
functions, initiate the zero and span cycle by pressing the CAL-INITIATE
button.
Note: The monitor will remain in the zero mode for approximately three
minutes. The span mode will follow automatically for an additional three
minutes. When the calibration cycle is complete, the monitor will
automatically return to normal operation. The cross-stack zero is
simulated using the zero mirror in the transceiver. The zero and span
checks provide an indication of the accuracy of the COMS relative to the
clear-path setting. They do not, however, indicate optical misalignment or
the actual instrument clear-path zero setting.
7. Record the zero and span responses in blanks 7 and 8. respectively.
8. If there is no CAL-INITIATE button in the control room, the calibration cycle
will have to be initiated from the transmissometer location. Go to the
transmissorneter location and locate the MODE switch next to the input/output
cable on the front of the transceiver.
9. Move the MODE switch to the up position (ZERO).
10. Allow the monitor to operate at least three minutes for the chart recorder
to log the zero response. Wait 13 minutes if the monitoring system
processes the data through a six-minute averaging circuit.
11. Move the MODE switch to the down position (SPAN).
12. Wait another 3 or 13 minutes (depending upon the use of an averaging
circuit) for the chart recorder to log the span response.
13. Return the MODE switch to the center position (OPERATE).
14. Record the COMS zero and span responses in blanks 7 and 8. respectively.
Retroreflector Dust Accumulation Check
15. Record the effluent opacity prior to cleaning the retroreflector optics in
DianK 9. r
16. Pull up and clean the window that separates the retroreflector from the
SuaCK*
s
17. Record the post-cleaning instantaneous effluent opacity in blank 10.
5-14
-------
Transceiver Dust Accumulation Check
18. Record the pre-cleaning effluent opacity in blank 11.
19. Pull up and clean the window that separates the light source from the
S LdCK.
20. Record in blank 12 the post-cleaning effluent opacity.
•
Calibration Error r
assembly (P/IJSSl ?nr?™JeCf It performed ^ Installing an EDC filter holder
filter hniH« L in,front of *ne corner cube retroref lector and securing the
fmE ?-2tr f"™?^ by means of two Allen head scre«s. The neutral density
tN™sce?ve0rdunite.C°ntaCt WUh the UV 11ght source 1ocated 1»«1««e the
21 ' lSd!l|.aUd1t f1Uer "r1al numbers and «P«1ty values in blanks 13.
22' cRleaneithe 10W ™* fi1ter fr™ its Prot«tive cover, and, if necessary,
23' and record the eff1uent
24. Insert the low range neutral density filter.
filter, wait approximately two minutes, and record the
27. Remove the mid range filter from its protective cover, inspect and if
necessary, clean it. v.uver, inspect, ana, if
28. Insert the mid range audit filter.
and record the COMS response tc
5-15
-------
30. Remove the mid range filter, wait approximately two minutes, and record
the effluent opacity.
31. Remove the high range filter from its protective cover, inspect, and if
necessary, clean it.
32. Insert the high range audit filter.
33. Wait approximately two minutes and record the COMS response to the hiah
range neutral density filter. y
34. Remove the high range filter.
35. Wait approximately two minutes and record the effluent opacity.
36. Repeat steps 24 through 35 until a total of five opacity readings is
obtained for each neutral density filter.
If six-minute integrated opacity data are recorded, repeat steps 23 through
35 once more, changing the waiting periods to 13 minutes. tnrougn
37. Record the six-minute integrated data, if available.
to the
39. Obtain a copy of the audit data from the opacity data recorder.
4°' MiJXrf!!**?1" Ca1l£ra!1on error data fro" the opacity data recorder to
calculations™'"' 1Ud1t "*** Sheet and "^te the audit data
5-2.3 Interpretation of fudlt Results
This section is designed to help the auditor Interpret the Model
C
Stack Exit Correlation Error
The path length correction error in blank 87 should be within +2% This
error exponentially affects the opacity readings, resulting in oveV- or
tUh1e0rntSi«iat^tnh°f th*VtaCk "I* °Sac1t*- Th* iost c« «™ ?n imputing
dlJtSrl ?I S?th 1659K! C°rre^0n factor 1s the use of the flange-to-flange
distance in place of the stack/duct Inside diameter at the monitor location
^idPnt^f -^l reSUU ^ ™ ""^estimation of the stack exi? opac ?y and can
Sai«d
-------
Internal Zero and Scan Check
I Ll A ?nterPal ?ero should be set to indicate 0% opacity. A zero error
greater than 4% opacity is usually due to excessive dust accumulation
on the optical surfaces, electronic drift, or data recorder electronic/
mechanical offset. Note that the EDC 1000A does not automatically compensate
for dust accumulation on the transmissometer exit window (i.e., 2^0fflpens"e
compensation). Instrument span error (blank 89) may be caused by the same
problems that cause zero errors. Span error may also be caused by an
inaccurately named span filter.
«
-------
5.3 THERMO ENVIRONMENTAL INSTRUMENTS, INC. MODEL D-R280 AV (DURAG)
The major components of the Model D-R280 AV opacity monitor were
manufactured 1n Germany by Durag Industrie Electronik, GMBH. Thermo
Environmental Instruments, Inc. imported the monitoring system components and
acted as the U.S. distributor of the instrument. The most recent version of the
f 1S the Envlr?Plan CEMOP-281. Audit procedures for the Env"o??an
1 are covered in Section 6 of this document.
5.3.1 COMS Description
The Thermo Environmental Instruments D-R280 AV continuous opacity
?nTtp™?LSySt6? (?°KS) C?!!S1^S °f four major comP°"ents: the transinissometer,
the terminal control box, the air-purging system, and the remote control unit
and data acquisition equipment. The transmissometer component consists of an
nr JSJ t™»"tter/ ™ce:ver (transceiver) unit mounted on one side of a stack
or duct and a retrorefl ector unit mounted on the opposite side. The transceiver
unit contains a light source, a photodl ode 'detector, and the associated
electronics Figure 5-3 illustrates the general arrangement of the transceiver
s
The terminal control box mounted beside the transceiver unit
"n""p
=
lht rem?Je fontro1 Un1t (Figure 5-4) converts the nonlinear transmittance
into
effl Jnt ?r™ IL T measures the amount of light transmitted through the
,!II] ??* * Jhe transceiver to the retrorefl ector and back again. The monitor
ef?luontSa?°thle'P"tS transl"i"an« to calculate the optical density of the
effluent at the monitor location, or the 'path' optical density In order to
?hT±rfrta-k e*n °pa?Uy d*ta, the path Optical densitr«ustoe «r?e£ed
The correction factor is expressed as the ratio of the stack exit Inside
diameter to the inside diameter of the stack or duct at the transm ssometer
location. This ratio is called the "ootical path length correction factor • The
eSrlSSn'ffiS'pia"^^^ffiLSSK opt??^"1 "*" le"9th
5-18
-------
s.
Qi
4->
0)
O
c
O)
m
i
m
O)
s-
5-19
-------
r
>
ALARMS
M
INTEG.
ET POINT
IA
DIRECT
10\^'^ttl' '
14^3
V •"•>• -w.
^Jj-Tjsj
CAUB
CYCLE
HOURS
MA
, , „ , CHECK
^
HIGH
NTEG.
(
: ' ' :
HIGH
3PACTTY
" ' I
x x j
^
*1
ACK
-
R
1 .
2.
3.
4.
5.
UN
ANGE
.0-20
• 0-40
.0-80
• 0-100
• 0-100%
(CORRECTED
RESET DIRECT
-
» -
ggWER) Fgg, ("-OWJagJgjLJCAUBR | W.
D-R280 AV
Figure 5-4. Thermo Environmental Instruments Model D-R280 AV Control Unit
4408 12/91
DR280 Op control.
5-20
-------
- optical path length correction factor
where: L* « stack exit inside diameter (ft)
L, - the stack or duct inside diameter at
the transmissometer location (ft)
OPX -|1 - KT^'-tMuujj x 10Q
where: OPX « stack exit opacity (%)
00 « transmissometer optical density (path)
5.3.2 Performance Audit Procedures
Preliminary Data
nr a,,rt >? +t + exit inside diameter and the inside diameter of the stack
or duct at the transmissometer location. Record these values in blanks 1
ano_2 of the D-R280 AV Performance Audit Data Sheet. Dianicsj,
Note: Effluent handling system dimensions may be acquired from the
meal2rementsUrC2S "^ in.descend™9 6rder of reliability: (1) physical
certification documents, and (4) source'personnel recollections.
2. £alc"late the optical path length correction factor (divide the value in
blank.! by the value in blank 2). Record the result in blank 3.
3. Record the source-cited optical path length correction factor in blank 4.
Note: The optical path length correction factor is preset by the
manufacturer using information supplied by the source. The value recorded
tL^^ML T • nJhe !a^ue s?urce Personnel agree should be set inside
the monitor. Typically, this value is cited from monitor installation
data, monitor certification data, or from COMS service reports
4' ?ntblank1 TnHeM^ ?" ™* fP™"1 ib™tion values. Record these values
in DianK 5 and blank 6. respectively.
Note: The reference zero and span calibration values may not be the same
as the values recorded during instrument installation and/or certification
The zero and span values recorded in blank 5 and blank 6 should be the
theecOMS6 V recorded during the most recent clear-path calibration of
5. Inspect the opacity data recorder (strip chart or computer) to ensure
proper operation. Annotate the data record with the auditor's name
affiliation, plant, unit, date, and time.
5-21
-------
Fault Lamp Checks
The following steps describe the fault lamp analysis for the D-R280 AV remote
SJlt°!JHll nrSlSn ?h fTi!" noted- thVud1t can continue with illuminated
fault lamps, provided that the source has been informed of the fault conditions.
6. Record the status (ON or OFF) of the BLOWER FAILURE fault lamp in blank 7.
Note: An Illuminated BLOWER FAILURE fault lamp indicates a loss of power
to the transceiver or to purge air blowers. If a blower failure fault is
indicated, the audit should be postponed until source personnel repair the
problem. Source personnel should be told of this fault immediately Los!
of purge air may damage the on-stack components of the COMS due to
prolonged exposure to corrosive stack gases.
7. Record the status (ON or OFF) of the FILTER BLOCK fault lamp in blank 8.
at? fillumi!natud FI!:TER BLOCK fault 1al»P indicates that a reduction in
air flow has been detected. The most likely causes of a filter block
8. Record the status (ON or OFF) of the WINDOW fault lamp in blank 9.
Control Unit Checks
the <
10. Record the position of the range switch in blank 10.
11. Set the opacity range switch to range position "4."
Reference Signal. 7ero and Span rhorirc
Cal1brat1on c^cle * Pining the CALIBR button on the control
Jally cIc?egtherSuahLth? -T ^i" ^9ht' and,the mon1tor w111 au
cany cycle through the internal and external zero and span modes.
13' **' " ^ 1nter"al "^ m1111amp Value d1sPla^d <>n the
control
5-22
-------
Note: The internal zero checks the reference beam inside the transceiver.
After two minutes in the internal zero mode, the monitor will automatically
switch to the external zero mode.
14. Record the external zero value (in milliamps) displayed on the panel meter
in blank 12. Record the zero value (in percent opacity) displayed on the
opacity data recorder in blank 13.
Note: During the zero calibration check, the zero mirror is moved into the
path of the measurement beam by a servomotor. The zero mechanism is
designed to present the transceiver with a simulated clear-path condition
The daily zero check does not test the actual clear-path zero, nor does it
provide a check of cross-stack parameters such as the optical alignment of
the transmissometer or drift in the reflectance of the retroref lector. The
actual clear-path zero can only be checked during clear-stack or off-stack
calibration the COM3. In addition to simulating the instrument clear-path
zero, the zero mechanism allows the amount of dust on the transceiver
optics (primary lens and zero mirror) to be quantified. After two minutes
in the external zero mode, the COMS will automatically enter the span mode.
15. Record in blank 14 the span value (in milliamps) displayed on the control
+K! V? met!T' .Re"rd the sPan value <1n Percent opacity) displayed on
the data recorder in blank 15. Go to the transmissometer location.
Note: During the span calibration check, a servomotor moves a span filter
into the path of the measurement beam while the zero mirror is in place
ihe span mechanism is designed to provide an indication of the upscale '
accuracy of the COM3 relative to the simulated clear-path zero. PThe COM3
m°de When the
Retroref lector Dust Accumulation Check
16* bUnkd16he 6ffluent °pacity prior to cleaning the retroref lector optics in
17. Open the transceiver housing, inspect and clean the retroref lector optics
and close the housing. K *
18. Record the post-cleaning effluent opacity in blank 17. Go to the
transceiver location. -
Transceiver Dust Accumulation Check
19. Record the pre-cleaning effluent opacity in blank 18.
20. Open the transceiver head, clean the optics (primary lens and zero mirror)
and close the transceiver head.
21. Record the post-cleaning effluent opacity in blank 19.
5-23
-------
Optical Alignment Check
22. Determine the optical alignment by looking through the bull's eye on the
side of the transceiver.
23. Observe whether the twin Images are centered on either side of the cross
hairs and record this information (YES or NO) in blank 20.
Note: The type of Image that will appear In the alignment sight will
depend on the type of reflector installed in the retrorefl ector housing
The Scotch-lite Type F reflector (flange-to-flange distance - 1.5 to 10
feet) will produce twin overlapping circles in the alignment sight. The
glass corner cube reflector (flange- to- flange distance - 9 to 49 feet) will
produce smaller discrete twin circular images in the alignment sight. The
?C ? aliment has no affect on the internal checks of the instrument or
the calibration error determination; however, if the instrument is
misaligned, the effluent opacity data will be biased high since a portion
of the measurement beam will be misdirected before it is returned to the
measurement detector.
Calibration Error Chprlr
The calibration error check is performed using three neutral density
filters and an audit device called an audit jig. When installed on
When installed on the
re^rn^it^irlctl'^rt'^ J1g 1nt6rC^S "» asuremen? l^nt beSm' n'd
returns it directly to the measurement detector. Performing the calibra-
1 n0enaritTofhtehCek TnlZu? J*1"9 the ^ J1g and f11ters StSlS the*
7Pr« riJt^I th?Jnstrumen* response relative to the current clear-path
zero setting. This calibration error check does not determine the accuracy
™ecta!;\Ual instruinent clear-path zero setting or the stltS of any
mo^nn thnk paramejers- A *™ calibration errir check is performed by
mak na sure Jh^t'th comP°nents * * loc^°n with minimal am^ntlpacny,
?hpn SifrEn *a the proper path length and alignments are attained, and
then placing the calibration filters in the measurement path.
24. Install the audit jig.
25. Adjust the audit jig iris to produce a 4 mA output current on the junction
ze°romseetetringSee ^^ ^ ™S adjustment *™^** the WMS clea?-Ja?h
Note: The junction box meter allows the auditor to get the jig zero value
near the zero vaue displayed on the data recorder. The fini j?g zero
adjustments should be based on readings from the data recorder The jig
be exactly W °Pac1t^ s1nce the 9
™rto
correction equations can account for an offset 1n the jig zero. A jig zero
value in the range of 0-2% opacity is acceptable. 9
27. Record the audit filter serial numbers and opacity values in blanks 22.
c6* ana Z4. 1
5-24
-------
Transceiver
Cable
Connector
Power
Fuse
88888888883
-' * 3 4 5 i ; A A tf-fi-
mA Output
Meter
Calibration
Indicator
Check/Output
Meter Switch
Junction
Terminal Block
Figure 5-5. Thermo Environmental Instruments Model D-R280 AV Junction Box (J-Box)
4408 12/91
DR280 J-Box.
5-25
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28. Remove the filters from their protective covers, inspect, and, if
necessary, clean them.
29. Record the jig zero value from the data recorder in blank 21.
Note: The acquisition of monitor responses from the data recorder requires
communication between the auditor at the transmissometer location and an
assistant at the data recorder location.
30. Insert the low range neutral density filter into the audit jig.
31. Wait approximately two minutes or until a clear value has been recorded and
displayed on the data recorder. w"U*g ana
Note: The audit data should be taken from a data record ing/report inq
device that presents instantaneous opacity (or opacity data with the
shortest available integration period).
32. Record the COMS response to the low range neutral density filter.
the mid
t0 the
35. Remove the mid range filter from the audit jig and insert the high range
reC°rd ^ COMS reSP°nSe t0 the hi*h
aPP^ox1mate^ two -mutes, and record
JEnS*1! th?/inal J1? Zero value d1ffers from the initial value by more
than 1% opacity, the jig zero should be adjusted to agree with the initial
three-filter run (i.e., low, mid, and high) should be
38' nh?631 ?*** 3° uhrough 37 until a total of five opacity readings are
obtained for each neutral density filter. ««u«"yi are
39. If six-minute integrated opacity data are recorded, repeat steps 29 throuah
37 once more, changing the waiting periods to 13 minutes. 9
40. Record the six-minute integrated data.
Note: In order to acquire valid six-minute averaged opacity data each
filter must remain in the jig for at least two consecutive six-minute
fhl1?-?; the f1^st period wil1 be 1nvalid because it was in progress when
the filter was inserted. A waiting period of 13 minutes is recommended
5-26
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41. When the calibration error check is complete, remove the audit jig. Close
the transceiver head and the weather cover, and return to the COMS control
unit.
Final Control Unit Adjustment Reset
42. Reset the opacity range switch to the position recorded in Blank 10.
43. Obtain a copy of the audit data from the data recorder-:
44. Transcribe the calibration error data from the data recorder to
blanks 25 through 50 of the audit data form and complete the audit data
calculations.
5-3.3 Interpretation of Audit Results
1s d?J19neJ to nel? the au^tor interpret the Model D-R280 AV
•' P"*™. audit results is
Stack Exit Correlation Error
The path length correction error 1n blank 51 should be within +2X This
error exponentially affects the opacity readings, resulting Tn over- or
theeorDetS «!atna0?h°f th+Vtack 6x1t °2ac1ty- Th* most c°™°n error In computing
the optical path length correction factor is the use of the flange-to-flanae
distance in p ace of the stack/duct inside diameter at the monUor locattSn
E1" reSU * 1"underest1mat1on of the stack exit opacity and can 'be
n
ds?anl LC^an"? *5? I"°n1i?r Opt1cal Path 1en9th to the flange-to-flange
to four feel f1ange-to-f1an9e disti"'« should be greater by approximately two
Fault Lamp Analysis
'If1* 1a™Ps,are typically associated with parameters that the monitor
1!^ ?if are Cr|tiCa1 t0 COMS funct10" and to the col"ct?on of valid
in'tt, P^eters associated with each of the fault lamps are
-J6 i* ? Pro«dures. With the exception of lamps that warn of
ndcates thaCtthlecn^ a1aT T T"1"9 1amps)l an "l«1"»t«d fault Ump
indicates tnat the COMS is not functioning- properly.
Control Panel Heter Error (Optional)
m=t TIle accuracy of the control panel meter is important at sources using the
meter during monitor adjustment and calibration. The accuracy of the control
unit panel meter (blank 52 and blank 541 is determined by comparing the «ro and
span reference values to the panel meter output recorded during the COMS
calibration check. Errors in the control panel meter should not affect the
opacny data reported by the monitoring system unless the control panel meter is
all, t°hodJ"st the calibration of the COMS. At sources using the panel metlr
data, the panel meter should be adjusted so that the error is less than 2X
Since the control panel meter error is determined using the span filter any
5-27
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change 1n the specified values for the span filter will cause an erroneous
assessment of the control panel meter errors. Each time the monitor is
thoroughly calibrated, the internal span filter should be renamed. The new span
value should be recorded and used in all subsequent adjustments.
Zero and Span Check
The D-R280 AY internal zero (blank 111 should be set to indicate 0* opacity
(equivalent to 3.7 - 4.3 mA). An external zero error (blank 53) greater than 4%
opacity 1s usually due to excessive dust accumulation on the optical surfaces
electronic drift, or an electronic/mechanical offset of the data recorder '
Excessive dust on the optical surfaces sufficient to cause a significant zero
error would be indicated by the difference in the internal and external zero
values and/or an illuminated "window" fault lamp. Instrument span error
(blank 55) may be caused by the same problems that cause zero errors. A span
error may also be caused by an inaccurately named span filter.
•n uf *he ?ero and span errors are due to a data recorder offset, both errors
will be in the same direction and will be of the same magnitude.
The external zero displayed on the panel meter of the control unit is an
indication of the amount of dust deposition on the zero mirror and the
transceiver exit window. The difference between the internal and external zero
values should equal the amount of dust found on the transceiver optics
(DianK 57). To convert the zero responses to a value that represents the lens
dusting in percent opacity, use the following equation: Presen« ™e len*
Meter response 1n % opacity - 6.25 [(Blank 12} - (Blank 1111
Transmissometer Dust Accumulation Check
The results of the dust accumulation check (blank 581 should not exceed 4%
SSi2' AKUSt accumulatio" value of more than 4TSpEiiy indicates th" the
airflow of the purge system and/or the cleaning frequency of the optical
surfaces are inadequate When determining the optical sirface dust accumula-
nh* audltor s^ n°te ?hether the effluent °Pacitv 1* reasonably stable
n ±2% opacity) before and after cleaning the optical surfaces. If the
nuctuating by more than ±»* th« *«t accumulation analysis
Optical Alignment Check
When the transceiver and retroref1ector are misaligned, a portion of the
measurement beam that should be returned to the measurement detector is
misdirected, resulting 1n a positive bias in the data reported by the COMS. One
of the most common causes of misalignment Is vibration which may cause the on-
stack components to shift slightly on the Instrument mounting flanges. Another
common cause of misalignment is thermal expansion and contraction of the
structure on which the transmissometer is mounted. If the COMS is being audited
while the unit is off-line (cold stack), the results of the alignment analysis
may not be representative of the alignment of the Instrument when the stack or
duct is at normal operating temperature.
5-28
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Calibration Error Check
Calibration error results (blanks 68, 69. and 70) in excess of +3% are
indicative of a non-linear or miscalibrated instrument. However, the absolute
calibration accuracy of the monitor can be determined only when the instrument
clear-path zero setting is known. If the zero and span data are out-of-
specification, the calibration error data will often be biased in the direction
of the zero and span errors. Even if the zero and span data indicate that the
COMS is calibrated properly, the monitor may still be inaccurate due to error in
the clear-path zero adjustment. The optimum calibration procedure involves
using neutral density filters during clear-stack or off-stack COMS calibration.
This procedure would establish both the absolute calibration accuracy and
linearity of the COMS. If this procedure is impractical, and it is reasonable
to assume that the clear-path zero is set correctly, the monitor's calibration
can be set on-stack using either the neutral density filters or the internal
zero and span values.
5-29
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-------
SECTION 6
PERFORMANCE AUDIT PROCEDURES FOR THE
ENVIROPLAN OPACITY MONITOR
6.1 ENVIROPLAN MODEL CEMOP-281
The Enviroplan CEMOP-281 is an updated version of the D-R280AY formerly
distributed by Thermo Environmental Instruments, Inc. Audit procedures for the
D-R280AV are covered in Section 5 of this manual. Both instruments are
manufactured by Durag.
6.1.1 COMS Description
The Enviroplan CEMOP-281 continuous opacity monitoring system (COMS)
consists of four major components: the transmissometer, the terminal control
box, the air-purging system, and the remote control unit and data acquisition
equipment. The transmissometer component consists of an optical
transmitter/receiver (transceiver) unit mounted on one side of a stack or duct
and a retroreflector unit mounted on the opposite side. The transceiver unit
contains the light source, the photodiode detector, and the associated
electronics. Figure 6-1 illustrates the general arrangement of the transceiver
and retroreflector units on the stack. The transceiver uses a single-lamp,
• single-detector system to determine effluent opacity. A chopper, located
inside the optical compartment, modulates the light beam to eliminate
interference from ambient light. The modulated beam is configured to
alternately produce reference and measurement signals so that the effects of
variations in the optical and electronic components of the COMS are minimized.
The terminal control box mounted beside the transceiver unit provides an
on-stack analog readout of the milliamp output from the transceiver and can be
used as a diagnostic tool.
The air purging system serves a threefold purpose: (1) it provides an air
window to keep exposed optical surfaces clean; (2) it protects the optical
surfaces from condensation of stack gas moisture; and (3) it minimizes thermal
conduction from the stack to the instrument. A standard installation has one
air-purging system for both the transceiver and the retroreflector units.
The remote control unit (Figure 6-2) converts the nonlinear transmittance
output from the transceiver (a milliamp signal) into linear opacity corrected
to stack exit conditions.
The opacity monitor measures the amount of light transmitted through the
effluent from the transceiver to the retroreflector and back again. The
control unit uses the effluent transmittance to calculate the optical
density of the effluent at the monitor location, or the "path" optical
density. In order to provide stack exit opacity data, the path optical density
must be corrected. The correction factor is expressed as the ratio of the
stack exit inside diameter to the inside diameter of the stack at the
6-1
-------
0)
o
c
(O
00
CM
Q.
O
e
10
o
>
O)
6-2
-------
00
CNJ
i
O.
O
o.
o
CNJ
0)
55 < <
6-3
-------
transmissometer location. This ratio is called the "stack correction factor
(SCF) by Enviroplan. The following equations illustrate the relationship
between this ratio, path optical density, and stack exit opacity.
- stack correction factor
where: L, - stack exit inside diameter (ft)
Lt - the stack inside diameter (or the duct width) at
the monitor location (ft)
OP, .[l-10-(L*/LtH°D)] xlOO
where: OP, - stack exit opacity (X)
OD - transmissometer optical density (path)
6.1.2 Performance Audit Procedures
Preliminary Data
1. Obtain the stack exit inside diameter and the stack or duct inside diameter
or width at the monitor location. Record these values in blanks 1 and 2 of
the Enviroplan CEMOP-281 Performance Audit Data Sheet.
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order of reliability: (1) physical
SSIffE!?*' i2) con?truction drawings, (3) opacity monitor installation/
certification documents, and (4) source personnel recollections.
2. Calculate the stack correction factor (divide the value in blank 1 by the
value in blank 2K Record the result in blank 3. -
3. Record the source-cited stack correction factor in blank 4.
Note: The stack correction factor is preset by the manufacturer using
information supplied by the source. The value recorded in blank 4 should
be the value source personnel agree should be set inside the monitor. The
stack correction factor setting can be verified by opening the control unit
and checking the positions of switches 42 through 49 on circuit board 40
against information supplied in the CEMOP-281 instrument manual. This
operation should only be attempted by qualified personnel.
4. Obtain the reference zero and span calibration values. Record these values
in blank 5 and blank 6. respectively.
6-4
-------
Note: The reference zero and span calibration values may not be the same
as the values recorded during instrument installation and/or certification.
The zero and span values recorded in blank 5 and blank 6 should be the
reference values recorded during the most recent clear-path calibration of
the COMS.
5. Inspect the opacity data recorder (strip chart or computer) to ensure
proper operation. Annotate the data record with the auditor's name,
affiliation, plant, unit, date, and time.
Fault Lamp Checks
The following steps describe the fault lamp analysis for the Enviroplan
CEMOP-281 remote control unit. Unless otherwise noted, the audit can continue
with illuminated fault lamps, provided the source has been informed of the
fault conditions.
6. Record the status (ON or OFF) of the BLOWER fault lamp in blank 7.
Note: An illuminated BLOWER fault lamp indicates a loss of power to the
purge air blowers. If a blower fault is indicated, the audit should be
postponed until source personnel repair the problem. Source personnel
should be told of this fault immediately. Loss of purge air may damage the
on-stack components of the COMS due to prolonged exposure to corrosive
stack gases.
7. Record the status (ON or OFF) of the FILTER fault lamp in blank 8.
Note: An illuminated FILTER fault lamp indicates that a reduction in purge
air flow has been detected. The most likely causes of a filter fault are a
clogged purge air filter or a crimped purge air hose. The audit can
continue under filter block conditions; however, source personnel should be
made aware of the condition so that repairs can be made at the completion
of the audit.
8. Record the status (ON or OFF) of the WINDOW fault lamp in blank 9.
Note: An illuminated WINDOW fault lamp indicates that the opacity of the
measurement window exceeds the factory preset limit of 3.5 percent.
Excessive window opacity may produce a positive bias in the effluent
opacity data.
9. Record the status (On or Off) of the FAULT lamp in blank 10.
Note: An illuminated FAULT lamp indicates that one or more critical COMS
components have malfunctioned or are out of adjustment. An illuminated
FAULT lamp should be accompanied by a fault code displayed on the front
panel meter of the control unit. The nature of the fault can then be
determined by consulting the instrument manual. If this lamp is
illuminated, source personnel should determine the exact cause of the fault
condition. The auditor should discuss the cause and magnitude of the fault
condition with source personnel to determine if the audit can continue.
6-5
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Instrument Range Check
10. Check the COMS measurement range by pressing the RANGE button
on the front panel of the control unit.
11. Record the instrument range in blank 11.
Note: If the instrument image is not greater than the highest corrected
neutral density filter value to be used during the calibration error
portion of the audit, the instrument range must be increased by
manipulating Switch S51 on circuit board no. 50. This operation should
only be attempted by qualified personnel.
Reference Signal. Zero and Span Checks
12. Initiate the calibration cycle by pushing the CALIBR button.
Note: The green CALIBR lamp will light, and the monitor will
automatically cycle through the internal and external zero and span
modes. r
13. Record the internal zero mi Hi amp value displayed on the control panel in
Note: The internal zero checks the instrument reference signal Since the
" '' ^l1 S"le °utput of 4 to 20 -mi"*? a valw of 4
on ?he contro1 Un1t Pane1 •*«• represents a zero
itV1?!!*'* *" th? 1nterna1 zero mode' the monitor
switch to the external zero mode.
*?"* J1? «1111amPs) dlspl^d^on the control unit
nt Record the external zero value (in percent
opacity) displayed on the opacity data recorder in blank 14.
«th:nfDthl"9 the zen> cal1brat1on check, the zero mirror is moved into the
path of the measurement beam by a servomotor. The zero mechanism is
designed to present the transceiver with a simulated clear-path condition.
Jrovda» { r^Vf k d°es ?°\test the actua1 clear-path ze?o, nor does U
provide a check of cross-stack parameters such as the optical alignment of
the transmissometer or drift in the reflectance of the retroreflect^ ?he
actual c ear-path zero can only be checked during clear-stack or off-stack
nalh !±0nt£f the COMSi ?n add,U1on to »1««l«t1n9 the instruSen? clea?-
path zero, the zero mechanism allows the amount of dust on the transceiver
optics (primary lens and zero mirror ) to be quantified. After two minutes
in the external zero mode, the COMS will automatically enter the span mode.
15' unurdJ»ibl!^ 1S She SSa!!uVa1ue (*» •"""!>») ^splayed on the control
?hl nSfS ! •Reu?rd,t?e span value (1n Percent opacity) displayed on
the data recorder in blank 16. Go to the transmissometer location
6-6
-------
Note: During the span calibration check, a servomotor moves a span filter
into the path of the measurement beam while the zero mirror is in place.
The span mechanism is designed to provide an indication of the upscale
accuracy of the COMS relative to the simulated clear-path zero. The COMS
automatically returns to the measurement mode when the span portion of the
calibration cycle is complete.
Retroreflector Dust Accumulation Check
16. Record the effluent opacity prior to cleaning the retroreflector optics in
blank 17.
17. Open the transceiver housing, inspect and clean the retroreflector optics
and close the housing. '
18. Record the post-cleaning effluent opacity in blank 18. Go to the
transceiver location.
Transceiver Dust Accumulation Check
19. Record the pre-cleaning effluent opacity in blank 19.
20. Open the transceiver, clean the optics (primary lens and zero mirror), and
close the transceiver.
•21. Record the post-cleaning effluent opacity in blank 20.
Alignment Check
22. Determine the monitor alignment by looking through the alignment port on
the side of the transceiver.
23. Observe whether the twin images are centered on either side of the cross
hairs and record this information (YES or NO) in blank 21.
Note: The type of image that will appear in the alignment sight will
depend on the type of reflector installed in the retroreflector housing
The Scotch-lite Type F reflector (flange-to-flange distance - 1.5 to 10
feet) will produce twin overlapping circles in the alignment sight. The
glass corner cube reflector (flange-to-flange distance - 9 to 49 feet) will
produce smaller discrete twin circular images in the alignment sight. The
alignment has no effect on the internal checks of the instrument or the
calibration error determination; however, if the instrument is misaligned,
the effluent opacity data will be biased high since a portion of the
measurement beam will be misdirected before it is returned to the
measurement detector.
Calibration Error Check
The calibration error check is performed using three neutral density
filters and an audit device called an audit jig. When installed on the
transmissometer, the audit jig returns the measurement light beam directly
6-7
-------
to the measurement detector. Performing the calibration error check on-
stack using the audit jig and filters determines the linearity of the
Instrument response relative to the current clear-path zero setting. This
calibration error check does not determine the accuracy of the actual
instrument clear-path zero or the status of any cross-stack parameters. A
true calibration error check 1s performed by moving the on-stack components
to a location with minimal ambient opacity, making sure that the proper
path length and alignments are attained, and then placing the calibration
filters in the measurement path.
24. Install the audit jig.
25. Adjust the audit jig iris to produce a 4 mA output current on the junction
box meter (see Section 5, Figure 5-5). This adjustment simulates the
instrument clear-path zero setting.
Note: The junction box meter allows the auditor to get the jig zero value
near the zero value displayed on the data recorder. The final jig zero
adjustments should be based on readings from the data recorder. The jig
zero does not have to be exactly 0% opacity since the audit filter
correction equations can account for an offset in the jig zero. A jig zero
value in the range of 0-2% opacity is acceptable.
26. Record the audit filter serial numbers and opacity values in blanks 22, 23
and 24. '
27. Remove the filters from their protective covers, inspect, and, if
.necessary, clean them.
28. Record the Jig zero value from the.data recorder.
Note: The acquisition of COM3 data from the data recorder requires
communication between the auditor at the transmissometer location and an
assistant at the data recorder location.
29. Insert the low range neutral density filter into the audit jig.
30. Wait approximately two minutes or until a clear value has been recorded and
displayed on the data recorder.
Note: The audit data should be taken from a data recording/reporting device
that presents instantaneous opacity (or opacity data with the shortest
available integration period).
31. Record the COMS response to the low range neutral density filter.
32. Remove the low range filter from the audit jig and insert the mid range
neutral density filter.
33. Wait approximately two minutes and record the COMS response to the mid
range neutral density filter.
6-8
-------
34. Remove the mid range filter from the audit jig and insert the high range
filter. 3
35. Wait approximately two minutes and record the COMS response to the hiah
range neutral density filter.
36. Remove the high range filter, wait approximately two minutes, and record
the jig zero value.
Note: If the final jig zero value differs from the initial value by more
than 1% opacity, the jig zero should be adjusted to agree with the initial
value and the three-filter run (i.e., low, mid, and high) should be
repeated.
Repeat steps 29 through 36 until a total of five opacity readings are
obtained for each neutral density filter.
If six-minute integrated opacity data are recorded, repeat steps 28 through
36 once more, changing the waiting periods to 13 minutes. ^nrougn
39. Record the six-minute integrated data.
Note: In order to acguire valid six-minute averaged opacity data each
filter must remain in the jig for at least two consecutive six-minute
periods; the first period will be invalid because it wa in progress when
the filter was inserted. A waiting period of 13 minutes is recSended
40. When the calibration error check is complete, remove the audit jig
control unHanSCeiVer h"d ^ the weather cover» and return to the COMS
Final Control Unit Adjustment Reset
37
38
43. Transcribe the cal^ration error response data from the data recorder to
bO of the audit data form and complete the audit data
Interpretation of Audit
is designed to help the auditor interpret the CEMOP-281
rw, ,«,„,«,,« auu.c results. A general discussion of performance audit results is
presented in Section 2 of this manual. results is
5-9
-------
Stack Exit Correlation Error Check
The path length correction error in blank 51 should be within +2%. This
error exponentially affects the opacity readings, resulting in over- or
underestimation of the stack exit opacity. The most common error in computing
the optical path length correction factor is the use of the flange-to-flange
distance in place of the stack/duct inside diameter at the monitor location
This error will result in underestimation of the stack exit opacity and can'be
identified by comparing the monitor optical path length to the flange-to-flange
distance; the flange-to-flange distance should be greater by approximately two
to four feet. J
Fault Lamp Analysis
Fault lamps are typically associated with parameters that the monitor
nnUrf? UT ?i* are critical to COMS Action, and to the collection of valid
opacity data. The parameters associated with each of the fault lamps is
discussed in the audit procedures. With the exception of lamps that warn of
P 1 ^ V 3 I On f\ T\ 3^*TiV/i£M/rtT**/*»1 * T \ *—**«**iiiwl
+ t ILjr Ieveis la'arm or warning lamps), an illuminated fault
that the COMS is not functioning properly.
Control Panel Meter Error (Optional]
mot*/!!6 accurac> of th* control panel meter 1s important at sources using the
meter during mom tor adjustment and calibration. The accuracy of the control
panel meter (blank 52 and blank 541 is determined by comparing the zero 2nd scan
chSenCEr™rSUe?ntt°hthe P?n6i ^ °UtpUt recordedVA Inl CWS c™1br,t on
renSrtpH h?Th •? C°ntl"01 """^ metfir Sh°Uld "Ot affect the °Pa"ty data
cap?bra?e thP rnS?" ?tnn9 $yStem ?"leSS the C0ntro1 Pane1 "*ter ?* «ed to
«hl,,irf I s- ? 5" Atusources "^19 the panel meter data, the panel meter
should be adjusted so that the error is less than zX. Since the control panel
meter error is determined using the span filter, any change in the specified
oa LurJr e span fjur wi11 cause an errone°us as'« ^ <* « pco n
panel meter errors. Each time the monitor is thoroughly calibrated, the
'a ?s" ' The '
(eguiv5'entET'3287 ™l*™} "1° (^^^ shou1d be set *° indicate OX opacity
(equTvalent to 3.7 - 4.3mA). An external zero error (blank 531 greater than 4%
opacity is usually due to excessive dust accumulation on the optical surfaces
electronic drift, or an electronic/mechanical offset of the data recorder
Excessive dust on the optical surfaces sufficient to cause a sign^cant zero
rWobe in-i^at?d M6 differen« i" "e internal and Ixierna zero
^ Illunl1nated '-indow- fault lamp. Instrument span error
ma> be caused by the same problems that cause zero errors and may be
- A span error raay also be caused b an
6-10
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The external zero displayed on the control unit panel meter also indicates
the level of dust accumulation on the zero retroreflector and transceiver
measurement window. The difference between the internal and external zero
responses should equal the amount of dust found on the transceiver optics
(blank 57). To convert the zero responses to a value that represents lens
dusting in percent opacity, use the following equation:
Meter response in % opacity - 6.25 [(Blank 13) - (Blank 12)1
Transmissometer Dust Accumulation Check
The results of the dust accumulation check (blank 58) should not exceed 4%.
A dust accumulation value of more than 4% opacity indicates that the airflow of*
the purge system and/or the cleaning frequency of the optical surfaces are
inadequate. When determining the optical surface dust accumulation, the auditor
should note whether the effluent opacity is relatively stable (within +2%
opacity) before and after cleaning the optical surfaces. If the effluent
opacity is fluctuating by more than ±2%, the dust accumulation analysis should
be omitted.
Optical Alignment Check
When the transceiver and retroreflector are misaligned, a portion of the
measurement beam that should be returned to the measurement detector is
misdirected, resulting in a positive bias in the data reported by the COMS One
of the most common causes of misalignment is vibration which may cause the
on-stack components to shift slightly on the instrument mounting flanges.
Another common cause of misalignment is thermal expansion and contraction of the
structure on which the transmissometer is mounted. If the COMS is being audited
while the unit is off-line (cold stack), the results of the alignment analysis
may not be representative of the alignment of the instrument when the stack or
duct is at normal operating temperature.
Calibration Error Check
•v- Jr d 'T«n-•, iiiaar or un ocai SDrateu instrument. However, me acsoiute
calibration accuracy of the monitor can be determined only when the instrument
clear-path zero value is known. If the zero and span data are out-of-
specification, the calibration error data will often be biased in the direction
of the zero and span errors. Even if the zero and span data indicate that the
COMS is calibrated properly, the monitor may still be inaccurate due to error in
the clear-path zero adjustment. The optimum calibration procedure involves
using neutral density filters.during clear-stack or off-stack COM3 calibration
This procedure would establish both the absolute calibration accuracy and
linearity of the COMS. If this procedure is impractical, and it is reasonable
to assume that the clear-path zero is set correctly, the monitor's calibration
can be set using either the neutral density filters or the internal zero and
span values.
6-11
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SECTION 7
PERFORMANCE AUDIT PROCEDURES
FOR THE UNITED SCIENCES, INC. OPACITY MONITOR
7.1 UNITED SCIENCES, INC. MODEL 500C OPACITY MONITOR
7.1.1 COMS Description
The United Sciences Inc. (USI) Model 500C continuous opacity monitoring
system (COMS) consists of three major components: the transmissometer, the air
purging system, and the digital control unit. The transmissometer unit
consists of a transceiver mounted on one side of the stack or duct and a
retroreflector mounted on the opposite side (see Figure 7-1). The
retroreflector is a passive unit designed to return the measurement light beam
to the transceiver. The transceiver contains the light source, the optical
bench, the reference and measurement detectors, and the essential on-stack
electronics. The Model 500C uses a dual-pass, dual detector measurement
technique. A green solid state light emitting diode (LED) is used as the light
source. The LED is modulated to allow the instrument to differentiate between
™*measurement beam and amb1ent liQht. Light produced by the LED passes to a
50/50 beam splitter which sends half of the light to the reference detector to
produce the reference signal. The remaining light (the measurement beam) is
focused across the stack or duct to the retroreflector. The retroref lector
returns the measurement beam to the measurement detector in the transceiver to
•produce the measurement signal. The transceiver electronics process the
reference and measurement signals into a 0 to 20mA output which represents
double-pass opacity. A second beam splitter in the transceiver housing allows
an image of the measurement beam to be viewed through the alignment site on the
back of the unit. The transceiver and retroreflector are properly aligned when
the inner circle of the alignment reticle is within the circular image of the
open retroreflector port. A three segmented rotating calibration wheel on the
rront of the transceiver allows the instrument to continuously cycle through
zero, span, and measurement modes. Two differentially reflective surfaces mak°
up the zero and span segments of the calibration wheel. The measurement
segment or tne _ca nbration *hsel -is ooe~ to 2!low the msasursme.nt beam to -ass
An on-stack indication of the transceiver output is displayed on an
analogue meter in the Model 500C junction box. This 8 x 10-inch box is
generally mounted on the transceiver unit blower plate. The junction box also
contains "on/off" and "run/test" switches. The "on/off switch controls power
to the transceiver. The "run/test" switch is used to start and stop the
rotation of the calibration wheel.
The primary component of the purge-air system is an electric blower that
floods the cavity within the instrument mounting flange with filtered ambient
air. The air purging system serves a threefold purpose: (1) it keeps the
transmissometer protective optics clean by providing a filtered air buffer
7-1
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Figure 7-1. United Sciences, Inc. Model 500C Transmissometer,
7-2
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between the protective optics and the effluent; (2) it keeps the protective
optics from accumulating condensed stack gas moisture; and (3) it minimizes
thermal conduction from the stack to the instrument. A standard installation
has separate purge-air systems for the transceiver and retroreflector units.
The Model 500C control unit converts the transceiver output to stack exit
opacity, controls the automatic daily calibration cycles, and performs several
self-diagnostic functions (see Figure 7-2). Effluent opacity values are
displayed on two digital front panel meters. The meter on" the right displays
instantaneous effluent opacity; it updates every four seconds. The meter on
the left displays integrated effluent opacity values; it updates at the end of
each integration period. Several indicator lamps on the front panel of the
control unit provide information regarding the status of the COMS. The
operation of the fault indicator lamps may be checked using a lamp test switch
Calibration data can be output manually to the front panel meter of the control
unit by positioning the "MODE" switch in either the "ZERO" or the "SPAN"
position. The mode switch does not affect the output from the control unit to
the data recording device(s).
The Model 500C opacity monitor measures the amount of light transmitted
through the effluent from the transceiver to the retroreflector and back again
Ihe monitor uses this double-pass transmittance to calculate the optical
density of the effluent at the monitor location, or the "path" optical density
To provide stack exit opacity data, the path optical density must be corrected
to stack exit conditions. The correction factor is expressed as the ratio of
the stack exit inside diameter to the inside diameter of the stack or duct at
the monitor location. This ratio is called the stack taper ratio (STR) by USI
The following equations illustrate the relationship between the STR, path
optical density, and stack exit opacity.
STR - stack taper ratio - 1,/L,
L, - stack exit inside diameter (ft)
the monitor location (ft)
OPX = [ 1 - 10 -(STR)(°D)j x 100
where: OPX -= stack exit opacity (%)
OD «= transmissometer optical density (path)
7-3
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OPACITY ANALYZER
AVERAGE
MODE
O NORMAL
• IN CAL
SPAN
| H NORMAL
ZERO
INSTANTANEOUS
Unh«d Scwnort »nc.
u» MONTH nowfCM J«JAO
OIMOMU. Mk 11044
OPERATIONAL
STATUS
£ SET
ALARMS
D
A SET
w «2
••M
Figure 7-2. United Sciences, Inc. Model 500C Control Unit.
7-4
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7.1.2 Performance Audit Procedures
Preliminary Data
1. Obtain the stack exit inside diameter and the stack or duct inside diameter
(or width) at the transmissometer location. Record these values in blanks
3 and 2 of the USI Model 500C Performance Audit Data Sheet.
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order of reliability: 1) physical
measurements; (2) construction drawings; (3) opacity monitor installation/
certification documents; and (4) source personnel recollections.
2. Calculate the SIR (divide the value in blank 1 by the value in blank 2)
Record the result in blank 3. - '"
3. Record the source-cited SIR value in blank 4.
cni- SIu 1s preset by the manufacturer using stack dimensions
supplied by the source. The value recorded in blank 4 should be the value
that source personnel cite as being set inside the control unit
installation data, monitor
an Record these values
Note: The reference zero and span calibration values may not be the same
as the values recorded during instrument installation and/or certifica
tho ;0/ Zer° ?nd Span values rec°rded in blank 5 and blank 6 should be
of the C'SMS" " reC°rded dUHn9 the mosri^t cleaT^aTh calibration
Data Acquisition Svstem Check
5. Go to the ooac~itv ^at3 i/~~ir-";"1"i^r «v/
-------
8. Record the status (ON or OFF) of the INST HALF lamp in blank 9.
Note: An illuminated INST HALF lamp indicates that one or several fault
conditions not covered by a specific fault lamp have been detected by the
instrument self-diagnostic circuitry.
If the INST HALF lamp is illuminated, specific fault information can be
output to the front panel meter in the form of a fault code by pressing the
"ALARM" "SET 1" and "SET 2" buttons simultaneously. Before continuing the
audit, source personnel should determine the cause of the fault. The
auditor should discuss the cause and magnitude of the COMS fault with
source personnel to determine if the audit can continue.
9. Record the status (ON or OFF) of the CAL FAIL lamp in blank 10.
Note: An illuminated CAL FAIL lamp indicates that the most recent zero or
span calibration results exceeded the calibration limits set inside the
control unit.
10. Record the status (ON or OFF) of the PURGE FAIL lamp in blank 11.
Note: An illuminated PURGE FAIL lamp indicates that a significant or total
loss of purge air has been detected. The audit can generally continue
under these circumstances; however, source personnel should be notified of
this condition immediately. Purge air failure can damage the on-stack COMS
components.
11. Record the status (ON or OFF) of the STACK PWR FAIL lamp in blank 12.
Note: An illuminated STACK PWR FAIL lamp indicates that power to the
on-stack COMS components has been lost. Power to the transceiver must be
restored before the audit can continue.
Zero Check
.2, In1*: ita *he z-.r-: cs: "'crifi-jr, ~od2 ^y Bovine *hs HODt switch *.s 'ihp *Tr9.n*
3C51C'Cn.
Note: During normal operation, the COMS reads the zero and span segments
of the rotating calibration wheel approximately once per second, and
compiles the one-second calibration data into six-minute averages. When
the MODE switch is moved to the "ZERO" position, the left hand front panel
meter of the control unit will display the six-minute integrated zero value
currently stored in the COMS memory; this value is updated at the end of
each six-minute integration period. Moving the MODE switch to the "ZERO"
position does not affect the COMS output to the data recorder; calibration
data are output to the data recorder only during an automatic calibration
cycle.
When the zero mode is initiated, the green NORMAL light will go out, and
the yellow IN CAL light will become illuminated.
7-6
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13. Record the zero value output to the left hand panel meter display in
blank 13.
Note: During the zero calibration check the COMS outputs the signal
produced by reading the zero segment of the calibration wheel. The zero
mechanism is designed to present the transceiver with a simulated clear-
path condition. The daily zero check does test the actual clear-path zero
setting, nor does it provide an indication of cross-stack parameters such
as the optical alignment of the transmissometer or drift in the reflectance
of the retroref lector. The actual clear-path zero can only be checked
during clear-stack or off-stack calibration of the COMS.
Dirt Compensation Check
14. With the COMS still in the ZERO mode, press and hold the "ALARM" "SET 1"
and "SET 2" buttons simultaneously.
15. Record the dirt compensation value displayed on the left hand front panel
meter in blank 14, and release the "ALARM SET" buttons.
Note: The amount of dust on the transceiver optics and zero segment of the
calibration wheel is quantified by reading the zero segment of the
o? thl'rn^ I1' +Whe" *deviation from zero is detected, the zero point
of the COMS is electronically reset, and the amount of electronic zero
compensation (dirt compensation) is stored in the COMS memory. The dirt
compensation value is automatically updated at six-minute intervals.
Span Check
.
position.
16' te th! .uPscale calibration mode by moving the MODE switch to the
Note: During normal operation the COMS reads the zero and span seaments of
.he. rotating calibration wheel approximately once per second and compiles
the one-second calibration data into six-minute averages. When the MODE
sw-cr> «:: -novad - ths "S^-ifl" oosition, the Is ft ha/uf^m* --- -^^ ,--
•::i? :c.i:r-D: -r ;- ^ •>.'.' .rs-::=y rns ^x-:r::u-3 ^nt3crar=r -n- v-'-s
currently stored in the COMS 'memory; this~va1ue "is updatecTat the%nd of
each six-minute integration period. Moving the MODE switch to the "SPAN"
position does not affect the COMS output to the data recorder; calibration
data are output to the data recorder only during an automatic calibration
^"jf *•» I C •
When the span mode is initiated, the green NORMAL light will go out, and
the yellow IN CAL light will become illuminated.
17. Record the span value output to the left hand panel meter display in
blank 15.
Note: During the span calibration check, the COMS outputs the signal
produced by reading the span segment of the calibration wheel. The
calibration mechanism is designed to provide an indication of the upscale
accuracy of the COMS.
7-7
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18* ?5nS™, *he C(??? to the normal mode by Placing the MODE switch in the
"NORMAL" position.
Note: The yellow IN CAL light will go out and the green NORMAL light will
become illuminated.
Stack Taper Ratio (SIR) Check
19. Open the front panel of the control unit and locate switch S2.
Note: Switch S2 is mounted on the lower left hand corner of the circuit
board attached to the back of the hinged front panel. tircun
2°' meter ^^ S2 t0 d1Splay th6 stack taPer ratio
-------
-F
©
*
X.
V
3
2.
1
&
T
^
B-7
c>)
^
^
o
o
o
o
Figure 7-3. United Sciences, Inc. Model 500C Junction Box (0-Box).
7-9
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Retroreflector dust Accumulation check
32. Open the retroreflector protective weather cover.
33. Record the effluent opacity reading prior to cleaning the retroreflector
optics in blank 19.
34. Open the retroreflector, inspect and clean the retroreflector optics, and
close the retroreflector.
35. Record the post-cleaning effluent opacity in blank 20.
Optical Alignment Check
36. Open the retroreflector. Swing the retroreflector cap assembly all the way
back so that ambient light will backlight the open retroreflector port.
37. Go to the transceiver location and look through the alignment sight on the
back of the transceiver unit. Observe the position of the alignment
reticle relative to the circular image of the open retroreflector port.
38. Indicate acceptable or unacceptable optical alignment (YES or NO) in
blank 21 of the 500C audit data form.
Note: The instrument is acceptably aligned if the inner circular image of
the alignment reticle is within the circular image of the open retrore-
flector port.
39. Draw the image seen in the alignment sight in the circle provided on the
audit data form.
Note: The optical alignment has no effect on the internal calibration
checks or the instrument, or on the calibration error test using the audit
Jig. However, if the transceiver and retroreflector are not optically
aligned, the effluent opacity data will be biased high since a portion of
tns Tieasurercen- .:aan: vi 11 D* nris-iir^ciad before it is returned to the
40. Return to the retroreflector location. Close and secure the retroreflector
cap assembly. Close and secure the protective weather.cover.
Note: After the transmissometer optics have been cleaned, the dirt
compensation circuitry must be reset so that it does not continue to
compensate for dust that is no longer present on the transceiver
optics.
41. Return to the transceiver location.
42. Reset the instrument dirt compensation by moving the "run/test" switch to
the run position. Allow the instrument to operate with the calibration
wheel running for 13 minutes.
7-10
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Note: It is important to allow the instrument to operate in the "run" mode
for a full 13 minutes before continuing the audit. This ensures that at
least one full six-minute zero, span, and measurement cycle is completed;
the dirt compensation is reset at the end of each six-minute measurement
cycle.
Calibration Error Check
The calibration error check is performed using three neutral density
filters and an audit device called an audit jig. When installed on the
transmissometer, the audit jig intercepts the measurement light beam and
returns it directly to the measurement detector. Performing the
calibration error check on-stack using the audit jig and filters determines
the linearity of the instrument response relative to the current clear-path
zero setting. This calibration error check does not determine the accuracy
of the actual instrument clear-path zero setting, or the status of any
cross-stack parameters. A true calibration error test is performed by
moving the on-stack components to a location with minimal ambient opacity,
making sure that the proper path length and alignments are attained, and
placing the calibration filters in the measurement beam path.
43. Move the "run/test" switch inside the junction box to the "test" position
This stops the transceiver calibration wheel.
Note: The "run/test" switch must always be moved to the "test" position
before the transceiver unit is opened. Placing the "run/test" switch in
the test position freezes the zero compensation value and prevents the
instrument from logging any portion of the transceiver output as zero and
span data.
44. Open the transceiver and install the audit jig over the transceiver exit
window.
Note: The source may have ordered a monitor-specific audit jig from US I
The monitor-specific audit jig is typically oreadjusted to simulate the
correct clear-oath zsro response -when instated on the transcs^'er ur^,
ir a ficr, it jr-uzec •:•:"-; c a-^c"-: aavc« '•$ iv-vi'^a^. ;~ snou
-------
47. Remove the filters from their protective covers, inspect, and, if
necessary, clean them.
48. Record the jig zero value from the data recorder.
Note: It is not necessary for the jig zero value to be exactly 0% opacity
since the audit filter correction equations can account for an offset in
the jig zero setting. A zero setting of 0-2% opacity is acceptable. To
adjust the audit jig iris, remove the three retaining screws that hold the
iris cover in place and remove the iris cover. (This is sometimes
difficult due to a snug fit between the iris cover and the 0-ring iris
compartment seal.) With the audit jig installed on the transceiver unit
loosen the iris set screw on top of the iris adjustment plate, and move the
screw clockwise or counterclockwise to obtain the desired COMS response.
49. Insert the low range neutral density filter into the audit jig.
50. Wait for approximately two minutes or until a clear value has been recorded
and displayed on the data recorder.
Note: The audit data should be taken from a data recording/reporting
device that presents instantaneous opacity (or opacity data with the
shortest available integration period).
51. Record the COMS response to the low range neutral density filter.
53. Wait approximately two minutes and record the COMS response.
54. Remove the mid range filter from the audit device and insert the high range
55. Wait for approximately two minutas and record the COMS rescense.
minutes, and record the jig zero value. *" ~" "''""
Note: If the final jig zero value differs from the initial value by more
than 1% opacity the jig zero should be reset to within 1% of the initial
value, and the 3-filter run (i.e., low, mid, and high) should be repeated.
57. Repeat steps 49 through 56 until a total of five opacity readings are
obtained for each neutral density filter.
58. If six-minute integrated opacity data are recorded, repeat steps 48 through
55 once more, changing the waiting periods to 13 minutes.
59. Record the six-minute integrated data.
7-12
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60. When the calibration error test is complete, remove the audit jig, close
and secure the transceiver, restart the calibration wheel by moving the
"run/test" switch to the "run" position, and replace the J-box cover.
61. Close and secure the protective weather cover.
62. Return to the control unit/data recorder location and obtain a copy of the
audit data from the data recorder.
63. Transcribe the calibration error response data from the data recorder to
blanks 25 through 50 and calculate the performance audit results.
7.1.3 Interpretation of Audit Results
This section is designed to help the auditor interpret the United
Sciences, Inc. Model 500C performance audit results. A general discussion of
performance audit results is presented in Section 2 of this manual.
Stack Exit Correlation Error Check
The path length correction factor (blank 51) should be within +2% This
error exponentially affects the opacity readings, resulting in over" or
underestimation of the stack exit opacity. The most common error in computing
the path length correction factor (STR) is the use of the flange-to-flange
-distance in p ace of the stack or duct inside diameter at the monitor location
This error will result in underestimation of the stack exit opacity and can be'
identified by comparing the monitor optical path length to the flange-to-flange
to four^feet flange'to'flan9e dis*ance should be greater by approximately two
Fault Lamp Analysis
Fault lamps are typically associated with parameters that the monitor
manufacturer feels are critical to COHS function, and to the collection of valid
ooacity cata. The VNST W.5' ' aim on ths 'JS! 50CC can be 1nd:-5t-ve of sav*r™
ons.
lamp are airt compensation in excess of 4% opacity, or a stopped calibration ~
wheel Specific fault information can be output to the front panel meter of the
»??TO" !!nit ln the form of a fault code b* Pressing the "ALARM" "SET 1" and
bhf 2 buttons simultaneously. The instrument manual must be consulted to
determine the meaning of the fault code. This is typical of the newer digital
control units. It allows for increased sophistication of the self diagnostic
circuitry without cluttering the face of the control unit with fault lamps that
are rarely used. In addition to the general "INST HALF" fault lamp, the 500C is
equipped with several parameter specific fault lamps that warn of calibration
failure, purge air failure, and stack power failure. The COMS is not
functioning properly if any of these fault lamps are illuminated.
Zero and Span Check
The internal zero and span errors (blank 53 and blank 55) should not exceed
±4% opacity. A zero or span error in excess cf ±4% opacity may be due to
7-13
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excessive dust accumulation on the transceiver optics, mlscalibration of the
CEMS, or an improperly named span segment of the calibration wheel. Dust
accumulation on the transceiver optics sufficient to cause significant zero
error will be accompanied by an excessive dirt compensation value and an
illuminated INST HALF" fault lamp. Other causes of zero and span error are
difficult to pinpoint during an audit.
w-n lf *he *ero and*Pan errors are due to a data recorder offset, both errors
will be in the same direction and will be of the same magnitude.
Dirt (Zero) Compensation Check
nn* • The ^r1 comPensation function is designed to minimize the effects of dirty
optics on the instrument output. The amount of dust on the transceiver exit
ze^™t2en? th9meni -Kf +the ca!1brat*°n whe*l ^ quantified each time the
zero segment of the calibration wheel is read. The dirt compensation value
recorded n blank 14 should not exceed ±4% opacity. If an excessive dirt
in^tSatlt0K ,Va t!6 1S dUG °nly to dust Euild UP °" the transceiver opt cs it
nsumcient L t6 ^T ^ flow and/or the frequency of lens cleaning li
insufficient to keep the transmissometer optics clean A neaative dirt
compensation value, or a value that persist'* after a thorougTc e n? g Of the
el2rtrSn?« °'n? in?lcates ^functioning or improperly adjusted COMS
electronics. The most common cause of negative dirt compensation valups -U
clear-path adjustment of the COMS when the optics are not clean The dirt
o"?K^
°s read °PaClty When the Zero portion of the calibration wheel
Transmissometer Dust Accumulation Check
A H,,Jhe resu.Uf .of thf dust accumulation check (blank 58) should not exceed 4r
A dust accumulation value of more than 4% opacity may Indicate that the airf low'
'' '
Optical Alignment Check
When the transceiver and retroref lector are misaligned, a portion of the
misdire^d ^ ^ Sh°"ld be returned to the measurement detector s
of ?hp ^ ?' resultlr)9 ln a Positive bias in the data reported by the COMS One
of the most common causes of misalignment is vibration, which mav cause th^ on
co±nCrT°nen^ t0 ?^1ft Sli9ht1y °n the instrument mount ng ?langes AnoC
structure on' ^1^1^^ -S ^mz} exPansi°" and contraction of {he
structure on which the transmissometer is mounted. If the COWS is beina auditprt
while the umt is off-line (cold stack), the results of the alignment ana' yj s
may not be representative of how well the instrument is aligned when the stack
or duct is
or duct is at normal operating temperature.
7-14
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Calibration Error Check
Calibration error results (blanks 68, 69, and 70) in excess of ±3% are
indicative of a non-linear or miscalibrated instrument. However, the absolute
calibration accuracy of the monitor can be determined only when the instrument
clear-path zero setting is known. If the zero and span are out-of-specification,
the calibration error data will often be biased in the same direction as the
zero and span errors. Even if the zero and span data indicate the COMS is
calibrated properly, the monitor may still be inaccurate due to error in the
clear-path zero adjustment. The optimum calibration procedure involves using
neutral density filters during clear-stack or off-stack COMS calibration. This
procedure would establish both the absolute calibration accuracy and linearity
of the COMS. If this procedure is impractical, and it is reasonable to assume
that the clear-path zero is set correctly, the monitor's calibration linearity
can be set using either the neutral density filters or the internal zero and
span values.
7-15
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-------
SECTION 8
PERFORMANCE AUDIT PROCEDURES FOR
THE LAND COMBUSTION OPACITY MONITOR
8.1 LAND COMBUSTION MODEL 4500 OPACITY MONITOR
8.1.1 COMS Description
The Land Combustion Model 4500 continuous opacity monitoring system (COMS)
consists of three major components: the transmissometer, the air purging
system, and the control unit. The transmissometer consists of a transceiver
unit mounted on one side of the stack or duct and a retroref lector mounted on
the opposite side (see Figure 8-1). The retroref lector is a passive unit
designed to return the measurement light beam to the transceiver The
transceiver contains the light source, the detector, the optical bench, and the
essential on-stack electronics. The Model 4500 uses a single source, single
detector system. Light emitted from an incandescent lamp at the back of the
transceiver unit is focused through a perforated rotating disc. The rotatinq
disc modulates the light beam to allow the instrument to differentiate between
the measurement beam and. ambient light. The light beam is then chopped into
reference and measurement beams by projecting the light through a rotating
bv nnMf tShaPiedKref1f^Ve t1ming Wheel- When the "Sht beam is intercepted
by one of the lobes of the timing wheel, the light is sent directly to the
?So r°hf K Pr°dUCe ? reference Si9nal- A measurement signal is produced when
the light beam is not intercepted by the timing wheel. The uninterrupted light
beam crosses the stack or duct and is returned to the detector in thetran -9
bt?r' The refe™nce and measurement signa s
electronics lnto a signai that *
throuohai'thp2n"p nfd "Pscal* "Cation of the opacity monitor is accomplished
through the use of a span filter and zero mirror. The span filter is sealed
inside the transceiver head while the zero mirror is mounted eternally on the
rroru or me transceiver unit. Vhen a calibration cycle is ^itistad
.;inu^c;r.g sn ijpsca.a jpaci:> ^cnai;icn. 7ne ciear-pacn zero concmion is
tShpUrnM< t y re™9 the Sf3an filter fr°m the measurement path and allowing
the COMS to read the zero mirror alone.
The primary component of the purge-air system is an electric blower that
floods the cavity within the instrument mounting flange with filtered ambient
air. The air purging system serves a threefold purpose: (1) it keeps the
transmisspmeter protective optics clean by providing a filtered air buffer
between the protective optics and the effluent; (2) it keeps the protective
optics from accumulating condensed stack gas moisture; and (3) it minimizes
thermal conduction from the stack to the instrument. A standard installation
has separate purge-air systems for the transceiver and retroreflector units.
The Model 4500 control unit converts the transceiver output to a signal
that represents stack exit opacity, controls the daily automatic calibration
cycles, and performs several self-diagnostic functions. Th* unH is
8-1
-------
Figure 8-1. Land Combustion Model 4500 Transmissometer
8-2
-------
^cn?^°HeSS°rv,b^ed.?n? 1S menu driven to allow several C°MS parameters to be
displayed on the digital front panel meter (see Figure 8-2). Several indicator
CoT °An "Ai lmn'\ m thn Un1Lf^jdfr1nformation regarding the status of the
and an. ALERT" LED warn of elevated effluent opacity
!"dcte that the COHS is in the calibration mode.
rtPtprtpH hv?L r™fS 11].1"'!'inated.when one or more COMS malfunctions have been
aetected Dy the COMS self-diagnostic circuitry. Specific fault information ran
be output to the panel meter by pressing the "AUTO TEST" key and scroTlinq
through the COMS faults (if multiple faults have occurred) using the "ENTER"
Key.
pfflnlnf Jrn^th TUor I1835":63 Jhe amount of Ught transmitted through the
effluent from the transceiver to the retroref lector and back again The
thits double-Pa" transmittance to calculate the opiical density
aVh!l m°nitor location' or the "path" optical density In
sack LC t'r^H0?3'1^ d#*' the pM °ptical densit> ™« »e
I t ! conditions. The correction factor is calculated as the
.* .
and the correction is automatically applied to the oath
'
,
OPLR « - - optical path length ratio
U
where: Lx - stack exit inside diameter (ft)
LT - measurement path length (ft) - two times the
effluent depth at the transmissometer location
where: OPX - stack exit opacity (%)
OD = transmissometer optical density (path)
8.1.2 Performance Audit Procedures
Prel iminary Data
l' a SCk 6Xl 1nside diameter
onth SC 6Xu nse diameter a"d transmissometer measurement path
length (two times the stack or duct inside diameter or width at the
transmissometer location). Record these values in blanks 1 and ? of the
Land Model 4500 Performance Audit Data Sheet -
8-3
-------
Figure 8-2. Land Combustion Model 4500 Control Unit,
8-4
-------
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order of reliability: (1) physical
measurements, (2) construction drawings, (3) opacity monitor installation/
certification documents, and (4) source personnel recollections.
2. Calculate the OPLR (divide the value in blank 1 by the value in blank 2)
Record the result in blank 3.
3. Record the source cited OPLR value in blank 4.
Note: The OPLR is preset by the manufacturer using stack dimensions
supplied by the source. The value recorded in blank 4 should be the value
source personnel cite as being set inside the control unit. Typically
this value is obtained from monitor installation data, monitor
certification data, or COMS service reports.
4* ?ntKin uhc re!er,encf zero and span calibration values. Record these values
in DianK b and blank 6. respectively.
Note: These values are set during monitor calibration and may not be equal
to the values recorded at COM3 installation and/or certification. Records
ot the zero and span values resulting from the most recent monitor
«?tP »n ,m2J 3 kSpt by "T" Personnel • ^ source personnel cannot
fi™i5 h P led ¥™ reference value, the factory assigned span value
should be entered in blank 6. The factory assigned span filter value is
calculated using data collected during the audit and the following formula:
Span value - 11- | 10 -(OPLR){O.D.)]| x m
where:
Span value - the factory assigned span filter value in
percent opacity
CPIR - the cotical oath length ^tio "rcm b' irk !3
vj.w. - :ns -;psn n i :er vaiue in opncai density reaci
from the serial number plate on the front of
the transceiver unit (blank 23).
5. Go to the opacity data acquisition system (DAS) location and inspect the
data recorder to ensure proper operation. Annotate the data record with
the auditor's name, affiliation, plant, unit, date, and time
8-5
-------
Control Unit Checks
Fault Lamp Checks
6. Record the status (ON or OFF) of the FAULT lamp in blank 7.
Note: An illuminated FAULT lamp indicates that one or more fault
T? tho^SniT Te b"" d?£ec?ed by the instrument self-diagnostic circuitry
If the FAULT lamp ls illuminated, source personnel should be asked to
determine the cause of the fault. The auditor should d scuss the cau« anri
magmtude of the COHS fault with source personnel to detlmlne if the audn
can continue. Specific fault information can be output to the digital
display of the control unit using the following procedure:
svctL^!,,?*70 TEuT rey to disPla> a tw° or three word description of the
k=v tn H » °" *•! fr?nt pane1 meter of the "ntrol unit. Press the ENTFR
alyn d. ""]"! lf mu1tiple faults have occurred; pressing the ENTER k»v
allows the audnor to scroll through additional fault information *
Press the SYSTEH DATA key to return to the system data menu.
Zero and Span
7. Press the CALIBRATE key. "ENTRY CODF . n- u,m
front panel meter of the control £S?f. Wl11 8PPear °" the di9ital
CALIBRATF'lFn^niV enter.^e sPan m°de for 1.5 minutes. The red
calibre mode "* l11uminated to 1ndi«te the COMS is inlhe
"' ^SnS.5^11 Va1Ue °UtpUt t0 the front Panel «*ter of the control unit
12. Record .the span value output to the data recorder in blank 9
8-6
-------
Note: After 1.5 minutes in the span mode, the COMS will automatically
enter the zero mode.
13. Record the zero value output to the front panel meter of the control unit
in blank 13.
14. Record the zero value output to the data recorder in blank 11.
Note: During the zero calibration check, the span filter is removed from
the measurement path allowing the instrument to read the zero mirror alone
The zero mechanism is designed to present the transceiver with a simulated'
clear-path condition. The daily zero check does not test the actual clear-
path zero, nor does it provide a check of cross-stack parameters such as
the optical alignment of the transmissometer or drift in the reflectance of
the retroreflector. The actual clear-path zero can only be checked durinq
clear-stack or off-stack calibration of the COMS. In addition to
simulating the instrument clear-path zero, the zero mechanism allows the
amount of dust on the transceiver optics (primary lens and zero mirror) to
be quantified by the COMS zero compensation circuitry. mirror; to
Note: After 1.5 minutes in the zero mode, the COMS will automatically
return to the measurement mode. The transition from the zero mode to the
l^mn"^??"1 + ^keS.uan additional 30 seconds. The CALIBRATE indicator
lamp will go out when the 3-minute calibration cycle is complete.
Zero Compensation Check
15. Press the SYSTEM DATA key to enter the system data menu.
16' (eT ^ fT*R7FkRe£ rnMpVhe 2%* ™"Pensat1on value in percent opacity
(e.g., #.# % ZERO COMF.") is displayed on the panel meter of the control
17, Record the zero compensation value in blank 12,
Before auditing the on-stack components of the COMS, several items on the
dam It* tmhenufmust be reset to ensure valid data are collected and to prevent
damage to the transceiver calibration mechanism. The original setting of each
parameter to be changed must be recorded so that it can be reset at the
conclusion of the audit. In addition, the OPLR set within the control unit can
be output as one of the items on the constants menu.
18'
19
FNTPY rnnr°NSTn«TS-ik?y t0 Qain aCC6SS to the items on the constants menu.
LNTRY CODE - 0 will appear on the panel meter of the control unit.
Enter ttenumber 10 as the entry code by pressing the YES (A) key until the
number 0 is replaced by the number 10. "ENTRY CODE - 10" should be
displayed on the panel meter of the control unit.
8-7
-------
20. Press the ENTER key to scroll through the items on the constants menu until
the OPLR value is displayed.
21. Record the OPLR value in blank 13.
Note: If the OPLR value is not determined directly from the control unit,
the OPLR in blank 4 should be entered in blank 13.
22. Press the ENTER key to scroll through the items on the constants menu until
the automatic calibration frequency ("CAL EVERY ## HOURS") is displayed on
the panel meter.
23. Record the automatic calibration frequency in blank 14.
24. Press the YES (A) or the NO (T) key until the automatic calibration
frequency is set at 00 (e.g., "CAL EVERY 00 HOURS").
Note: Setting the automatic calibration frequency at 00 disables the
automatic calibration function to prevent inadvertent movement of the zero
mirror during the calibration error portion of the audit. The zero
mechanism may be damaged if it is activated while the audit jig is
installed on the transceiver unit. If the automatic calibration frequency
is already disabled (set to 00) at the control unit, the daily COMS
calibration is probably initiated by some other COMS control device, such
as the computerized data acquisition system. If this is the case, the
auditor should have source personnel disable the automatic calibration
cycle at the appropriate stage of COMS control. The auditor must be
careful to note that the calibration cycle has been disabled and should
remind source personnel to reset the automatic calibration cycle at the end
of the COMS audit.
25. Press the ENTER key until the instrument output range 1 setting ("OUTPUT
RANGE 1: ###%") is displayed on the front panel meter of the control unit.
26. Record the value of output range 1 in blank 15.
:n? :":! . -, ;r :^s .:C ,'T-(
, -•< - ^ •"}''"r^! :T 7 i \j •"• C • • -jr***'*
V ^ • 3 • > W'w ) j w i . »^".H d k_ A« • vw/« / .
28. Press the ENTER key until the instrument output range 2 setting ("OUTPUT
RANGE 2: ###%") is displayed on the front panel meter of the control unit.
29. Record the value of output range 2 in blank 16.
30. Press the YES (A) or the NO (T) key until output range 2 is set at 100%
(e.g., "OUTPUT RANGE 2: 100%").
Note: Setting both output ranges to 100% ensures that the instrument range
will not be exceeded during the calibration error test,
31. Press the SYSTEM DATA key to display the items on the system data menu.
8-8
-------
32. Press the ENTER key until instantaneous effluent opacity values are
displayed on the front panel meter of the control unit.
33. Go to the transmissometer location.
Retroref lector Dust Accumulation check
34. Open the retroref lector protective weather cover.
35' o6t?cs i^blank"]"1 °pacUy readin9 Prior to cleaning the retroref lector
Note: Acquisition of effluent opacity data needed for the retroref lector
a«1sSnr»;V?ha SttaCiCUmU-;t1°nnSe?lcS may require c™ication with an
assistant at the control unit or DAS location.
"'""""tor optics, and
37. Record the post-cleaning effluent opacity in blank 18.
38. Close and secure the protective weather cover.
Transceiver Dust Accumulation r.hprfc
39. Open the transceiver protective weather cover.
4°' O eeffUnt °PaClty read1ng Pri°r t0 Cleanin9 the transceiver
anTzero6 1™%?™ """ ^ ^ ^ transce1w °Ptics (Primary lens
bUnk 20? tranSCeiVer and record the Post-cleaning effluent opacity in
s ,iava -san
-™._ ,
-o,,,p=,;,u.ion vc,Lie aus: ja jpaatea ;o ensure tnai cne zero comoensation
circuitry does not continue to adjust the transceiver output fSr dSst that
is no longer present on the optics. The zero compensation value is undated
stPn^I^th"9 \Z%° 8nd fpan "Hbration cycle at the contro un t
unU locatS9 mUSt be performed b> an assistant at the COHS control
: -ntll the
displayed on the panel meter. ^nuuia D.
45. Press the ENTER key. The word "CALIBRATE?" will appear on the panel meter
to ensure that the calibration cycle is not accidentally initiated
8-9
-------
46. Press the YES (A) key to initiate the calibration cycle.
Note: After 1.5 minutes in the span mode the COMS automatically enters the
rperfo™d,^ "ree neutral
-
. res ajarss s?srh,a?sSL£, ,
the instrument response relative to the current clear-path zero
r
1r1n'd> and placing the calibrat?on
^e zero compensation function be
the calibration error test and has installed an "AUTO COMP'
8-10
-------
switch inside the transceiver for this purpose (see figure 8-3). Defeating
the zero compensation with the "AUTO COMP" switch requires access to the
transceiver internal circuit boards and should only be attempted by an
experienced auditor or with the assistance of source personnel. If it is
impractical to defeat the zero compensation function, the auditor may
continue the audit with functioning zero compensation circuitry, provided
the zero compensation setting was updated following the transceiver dust
accumulation check. (Steps 43 through 46).
Note: Steps 52 through 54 should be omitted if the auditor does not wish
to defeat the zero compensation function for the calibration error check.
52. Remove the round lamp access plate from the back of the transceiver by
loosening the three captive retaining screws and pulling off the cover.
53. Look through the lamp access port into the rear upper right-hand corner of
the transceiver and locate the "AUTO COMP" toggle switch (see figure 8-
0 the ™
Note: The "AUTO COMP" toggle switch is mounted on the upper right-hand
d?f?1cul°t.the 6XtinCtion ^tical de"^y) Panted circuit' board'; access is
54. Replace the lamp access cover and temporarily secure the cover bv hand
tightening one or more of the retaining screws. y
"" C0mpensation funct1on ha' been defeated (YES or NO)
56. Open the gray junction box mounted near the transceiver uhit.
Note: The audit davics will net slice on until it is flush ^h ^ ^,-
^' ~ ' ~*:~* :r;CU-- -£ '-a-<-^ ^G: :o ^3- :; aca':,is'; ;he -~-~ *•> *-~~ -~ "-
v.-iL- ,,-c *~rz< :=rv-ng ;;ie ^ero jiirrcr .TiGior/
58' &d77he ^actor^ass^ned filter value in optical density in
MinOl. This value is written on a data plate located on the front of
t he transceiver unit just to the lower left of the primary ob ec 1 ens
8-11
-------
AUTO COMP SWITCH
DOWN "ON"
UP "OFF"
LAMP
OBJECTIVE LENS
MEASVALPOT
us-tr^r, .^ece; 353C Trarsscaivsr ^1:75 ,
axaggeraiaa view of -AUTO CDM?" 5w
D A.--*S-
8-12
-------
59. Adjust the audit jig iris to produce a 2 mA output current on the junction
box meter. This adjustment simulates the COMS clear-path zero setting.
Note: The junction box meter is located in a gray plastic box mounted near
the transceiver unit. The meter allows the auditor to get the jiq zero
value near the zero value on the data recorder. The final jig zero
adjustments should be based on readings from the data recorder The
jig zero does not have to be exactly 0% opacity since the audit
filter correction equations can account for an offset in the jiq
zero. A jig zero value in the range of 0-2% opacity is acceptable.
6°' and°26 ^ ^^ ^^ SeHal nUmberS a"d °pacity Values in blanks 24. ?^_
61. Remove the filters from their protective covers; inspect and, if necessary
ciean tnem. ^^••^jui^,
62. Record the jig zero value from the data recorder.
Note: The acquisition of monitor
assistant at the data recorder location!
63. Insert the low range neutral density filter into the audit jig.
64- vaiue
u * * H'^eriLs instantaneous opacity (or opacity data with th«'
shortest available integration period). P * th the
65. Record the COMS response to the low range neutral density filter.
the mid
range neutral
68. Remove^the mid range filter from the audit jig and insert the high range
^'* •*«*« v uuui u.Aiiiini.r**i v i IAJ 11 ininiirne- *^v*^i ^* ****** *_ _i _WL_ r+ r\* t n
. «..sc ..cut, a, ueium Tl the
70.
?hri?nt7prhl9hiraT fl'luer' Wait aPPr°^^tely two minutes, and record
the jig zero value from the opacity data recorder.
thln:i*lf the/in!u Ji-? 2er° Value differs from the initial value by more
than 1% opacity, the jig zero should be adjusted to agree with the init^
three-filter ™ d-e., low, mid, and h?Jh) should'be tl&
8-13
-------
71. Repeat steps 63 through 70 until a total of five opacity readings are
obtained for each neutral density filter.
72. If six-minute integrated opacity data are recorded, repeat steps 62 through
70 once more, changing the waiting periods to 13 minutes.
73. Record the six-minute integrated data.
Note: In order to acquire valid six-minute integrated opacity data each
filter must remain in the jig for at least two consecutive six-minute
periods. The first period will be invalid since it was in progress when
the filter was inserted. A waiting period of 13 minutes is recommended.
74. When the calibration error check is complete, remove the audit jig
close the protective cover on the junction box, and close the
transceiver head.
?-AiiTn rnMD-6 2eroucomPe"sation was defeated for the calibration error test
( AUTO COMP" switch moved to the "UP" position), the zero compensation
circuitry must be reactivated by following steps 75 through 77? If ?he
he "11bratio" emir
75. Remove the round lamp access cover from the back of the transceiver unit.
D° NOT
by ^hten^g the three
' ' i: -' ' af; K . 1 " ~-- "• - '• - ~ .- ~
compensation function «*, r.oc aeacnva ted 'foFthTctn brat lon^error test
Reset Control Unit
79' 1 C°ntro1 "1- Access the constants ^enu and return the
rhr eurn e
calibration frequency, the output range 1, and the output range 2 settinqs
to the values recorded in blanks 14. 15. and is F 9 settings
80. Obtain a copy of the audit data from the data recorder.
81. T^scribe the calibration error test results from the data recorder to
blanks 28 through S3, and complete the audit data calculations
8-14
-------
8.1.3 Interpretation of Audit Results
is designed to help the auditor interpret the Land Model 4500
Stack Exit Correlation Error
The path length correction errors in blanks 54 and S5 should be within +?
This error exponentially affects the opacity readings resulting in over or
?hee«?jTatl?h °f the+stac^ exU °Pacit>- The most cormnon er^or in —ting
the path length correction factor (OPLR) is the use of the flange-to-flanqe
distance in place of the stack or duct inside diameter at the monitor ocation
IdPnt?fr°H h111 rSSU * in "nderest1mat1on of the stack exit opacUy and can be
st c T>heC?Kntg *ne moniHtor °Ptica! Pa" length to theP flange ?o"ange
to four feet flange-to-f1an9e dist^« should be greater by approximately t2o
Fault Lamp Analysi?;
Zero and Span Check
named S'oer
of zero and span errors are difficult to pinpoint during an audit.
will 11 the"ro and span errors are due to data recorder offset, both errors
will be in the same direction and will be of the same magnitude
Zero Compensation Check
The 2!T0 comf>ensati°n function is designed to minimize the effects of dirtv
3 °V lnstrument outPut- ™e «nount of dust on the transceiver exit
and zero nnrror is quantified, in percent opacity, during each'zero
'
, ,
ceed" r°ooaci {y- If6,"" C°mPfinsation value reorde'ln bla« sh u d not
' -
ceed rooaci y f, o
hniirf ,m Pth +' " excesslve ze>-o compensation value is due only to dust
build up on the transceiver optics, it indicates that the purge air flow and/or
.he frequency of lens cleaning is insufficient to keep the trans'] ss^eter
8-15
-------
Optical Alignment
- ' -
Transmissometer Dust Accumulation Chec
stable within +2* opacity) before and after th. ?ff1Vent opacity is reasonably
If the effluent'opacity is fluctuattna h™ thf. clea^ng Jhe °Ptical surfaces.
analysis should be omitted tluctuatln9 b> "»™ than ±2X, the dust accumulation
Calibration ErrorCHprfc
riuwsYt.1;, ins s^so-11' a
•^ ;-Sjjr-0 c'.fi "orn cor—-1^,7 ., «- ^^^^^ T r fc w """" -•''-"-. •<".,' ^r^r ..*? ' ~'2~~,\"",~-'~~
s^^rin^rz^rij^s^rs'''^'!/!-!^^'1-!'^"''
""the ^ ,'.^^'3ssSi*^:~sjiLsT^^1?.
8-16
-------
9. PERFORMANCE AUDIT PROCEDURES FOR DATATEST MONITORS
9.1 DATATEST MODELS 900A AND 900RM
9.1.1 COMS Description
The Model 900A consists of three major components: the transmissometer
the air purge system, and the control unit. The transmissometer consists of a
transmitter mounted on one side of the stack or duct and a receiver mounted on
the other side. The transmitter contains the light source and a perforated
disc which rotates to produce the reference, measurement, zero, and span
signals The receiver contains the photodetector and the optical alignment
sight. The transmissometer is equipped with fiber optic cables used to
t^Hptltn6 °PMual reference and calibration signals from the transmitter to
LblPncpH t '? the rf°!uVer Sn1t' ^teg^ configuration of the fiber optic
len dustlno nfrtahSmit * * reffr,ence si9nal allows the instrument to monitor
lens ousting of the stack-mounted components.
cavitlp! w?t"hlaCtkKCOmp0?entS are e9uiPPed wnh a^ Mows" that flood the
f?r niirninn t lnstr« mounting flanges with filtered ambient air. The
kppAT3 9 ySiem ferV?S a threefold P^pose: (1) it provides an air window to
keep the exposed optical surfaces clean; (2) it protects the ootical surfar«
rro°: t™d™cTtoon ?hVfrr* Tstr: a"d (3) ?t •in*-iz" **•« »» °°
lir system^ f«r ?hp t lnstrument- A typical installation has separate purge
air systems for the transceiver and retroref lector assemblies.
receiver tolnn^r^V"1-*00™61^ the Sln91e-Pa" transmittance of the
resutant stack ^itPnnt^ ?e"si V°rrected to stack exit conditions. The
onar tv Th! T -, P ?a density is converted to instantaneous stack exit
°f inte9rat1^ ^^antaneous opacity
is a double-pass transmissometer. The transceiver
source, a^chopper, mirrors, lenses, and a detector. The
,^" " ~' '--~w' --^'-i '-"S only 3 ^irror. A nieHSur»'ne.it ^esni ^rrducorl "^ iU-
~t"wi
.
T- ris vHe iTiSasu. Siiien i jeam 10 t/ss transc3iver wnprp P
splitter d! verts the measurement beam to the detector The resultant
'* proportional to double-pass transmittance of the
qnna Th?, Model 9°°^ "ntrol unit is essentially identical to that of the Model
900A. The control unit converts the transceiver output to units of either
instantaneous or six-minute averaged stack exit opacity.
tran^i"ometer converts the amount of light received by the detector
J19 haf P-S?ed, thr°U9h the effluent to a measurement signal and
s anal The ^^^J'ti'9" transrai«edjb> the light source to a reference
signal. The ratio of the measurement and reference signals is processed into a
The model number of the DataTest 900RH COMS has been changed to 900RHD.
9-1
-------
f ?h represents double-pass (single-pass for the Model 900A) transmit-
th f«, f 5fflue"h at th? fansnlssoMter location. The control unit uses
H~c?tw «fnJh a55?ltt?nc! JS "1cu1ate "P^h" optical density, or the optical
density of the effluent at the transmissometer location. In order to provide
stack exit opacity data, the path optical density must be corrected to stack
exit conditions. The correction factor is calculated as the ratio of the stack
exit inside diameter to the inside diameter of the stack or duct at the
transmissometer location. This ratio is called the "stack exit correction
factor. The stack exit correction factor is preset within the control unit
circuitry by the manufacturer. The following equations illustrate the
rea exit opac'nj?6 ""* '*" Correct1on factor' Path "P""! density,
L,
— - stack exit correction factor
W
where: L, - stack exit inside diameter
L, - stack inside diameter or duct width at the
transmissometer location
op.-i - lo-- xloo
where: OPX - stack exit opacity (%)
OD - optical density measured by the transmissometer
9-1.2 Performance Audit Procedures
Prel Irrnnary Data
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order of reliab lity m n
«-?^^ ffl^rs^r^' ^^'^
3. Record the source-cited stack exit correction value in blank 4.
r^
Typ Jallv t'hir^r"0"^^3?1"66 Sh°uld be Set inside thrio^or ld
cer!" cation dat.nr'r CJ-ed fl"°m ™^°r installation data, monitor
reports continuous opacity monitoring system (COM3) service
reports.
9-2
-------
4* Jn%il!rrCe,iZ!:1r0 ^ ***n c^^br^^ valUBS. Record these
in blank 5 and blank 6, respectively.
5.
calibration and may not be
RomrHc nf fh Ues re:;orded at,COMS Installation and/or certification.
Records of the zero and span values resulting from the most recent monitor
calibration should be kept by source personnel.
Inspect the opacity data recorder (strip chart or computer) to ensure
proper operation. Annotate the data record with the auditor's name
affiliation, plant, unit, date, and time. '
Fault Lamp Checks
and
alnKd of
Record the status (On or Off) of the LAMP OUT fault lamp in blank 7.
Note: An illuminated LAMP OUT fault lamp indicates that the lamp cutout
has been reduced by more than 50%. This could have a dramatic effect on
the accuracy of the opacity data and should be repaired iSately
Record the status (On or Off) of the BLOWER OUT fault lamp in blank 8
Record the status (On or Off) of the OVER EMISSION fault lamp in blank 9.
Record the status (On or Off) of the MAINTENANCE fault lamp in blank 10.
Note: Illumination of the MAINTENANCE fault lamp indicates the stack exit
opacity has exceeded a value set by the source. The MAINTENANCE fault
lamp is typically adjusted to a lower set point than the OVER EMISSION
opacity^ Pr°Vlde an 1ntermediate indication of elevated effluent
°ff) °f the 4 percent DUST fault lan)P
amn,mt nJ i ^°J- he f percent DUST fault ^mp'indicates that the
amount of lens dusting on the optics of the transceiver (Model 900RM) or
the transmitter and receiver (Model 900A) exceeds the equivalent of 4
unCrcp S??*1"^-^;^12 1SVe1 °f dust accumulation, federal standards
^ .«-,.. Part oO.i^^jj require that the transmissometer cptics be claansd
9-3
-------
Control Unit Checks
Stack exit correction factor measurement (optional).
Note: This measurement can be made only on Model 900 monitors equipped
ana-ed P~2 *
-------
24. Open the Model 900 RM retroreflector. Inspect and clean the optical
surfaces, and close the retroreflector. (If auditing the Model 900A,
inspect and clean the detector optics and fiber optics dust monitor.)
25. Record the post-cleaning effluent opacity value from the opacity data
recorder in blank 19.
Transceiver (or Transmitter) Dust Accumulation Check
26. Record a pre-cleaning effluent opacity value from the opacity data
recorder in blank 20.
27. Open the transceiver or transmitter. Inspect and clean the primary lens
and the fiber optics dust monitor and close the transceiver or
transmitter.
28. Record the post-cleaning effluent opacity value from the opacity data
recorder in blank 21. -
Optical Alignment Check - Model 900RM
29A. Remove the silicon cell detector from the transceiver and install the
alignment bull's eye in its place. Note the position of the image of the
measurement beam with respect to the cross hairs. Remove the bull's eye
and reinstall the detector. y
30A. Indicate whether the image of the measurement beam is centered on the
alignment reticle in blank 22.
Optical Alignment Check - Model 90QA
29B. Swing the 0.010-in. aperture in the transmitter into position and look
through the alignment port at the back of the detector housing Not* the
^?nnU?!L0n mn I?easuren*nt beam image with respect to the cross-hairs.'
Swing the 0.010-in. aperture back to its original position
;n D ar< K ^ 2.
Calibration Error Check - Model 900RM (Jig Procedure)
31. Open the transceiver and install the audit jig.
32. Install the clear hole filter and adjust the jig until a zero value
between 0% and 2% opacity is read on the opacity data recorder.
33. Record the audit filter data in blanks 23. 24, and 25.
34. Remove the audit filters from their protective covers. Inspect and clean
each filter.
35. Alternately insert the low,-mid, and high range audit filters into the
audit jig. Wait approximatsly two minutes per filter for a clear resoons-
to be recorded and displayed on the data recorder.
9-5
-------
36' '1 6ach run of fmers How, mid, and high)
any °f the
38. If six-minute integrated opacity data are recorded, repeat steps 35 and
once more, changing the waiting periods to 13 minutes.
39. Remove the audit jig and close the transceiver.
40. Return to the control unit location.
§|"brat1on error data f™ ^e opacity data recorder in blanks
Lens Dusting Check (Final)
u^^
the necessary test terminal, write "K; in blank 26 "Ot
42. Turn the "zero calibration' switch to the 'On' position.
43. Measure the voltage at TP-3 on PC-5 in millivolts.
45. Turn the "zero calibration' switch to the 'Off position.
Calibration Error Chgclt - Model 90HA
900A transmlssoiseter requires the use cf an
tne calibration error cneck cannot' be "performed"^"'" :*"" -« -"- --
1-31. Open the transmitter and install the audit jig.
1-32. Record the audit filter data in blanks 1-23. T-24. and T.JMJ
1-33. jJ^tJe^iKHt filters from their protective covers. Inspect and clean
1-34. Install the clear hole filter and record the effluent opacity.
9-6
-------
1-37. Repeat steps 1-34 through 1-36 until a total of five opacity readings are
obtained for each audit filter.
1-38. If six-minute integrated opacity data are recorded, repeat steps 1-34
through 1-36 once more, changing the waiting periods to 13 minutes.
1-39. Remove the audit jig and close the transmitter.
1-40. Return to the control unit location.
1-41. Record the calibration error data from the opacity data recorder in blanks
1-26 through 1-63.
Lens Dusting Check (Final)
Note: This check can only be conducted on Model 900 monitors equipped with
an updated PC-5 circuit card that has a TP-3 terminal. If the COMS is not
equipped with the necessary test terminal, write "N/A" in blank 26.
42. Turn the "zero calibration" switch to the "On" position.
43. Measure the voltage at TP-3 on PC-5 in millivolts.
44. Divide this millivolt value by 100, and record the result in blank 26
mis value is the less dusting in percent opacity. ' '
45. Turn the "zero calibration" switch to the "Off" position.
9.1.3 Interpretation of Audit Results
This section is designed to help the auditor interpret the Datatest COMS
performance audit results. A general discussion of performance audit results is
presented in Section 2 of this manual' re>u,i:» is
±w Th6 P 9 h correction errors ™ blanks 53 and 54 should be within
±2%. This error exponentially affects the opacity readings resulting in over or
underestimation of the stack exit opacity.- The most comnSn error in^omputing
the path length correction factor (OPLR) is the use of the flange-to-flange
distance in place of the stack or duct inside diameter at the monitor location
This error will result in an underestimation of the stack exit opacity and can'
be identified by comparing the monitor optical path length to the flange-to-
flange distance. The flange-to-flange distance should be greater bv
approximately two to four feet.
Fault Lamp Analysis
Fault lamps are typically associated with parameters that the monitor
manufacturer feels are critical to COMS function, and to the collection of valid
opacity data. The parameters associated with each of the fault lamps found on
cne L^atest control unit are discussed in the audit procedures. With tne
9-7
-------
exception of lamps that warn of elevated opacity levels (alarm or warning
lamps), an illuminated fault lamp indicates that the COMS is not functioning
properly.
Zero and Span Check
The internal zero and span errors (blank 56 and blank 58) should not
exceed 4% opacity. A zero or span error in excess of 4% opacity may be due to
excessive dust accumulation on the transceiver optics, misoalibration of the
COMS, or an improperly named span filter. Dust accumulation on the transceiver
optics sufficient to cause significant zero error will be accompanied by an
excessive lens dusting value and an illuminated 4% dust lamp. Other causes of
zero and span errors are difficult to pinpoint during an audit.
If the zero and span errors are due to data recorder offset, both errors
will be in the same direction and will be of the same magnitude.
Zero Compensation Check
The zero compensation function is designed to minimize the effects of
dirty optics on the instrument output. The zero compensation value recorded in
blanks 59 and 60 should not exceed 4% opacity. If an excessive zero
compensation value is due only to dust build up on the transceiver optics it
indicates that the purge air flow and/or the frequency of lens cleaning is
insufficient to keep the transmissometer optics clean. A negative zero
compensation value, or a value that persists after thorough cleaning of the
transceiver optics, indicates malfunctioning or improperly adjusted COMS
electronics. The most common cause of negative zero compensation values is
clear-path adjustment of the COMS when the optics are not clean.
Optical Alignment
When the transceiver and retroreflector are misaligned, a portion of th«
measurement beam that should be returned to the measurement detector is
misdirected, resulting in a positive bias in the data reported by the COMS. Onp
o, I.T? nest :CTIO- -s-usss :f ~r; sa^srijrsrjt i vr - ~ -'"
common cause of nrisal ignmeni is thermal expansion and contraction of'the
structure on which the transmissometer is mounted. If the COMS is being audited
while the unit is off-line (cold stack), the results of the alignment analysis
may not be representative of the alignment of the instrument when the stack or
duct is at normal operating temperature.
Transmissometer Dust Accumulation Check
The results of the dust accumulation check (blank 63) should not exceed 4%
opacity. A dust accumulation value of more than 4% opacity indicates that the
airflow of the purge system and/or the cleaning frequency of the optical
surfaces are inadequate. When determining the optical surface dust accum-
ulation, the auditor should note whether the effluent opacity is reasonably
stable (within ±2% opacity) before and after the cleaning the optical surfaces
If the effluent opacity is fluctuating by more than ±2%, the dust accumulation
analysis should be omitted,
9-8
-------
Calibration Error Check
Calibration error results (blanks 73. 74, and 75 or blanks 1-91, 1-92, and
ii92!) in excess of ±3% are indicative of a non-linear or miscalibrated
instrument. However, the absolute calibration accuracy of the monitor can be
determined only when the instrument clear-path zero setting is known. If the
zero and span data are out-of-specification, the calibration error data will
often be biased in the same direction as the zero and span errors. Even if the
zero and span data indicate that the COMS is calibrated properly, the monitor
may still be inaccurate due to error in the clear-path zero adjustment The
optimum calibration procedure involves using neutral density filters during a
clear-stack or off-stack COMS calibration. This procedure would establish both
the absolute calibration accuracy and linearity of the COMS. If this procedure
is impractical and it is reasonable to assume that the clear-path zero is set
correctly, the monitor's calibration can be set on-stack using either the
neutral density filters or the internal zero and span values.
9-9
-------
-------
SECTION 10
PERFORMANCE AUDIT PROCEDURES FOR COMS WITH COMBINERS
The audit procedures described in the previous sections of this manual
presume that the continuous opacity monitoring system (COMS) includes only a
single transmissometer installed to view the total emissions from a source
However, at many sources, the COMS includes multiple transmissometers which are
installed to view separate effluent streams that are subsequently combined and
released to the atmosphere through a common stack. This situation is
encountered frequently in the electric utility industry where the boiler
effluent is often routed through twin preheaters, twin ESPs, and twin I D fans
before being recombined in a single exhaust stack. At many such sources
transmissometers are installed in each duct to facilitate use of the monitoring
data for control equipment evaluation and to provide convenient access to the
transmissometers for maintenance and quality assurance activities.
COMS's with multiple transmissometers include analog or digital
devices that automatically determine the equivalent stack-exit opacity for the
entire effluent stream based on the individual opacity measurements provided by
the transmissometers. These devices are typically referred to as "combiners "
The combiner device may be a separate device or may incorporate some or all of
the functions normally associated with the standard control unit.
. Audits of COMS's with combiners necessitate the use of
modified audit procedures. However, these procedures rely heavily on the
monitor-specific procedures detailed in Sections 3 through 9 of this manual.
rni?'ce£ t?n d"cnbes a generic approach for conducting audits of opacity
COMS s with combiners The approach requires that the auditor evaluate (1) the
ability of each transmissometer to provide accurate and precise effluent
opacity measurements at their respective monitoring locations, and m the
accuracy o, the stack-exit opacity values recorded by the COMS. To accomplish
.his the auditor must first conduct evaluations of the individual transmis-
someters using* standard audit procedures. Minor procedural modifications may
be necessary ,o 5cconMod.it a equipment differences oet*een combin-r and --]*
determined using either a one-"point orT multl-point"audirtechnique "depending
on the type of monitoring system being audited.
10.1 CALCULATION OF STACK-EXIT OPACITY FOR COMBINER SYSTEMS
Both the single-point and multi-point audit techniques require the
calculation of "correct" or "expected" stack-exit opacity values as a function
of the opacity at each monitoring location. The appropriate equations for
calculating the stack-exit opacity values depend on source-specific conditions
beveral equations ranging from the most general approach to commonly applicable
simplifications are presented below. The auditor must select the form of
equation which is appropriate for the particular situation. It is generally
recognized that the various methods for calculating the stack-exit opacity
involve some assumptions which are not necessarily accurate under all
10-1
-------
conditions. The calculation method selected should be consistent with the
beingnauditedP tatl°n °f the °pacity m°nit°rin9 program at the facility
The general relationship between multiple duct mounted transmissometer
measurements and stack-exit opacity values is most conveniently IxpresslHn
units of optical density (Conversions between opacity and optica? density
will be discussed later.) The relationship is based on conservation of
mass and an assumed linear relationship between the optical density and the
mass concentration of the aerosol. The relationship for double-pass
transmissometers is described by Equation (10-1):
where:
Equation 10-1
nn n
KE 1 -IV,
LE 1-1
V = average velocity at measured location or stack-exit
K I ^fi8;!^!^?!.?:.68.?1,1?6"^?1?6"? locati°n ^ stack-exit
inetaeSrnaTdniaLater)en9th (e'9" 1nternal d"Ct d1»»^«» "r stack exit
subscripts:
stack-exit location
transmissometer locations; l,2,...n
, r .,
<2 " ^ "'' '^ the=facm1 to'be eliminated "from
of e6 ch oetheare " Fo^th"1" duct^onit°r1t19 locations are mirror images
cross section- M I I "?e °f, two,Tit0rin9 locati°^ ^th identical duct
becomes ( ' L' ' L= ' L and ^ ' Az - A). The general equation
10-2
-------
Equation 10-2
°DE • 4 -^ (Vi OD'+ v< °^
Assuming any temperature and pressure differences between the monitoring
Slvs ? • • ?ta£k 6Xlt are insi9"1f1«nt, and that there is no
sigmficant air inleakage, the effluent flow variable can-be expressed as:
VE AE = A (V, + V2) Equation 10-3
Thus:
LE (V,OD, + V2OD2) Equation 10-4
2
ODE
2L (V, + V2)
In most cases, measurement of the velocity or volumetric fl
ow
LE (OD, + OD2) Equation 10-5
OD
,£ _
2L
"u""""
where:
single pass optical density of the filter inserted at the N
monitoring location
Thus:
Equation 10-7
'F2.'
ODE = — (ODF1 + ODF2)
2L
For Lear Siegler monitors, the factor LE/2L is referred to as the "OPL R " Fnr
Thermo Environmental Instruments monitors (formerly Contraves-Goerz monitors
tors)
10-3
-------
the term LE/L is referred to as the "SIR." These terms are useful for modifying
the above equations to be consistent with the manufacturer's technology.
Equations (10-2), (10-4), and (10-5) may be used to calculate the optical
density at the stack-exit based on the optical density measured by multiple
transmissometers under the conditions described above. Equation (10-7) may be
used to calculate the optical density at the stack-exit based on the single
pass optical density values of calibration attenuators inserted into the
transmissometer light beams under the specified conditions. Many other
combinations and arrangements of the above equations are possible. In any
case, the equation selected should yield the optical density at the stack-exit
as a function of the optical density at each monitoring location. The optical
density values are easily converted to units of opacity as follows:
nn Equation 10-8
OpacityE « 1 - 10~UUE
Conversely, if the opacity values at the monitoring location are known, the
optical density values can be calculated as follows:
°DE * -Iog10 (l-OpacityE) Equation 10-9
10.2 GENERAL AUDIT PROCEDURES
10.2.1 Audit Procedures for Individual Duct Transmissometers
Performance audits of each duct-mounted transmissometer must be conducted
using the standard audit procedures for single transmissometer CQMS's.
These audits are straightforward if each transmissometer is provided with a
separate control unit and data recording device. However, if the control unit
or data recording device is time shared between several transmissometers, or if
the control unit functions are incorporated into the combiner unit, some
modifications to the standard ludit ^r^csdurss 7-av be r^casrar^ in'crdsr to
:IiCri i IC.^S inC 00-"5. " '"' 4CC5-S5 "0 t,^2 3 £ ^ r n n *• •i 5 r c <- ' ^^ ; ^ c
ana responses, nie auditor j.ay need to refer to tne operator's manuai or seek
assistance from source personnel familiar with the COMS to obtain the
necessary data.
As an example of the above considerations, the applicable procedural
modifications for the Lear Siegler Model 622 Emission Monitor Combiner and two
RM-41 duct-mounted transmissometers are described here. The reader is
cautioned that these procedures are not necessarily applicable to other opacity
COMS's with combiners. The analog combiner also serves as the control unit for
both transmissometers and contains several features not included on the typical
RM-41 control unit. The two most important are:
(a) the analyzer switch - located on the front panel, this switch allows
selection of measurements from: analyzer #1, analyzer #2, or
"stack-exit" values, and
10-4
-------
(b) the out-of-service switch - located inside the combiner control unit
on the upper right hand side of the card rack. This switch allows
either the A or B side monitors to be taken out of service The
remaining monitor will function normally.
To obtain meaningful audit data, the "analyzer" and "out-of-service"
are a°s fo^ows:6 C°nfigUred Correctly. The most important considerations
• Fault Lamps - With the analyzer switch in the "exit" position, any
fault condition existing for either monitor should result in the
illumination of the appropriate fault lamp. The fault lamp will flash
-' 1s pos1tioned to the monitor
=^h?Ce TI!6"*,' Zer° compensation, or input current measurements
are obtained by placing the measurement switch in the proper
position (same procedure as used for single RH-41 applications) The
analyzer switch must be placed in the position corresponding to'the
individual monitor for which these measurements are desired
°f test funct1ons (^g., reference current, zero
meaningful if the
combined stack-exit opacity, both the A- and B-side monHo^s must
remain in service. To obtain the stack-exit opacity for either the
A- or B-side monitors independently, the alternate monitor
service ra°nit0r is removed
ce
Source personnel v^l ususv cv^
.;r ir,a w^.v;5 oy ooservinq the ^^niD
span errors for each transmissometer provides the best ral ihratinn riv^-p*
^-^r!±i^ir£rr s'^alreErr^;?
extremely unlikely that a major zero or span shift in one monitor wnniH ho
completely offset by an oooositP anH pn,,ai *hitl • J^°nL^_°r,?ou1d 2e
. zero or span shift in one monitor would be
iiroiu taVPP°S1ue a?d equal shift in the other monitor. Thus,
ikely that a combined system calibration value would disguise
m, 70.o 6i °r both worn'tors. It is recommended that the auditor
nn zero and span error determinations for the combined system, and perform
lonal zero and span error checks for each transmissometer when the errors
observed tor tne combined system calibration exceed +1 percent opacity
10-5
-------
10-2-2 Audit Procedures for Combiner Stack-Exit Opacity Val
a
int check is sufficient to detect programming errors The
'"
..,
that the audnor (1) determines the outputs of all of the duct-mountpH
transmissometers for any convenient time period e g sfmultaneous
instantaneous measurements or six-minute averages) (2) calculatef thp
(2) Multi-Point Check - For a COM3 with two duct-mounted
""
at the
2
combiner responses be obtained for the multi-point check
wnhb,1ne;3reSSeSandt ""^P0"-^' «P«t- v.lu^
10-6
-------
SECTION 11
ZERO ALIGNMENT CHECKS
The zero alignment of a continuous opacity monitoring system (COMS) is the
response of the COMS to the daily zero and span check relative to the COMS
response to an actual clear-path zero condition. The zero alignment is
^SnH !C?HSe H!6 d?u1y asse?sment of the COMS calibration is based on the
simulated, rather than the actual clear-path zero check.
The technical complexity and amount of time required to check the zero
alignment places a check of this parameter beyond the scope of a performance
audit. Although not included as part of the audit procedures, th^mpXce
wLL tZ6H° all9nmenVn obtainin? * representative assessment of COMS accuracy
warrants discussion of generic alignment procedures in this document Several
through 11.3° C°nduct1ng 2ero aliment checks are presented in Sections 11.1
11.1 OFF-STACK ZERO ALIGNMENT
.linn^nf0^3^6 rESc'T"11011 ' (4° CFR 50> requires that an off-stack zero
a i lynmeni- Or me LUMS DP nprrnrmorl nr"in*» 4r» •! r»r-*-->T T ,• __ 4.L j.
_it . f»»iiwiiiicvj uiiui Uu liloLallinn TnP Ty*3ncfmccr>mQTn*« -^^
"tnP mnnitn»-inn 1n/-T4--;« TL • ~ IH^WMI i iuy unc ti all-in i ibOine ter 3L
Pnnrthe
procedures require that the transmitter and receiver single pass systems) or
i'occasiTi
• + jhejoff-stac^ zero alignment check can be repeated after the COMS has hPPn
installed and operating for some time; however, this approach Is Inherently
d srconnecteerdTn:n?htime ""f™1"?' Typically, the transceiver m st be "
disconnected from the control unit, and both the transceiver and reflector
components must be transported to a clean environment. In order to evaluate
the entire system, the control unit and data recording device must also be
removed and transported to the test location. Substitute signal and power
cables and test stands must be fabricated or obtained to allow the various
components to be electrically reconnected and set-up at the test local on
In addition precautions must be taken to ensure that ambient dus levels' and
other potential mterferents are minimized while the tests are performed
11-1
-------
When the off-stack zero alignment is completed, each of the COMS
components must be electrically disconnected, transported back to the
measurement location, mechanically reinstalled, and electrically reconnected
The optical alignment of the transceiver and reflector components must be
reestablished or, at least, verified to complete the procedure All of the
above activities must be performed with extraordinary care to ensure that
the off-stack zero alignment procedure provides a reasonable assurance of
accuracy. Nevertheless, there is always a chance that transporting the
transceiver to the monitoring location and/or reinstallation activities will
adversely impact the accuracy of the zero alignment procedure. Many source
personne believe that the likelihood of such problems are much greater than
the likelihood that the zero alignment has shifted, and are therefore
hesitant to attempt off-stack zero alignment checks.
11.2 ON-STACK ZERO ALIGNMENT
accnr^S^Ju6*^60!!103110" ] recogni2es the difficulties and problems
associated with the off-stack zero alignment approach. Section 7 2 1 footical
2l1an^talMnt) °f Prformance Specification 1 requires that the oj??cal
alignment and the zero alignment performed prior to installation be verified
and adjusted if necessary, when the facility is not operating and "clear
stack conditions exist. If the facility is operating at the time the COMS is
"
°P6rate SSuS™?""""!? !!" "IL^""* '»f9«. Tb^'SltTiiy
-.y - — o-----o
""
cne outscc- -o^'jirts suostant- a i . — o-----o • -
typical ]>• service ana calibrate tne monitoring "equipment" 'fherefore^it i.
unlikely that the zero alignment of the COMS can be performed at such sources
The problem is compounded when several units are served b™a si "
since n is
conditions do not occur at the monitoring location
operation. Residual opacity may exist because of
or duct maintenance being conducted with the fans
protect personnel, (2) fan operation or natural draft
""-s4""4 material remaining in the ducts, stack or
after the facility is off-line, or (3) rain
stack. For many sources, residual effluent
t . -r__ity observed during oparation si
equipment is not operated during unit outages.
11-2
-------
The presence of residual opacity during an on-stack zero alignment check
will result in the simulated zero device being set at the level of the residual
opacity rather than at the zero opacity level. For most COMS's this
error will bias all subsequent opacity measurements low by the amount of the
residual opacity present in the stack when the adjustment was made. Therefore,
it is fundamentally important to determine if residual opacity is present
before performing an on-stack zero alignment check. Performance Specification
1 recommends that the instantaneous output of the COMS be examined to determine
whether fluctuations from zero opacity are occurring before a clear-path
condition is assumed to exist. Visible emission observations may also be
performed to detect residual opacity; however, it should be kept in mind that
effluent opacities of less than 5 percent are nearly impossible for the human
observer to detect. In addition, the on-stack zero alignment procedures should
not be performed during periods of precipitation for stack-mounted
transmissometers. Condensed moisture (rain, steam, fog, etc.) will be read as
effluent opacity by the COMS.
eh*,,™ if/n- 2n"?Jack 2er? ali9nment is performed, the optical alignment
should be checked and all optical surfaces should be cleaned before adjusting
the simulated zero level. After the zero alignment procedure is completed and
the facility is again operating, the optical alignment should be rechecked
since thermal expansion is likely to affect the optical alignment.
11.3 ALTERNATE ZERO ALIGNMENT APPROACHES
Alternate approaches for conducting the zero alignment checks are
available for some COMS's. The applicability of these procedures depends on
monitor- and source-specific constraints.
For certain monitors such as the DIGI 1400 (formerly manufactured by
Environmental Data Corporation) that combine the COMS with the S02, NO , and
C02 monitoring channels and also include a "zero-pipe," the zero alignment
procedure is quite simple. For these systems, the zero-pipe can be closed so
that the flow of effluent through the slotted tube is obstructed and the
measurement path is filled with filtered air from the purge air system.
Thus, each time the zero pipe is closed, the zero alignment can be checked and
adjusted, if necessary, under clear-path conditions.
Another approach is often available for COMS's which allow access for
cleaning of the transceiver and reflector windows through a hinged support
system. For many of these types of COMS's, zero alignment checks can be
performed at the monitoring location without electrically disconnecting the
transceiver. The following procedures are followed when this approach is
applicable:
(1) The transceiver is opened as when cleaning the optical window.
(2) The reflector is opened and removed from its hinges; the optical
alignment adjustment bolts must not be disturbed.
(3) All external optical surfaces of the transceiver and reflector
components are thoroughly cleaned.
11-3
-------
(4) The reflector is mounted on a test stand at the appropriate
distance from the transceiver as shown in Figure 11-1. (This is most
easily accomplished using a zero alignment jig which maintains
the correct separation distance between the transceiver and
retroreflector, and prevents interference from ambient
dust or precipitation. It is often convenient to orient the
measurement path tangent to the outside of the stack or duct.)
(5) Correct optical alignment is established and verified- through direct
observation of the light beam on the reflector surface and by means of
the transmissometer optical alignment sight.
(6) If necessary, appropriate adjustments are made to establish the
accuracy of the transmissometer calibration in accordance with the
manufacturer's instructions.
(7) The zero alignment is checked and adjusted, if necessary, in
accordance with the procedures specified by the manufacturer.
(8) The reflector is reinstalled on its hinges, and both the reflector and
transceiver are closed and returned to normal operation. The optical
alignment must be rechecked and, if necessary, adjusted.
I!^S proce?Vre av°ids the Problems associated with both the off-stack and
all9nmen} Procedures. However, problems in maintaining the exact
tanC%and °P^ *"*«*** during the zero alignment check can
+due to *Patial constraints, physical limitations, and the
> f *xKeme v1br?t1on at the monitoring location. In some cases.
spatial limitations can be overcome by removing the transceiver from its hinges
For ™?realKr f1r?ed°mjn orien*™9 th« Ught path in a convenient direction!
c£^W?;nthJ alt?rnate z?ro al19"ment approach can sometimes be used for
bv orion^nn tK l" K+* ^ ** $P1?? ***"**" ^ StaCk 11n6r and 'tack Shell
by orienting the light path vertically, parallel to the access ladder, and
positioning the reflector at a different elevation.
surf SsnH^ainr?11*?^ ""* • ** UsiBd t0 avo1d contamination of the optical
surfaces and damage to the transmissometer components if this alternate
approach is used. Because of the risk of damage to the COMS and personal
safety considerations, it is recommended that the alternate zero alignment
technique be performed only by experienced and qualified personnel
11-4
-------
•STACK
\' TRANCEIVER MOUNTING
-V ADAPTER
INSTALLED
OPTICAL PATHLEN6TH
REFLECTOR
Figure 11-1. Alternate Zero Alignment Procedure Using Zero Alignment Jig
11-5
-------
-------
APPENDIX A.
Lear Siegler Measurement Controls Corporation
Dynatron 1100M and MC2000 Data Forms
-------
-------
LEAR SIEGLER 1100M / MC2000 OPACITY MONITOR
SOURCE IDENTIFICATION:
PROCESS UNIT/STACK IDENTIFICATION:.
AUDITOR: __
CORPORATION:
PLANT/SITE:
ATTENDEES:
DATE:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
PRELIMINARY PAJft
1 Stack exit inside dumeter (FT) -L,
2 fSu^(orduct)mid«
-------
-------
, ^ . « AUDIT DATA SHEET
LEAR SIEGLER 1100M / MC2000 OPACrTY MONITOR
(Continued)
[MOVE THE ZERO/SPAN SWITCH TO THE *SPAN' POSITION.]
11 Panel meter span calibration value (% Op)
12 Opadty datarecorder span cafbration value f% Op)
EoT^SS£!£^.™* CB"B' «*"»" AND SECURE THE CONTROL UNrt|
RETBPRgfl PCTDR Ot *T
13 Pre-deanina, effluent opadty (% Op)
[Remove, inspect, dean, and replace protective window.]
14 Po*t-deaning effluent opacity (% Op)
[Go to transceiver location.]
TRANSCEIVER BUST Arr», WLJL AT1OM ffMPP?K
15 Pre-deaning effluent opacity {% Op)
fRemove. rapect. dean, and replace protective window.]
18 Post-deaning effluent opadty (% Op)
OPTICAL
17 Image Centered?
PRAW IMAGE,]
[TURN THE TARGET UGHT OR 'LAMP STEADV SWITCH OFFJ
CALIBRATION gRRQR CHPfflf
[REMOVE THE DIRTY WINDOW DETECTOR PHOTOCELL.]
[REMOVE THE TRANSCEIVER PROTECTIVE WINDOW.]
YES
NO
^
* TRAN8CBVa WOTCC^WND^^D'^0«0 THE PROTECTS WINDOW
[REMOVE THE TRANSCEIVER PROTECTIVE WINDOW.]
[RECORD AUDIT FILTER DATA.] "wwj
FILTER
19 LOW
20 MED
21 HIGH
SEBJALNO
% OPACtTV
4406
-------
-------
AUDFT DATA SHEET
LEAR SIEGLER 1100M / MC2000 OPACITY MONITOR
(Continued)
[REMOVE THE AUDIT FILTERS FROM THEIR PROTECTIVE COVERS. INSPECT. AND
[INSERT A FILTER. WAIT APPROXIMATELY 2 MINUTES. AND RECORD THE OPACITY
ct^m^SF—f ™E OPACITY DATA RECORDER. REPEAT THE PROCESS 5 TIMES
FOR cACn FILTER.]
E?,2JEiG F*0 VALUES CHANGE BY MORE THAN 1.0% OPACITY DURING ANY OF THE
RUNS. READJUST THE JIG ZERO TO THE ORIGINAL VALUE AND REPEAT THE RUN.]
ZERO
LOW
MID
HIGH
ZERO
ZERO
LOW
MID
HIGH
ZERO
[RETURN TO CONTROL UNIT LOCATION.]
[READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA.)
ZERO
22
LOW MID
» 24
27.
31
28.
32.
36,
40
33.
37.
41.
HIGH
ZERO
26.
30.
34
PIX-MINUTE AVERAGE DATA. IF APPLICABLE.]
43
4406
-------
-------
LEAR SIEGLER 1100M / MC2000 OPACITY MONITOR
(Continued)
CALCULATION OP AUDPT RESULTS
STACK EXIT CORRELATION ERROR (%):
44
ZERO ERROF
49 Panel n
50 Opacity
SPAN ERROR
51 Panel V
52 Opacity
OPTICAL SUR
S3 Retroren
54 Transcer
55 Total
STACK EXIT CC
56 Low: 1
57 Mid: 1
« High: 1 •
-]
3LANK 4) (BlANK 3)~ "
(BLANKS)
*(%Op):
(BLANK9) (BLANKS)
data recorder
~ m
(BLANK"l6) (BLANK Si ~ • —
(* Op):
*•* (BLANK 11) (BLANKS) •
— 8
uaiaMecoroer (BLANK 12) (BLANKS)
FACE DUST ACCUMULATION (% Op):
•Cl0r (BLANK 13) (BLANK"l4) " " •
"* (BLANK~15) (BLANK"l5 " ~
^ •
(BLANK53) (BLANK"s4) •
>RRELATION RATIO AND ZERO OFFSET CORRECTION OF AUDIT FILTERS:
2 x (BLANK 4)
-1 r -n"l
(BLANK 19) | „ 1 ~ «LANk42) 1
^ 100 J L 100 J
2 x (BLANK 4)
fr .n r -nl
• 1- (BLANK20) x L (BLANK42,
L J L 100 x 100 .
2 x (BLANK 4)
E*" n r -n"
u. • 10°- J L 100 J
4408 9/91
-------
-------
uiu
-------
-------
LEAR SIEGLER 1100M / MC2000 OPACITY MONITOR
PERFORMANCE AUDIT DATA SUMMARY
AUDITOR
SOURCE
RESULTS CHECKED BY
DATE
UNIT
DATE
AUDIT RESULT
SPECIFICATION
WINDOW
FAULT DIAGNOSTIC
STACK EXIT CORRELATION ERROR
INTERNAL ZERO ERROR
DATA RECORDER
INTERNAL SPAN ERROR
DATA RECORDER
JJGNMENT ANALYSI
OPTICAL SURFACE DUST ACCUMULATION
RETROREFLECTDR
TRANSCEIVER
TOTAL
CALIBRATION ERROR ANALYSIS
MEAN ERROR
LOW
CONFIDENCE INTERVAL
LOW
MID
HIGH
CALIBRATION ERROR
LOW
MID
HIGH
ERROR
BASED ON SIX-MINUTE AVERAGED DATA. FROM A SINGLE FILTER INSERTION.
4406 0/91
A-6
-------
-------
APPENDIX B.
Lear Siegler Measurement Controls Corporation
Model RM-41 Audit Data Forms
-------
-------
AMD MODEL 611 CONTROL UNIT
SOURCE IDENTIRCATK3N
PROCESS UNIT/STACK IDENTIFICATION:.
AUDITOR:
ATTENDEES:
CORPORATION: .
PLANT/SITE:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
DATE
PRELIMINARY DATA
1 Stack exit inside diameter (FT)« Lx
2 [Stack (or dud) inside diameter (or width) at the tiansinissometer location (FT)] x 2
3 CalculatedOPLR«LX/L(
'4 Source-cited OPLR value
5 Source-cited zero automatic calbratbn values (% opacity)
6 Source-cited span automatic caforation value (% opacity)
flf unavailable, input the factory assigned span value.]
^ tm i^uJ^^s^^^S^S
[GO TO DATA RECORDER LOCATION.]
«2f CORDING SYSTEM AND MARK WITH -OPACITY AUDIT - AUDITOR'S NAME.
AFFILIATION. DATE. SOURCE. PROCESS UNIT/STACK IDENTIFICATION. AND THE TIME OF DAY.]
[GO TO CONTROL UNIT LOCATION.]
FAULT LAMP CHECKS
' 7 FILTER (status of purge air blowers]
8 SHUTTER [status of protective shutters]
9 REF[AGCfauharKi/or excessive reference signal error]
10 WINDOW [excessive zero compensation]
1 1 OVER RANGE [exceeding optical density range settng]
ON
OFF
CONTROL UNIT ADJUSTMFNT AMD CHECKS fTft up pong QM, y py Q^J
[OPEN CONTROL UNIT AND PULL POWER FUSE]
PULL CAL TIMER BOARD.)
12 CAL timer board S1 switch position
Hum CAL timer board S1 switch to sixth (Gth) position. I necessary, and reinstall board.]
[Pull OPTICAL DENSITY board.]
13 OPTICAL DENSITY board S1 switch position
[Turn OPTICAL DENSITY board S1 switch to flth (5th) posiion. if necessary, and reinstall board.]
[Pull OPACITY board.]
14 OPACITY board S1 switch position
[Turn OPACITY board to fifth (5th) position, if necessary.]
[Optional OPLR check: Measure the resistance in OHMsc* In. -R6' potentiometer on
the OPACITY board, and divide by 400 to get the intemaly set OPLR value.]
14. R6 - (OHMs)/400»
[If R 6 value is not measured, enter the value from (BLANK 4) in (BLANK 14a).J
[Reinstall the OPACITY board]
[Reinstall fuse and dose control unit]
15 Original position of -MEASUREMENT switch
B-l
4406 G/V1
-------
-------
AUDIT DATA SHEET
LEAR SEIGLER RM-41 TRANSMISSOMETER AND MODEL 611 CONTROL UNIT
(Continued)
REFERENCE SIQNAL CHECK " '
fTURN -MEASUREMENT- SWITCH TO THE "REFERENCE- POSITION AND TAP THE PANa METER FACE.]
READ REFERENCE SIGNAL CURRENT VALUE ON 0-30 mA SCALE.]
16 Reference signal currant value (mA)
[Turn •MEASUREMENT* switch to "100% Op* position.]
7ERO CHECK
[PRESS THE -OPERATE/DAL" SWITCH.]
[TAP THE PANEL METER AND READ THE ZERO CALIBRATION VALUE FROM THE 0-100% Op SCALE.]
17 Panel Mster zsro calbration valus (% Op)
18 Opacity data recorder zero cafibration value (% Op)
ZERO COMPENSATION CHECK /IMTTIAM
[TURN THE "MEASUREMENT SWITCH TO THE "COMP- POSITION.]
ToSaSOD*®" METER AN° REA° ™E ^^ COMPENSATION VALUE ON THE -0.02
19 Panel meter zero compensation value (O.D.)
SPAN CHECK
ff21S5JH£^iR£/?fAN" SWITCH AND TURN ™E -MEASUREMENT- SWITCH TO THE
• O0% Op POSITION.]
20 Panel meter span cafcralion value (% Op)
21 OpacHy data recorder span calbration value (% Op)
PRESS THE -OPERATE/CAL- SWITCH.]
[GO TO TRANSMISSOMETER LOCATION.]
RETRQREFLECTQR DUST ACCUMULaTiOM
22 Pre-deaning effluent opacity (% Op)
[Open the retroreflector. inspect and dean the retroreflector optical surface and dose
the retrorefiector.]
23 Post-deaning effluent opacity (% Op)
[Go to transceiver location.]
B-2
4406 8W
-------
-------
AUDrT DATA SHEET
LEAR SEIGLER RM-41 TRANSMISSOMETER AND MODEL 611
CONTROL UNIT
(Continued)
TRANSCEIVER DUST ACrtlUlt! AT1OM CHECK
24 Pre-deaning effluent opacity (% Op)
[Open the transceiver, inspect and dean the primary tans. inspect and clMn the zero
mirror, and doae th* transceiver.]
25 Post-cleaning effluent opacity (% Op)
[At control unit, press -OPERATECAL* awitch. turn "MEASUREMENT awfcch to -COMP-
poattion, tap matar faca, and road the zaro companaation value from the -0.02 to *0 05
O.D. Bcaie.]
26 Post-daaning zaro oonpenaation valua (O.O.)
[At cortrol unit, praas -OPERATECAL' atwitch and turn lyiEASUREMEhrr awitch to the
'100% Op* poaiion.]
AGC CHECK
27 AGC lamp status
OPTICAL ALIGNMFr/T CHgCK
ON
OFF
28 Image Centered?
[DRAW LOCATION OF THE BEAM IMAGE]
YES
NO
SPAN FILTER DATA
TH¥TRA^EIVERR] OPTICAL DENSrTY AND OUTPUT CURRENT FROM THE UNDERSIDE OF
29 Span filer optical density (O.D.)
30 Span filer output current (mA)
CALIBRATION ERROR CHECK
[OPEN THE TRANSCEIVER AND THE J-BOX.J
[RECORD AUDIT FILTER DATA.]
fLIEB SERIAL NQ %oPACfTv
31 LOW ..
32 MED
33 HIGH
4406 9/Q1
-------
-------
AUOrT DATA SHEET
LEAR SEIGLER RM-41 TRANSMISSOMETER AND MODEL 611 CONTROL UNIT
(Continued)
S^^JX^iST f LTERS raOM THEIR PROTECTIVE COVERS. INSPECT. AND
[INSERT A RLTER IN THE JIG. WAIT APPROXIMATELY 2 MINUTES PER FILTER FOR
A CLEAR RESPONSE. AND RECORD THE OPACITY VALUE REPORTED BY THE
OPACITY DATA RECORDER. REPEAT THE PROCESS 5 TMESFOR EACH FILTER]
[IF JIG ZERO VALUES CHANGE BY MORE THAN 1 0% OPACITY DURING ANY OP THP
RUNS. READJUST THE JIG ZERO TO THE ORSlNATvALui^ND REPEATTHE RUN J
2ER° LOW MID
HIGH ZERO
[REMOVE AUDIT JIG AND CLOSE TRANSCEIVER.]
k
[RETURN TO CONTROL UNIT LOCATION.]
ZERO COMPENSATION
34 Final zero compensation value (O.D.)
P»«s -OPERATE/CAL- switch.]
CONTROL UNFT ADJUSTMENT RESET (TO BE DONE ONLY BY OUALFED PERSONNEL)
[OPEN THE CONTROL UNIT AND PULL THE POWER FUSE.]
BLANK MO
Cal Timer 19
Optical Density Jf
[REINSTALL THE POWER FUSE AND CLOSE THE CONTROL UNIT.]
[TURN THE "MEASUREMENT SWITCH TO THE POSITION RECORDED M (BLANK 15).]
[IF SIX-MINUTE INTEGRATED DATA ARE AVAILABLE ALLOW 13 MINUTES EACH POD AM
£lcS^^^
2ER° LOW MID HIGH ZERO
4408
-------
-------
SEIGLER RM-41 TRANSMISSOMETER AND MODEL 611 CONTROL UNFT
(Continued)
[READ AND TRANSCRIBE F1N*L C ALJ6RATION ERROR DATA.]
20(0 LOW MID HIGH ZERO
35 - 36-- 37 3. M
40 41 42 43...
44 « 46 47 "_[
49 «• » 51 ~]
« 53 54 55
[SK-MINUTE AVERAGE DATA. IF APPLICABLE.]
56 57-- 58. SB «>_
CALCULATION OP AUPfT PC cm TS " ~ " ' '
STACK EXIT CORRELATION ERROR (%):
61 Source ched
x100.
(BLANK 3)"
Measure (BLMK-14J)" " "(BlANKs'
x100» (OPTIONAL)
(BLANKS)"
REFERENCE SIGNAL ERROR (%):
_ (BLANK"l6T
a - 1 x100.
20
ERO ERROR (% Op):
4 Panel meter *7aTAMiT^^ ~
(BLANK 17) (BLANK 5)
5 Opacity data recorder
~(BLANK~18) " " (BLANKS"
JAN ERROR (% Op):
i Panel Meter _ .
"(BLANK20) " " (BLANKST
Opacity Data Recorder . -
(BLANK21) " (BLANKS)
B-5
4406
-------
-------
AUDIT DATA SHEET
LEAR SIEGLER RM-41 TRANSMISSOMETER AND MODEL 611 CONTROL
UNIT
(Continued)
ZERO COMPENSATION (OS).):
68 Initial - - _ -
69 Post-cleaning
70 Final
(BLANK IB)
(BLANK 26)
(BLANK 34)
OPTICAL SURFACE DUST ACCUMULATION (% Op):
71 Retnxeflector --- _ ____ - _
72 Transceiver
73 Total
(BLANK 22)
(BLANK 24)"
(BLANK 71)
(BLANK 23)
(BLANK 25)"
(BLANK 72)
OPLR AND ZERO OFFSET CORRECTION OF AUDIT FILTERS (% OP):
74
1-
(BLANK 31)
100
2 x (BLANK 14aj
:] -f
(BLANK 55)
100
•i
x 100 -
75 Mid:
1 .
£""
^
(BLANK 32)
100
2 x (BLANK 14^
J -F
(BLANK 55)
100
•1
x 100
76 High:
1 .
E1" _
^
(BLANK 33)
100
2 x (BLANK 14a)
] I
(BLANK 55)
100
••
x 100 «
B-6
4406
-------
-------
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-------
-------
LEAR SIEGLER MODEL RIM1 TRANS4IISSOMETER AND
MODEL 611 CONTROL UNIT
PERFORMANCE AUDIT DATA SUMMARY
AUDfTOR
SOURCE
RESULTS CHECKED BY
AUDIT RESULT
SPECIFICATION
XXXXXXXXXXXX
SHinTER
REFERENCE
WINDOW
OVER RANGE
AGC aRcurr STATUS
PACKEXn
CORRELATION ERROR
REFERENCE SIGNAL ANALYSIS
INTERNAL ZERO ERROR
DATA RECORDER
INTERNAL SPAN ERROR
DATA RECORDER
MONITOR ALIGNMENT ANALYSIS
INITIAL ZERO COMPENSATION
POST-CLEANING ZERO COMPENSATION
FINAL ZERO COMPENSATION
OPTICAL SURFACE DUST ACCUMULATION
RETROREFLECTOR
LIBRATON ERROR ANALYSIS
xxxxxxxxxxxxx
WW* \XXXXXXXXXXXX
CONFIDENCE INTERVAL
CALIBRATION ERROR
• ERROR BASED ON SIX-MINUTE AVERAGED DATA. FROM A SINGLE FILTER INSERTION.
B-8
4406 0/91
-------
-------
APPENDIX C.
Lear Siegler Measurement Controls Corporation
Model RM-4 Audit Data Forms
-------
-------
AUDIT DATA SHEET
LEAR SIEGLER RM-4 OPACITY MONTOR
SOURCE IDENTIFICATION: CORPORATION:
PROCESS UNIT/STACK IDENTIFICATION: PLANT/SITE"
AUDITOR: , REPRESENTING:
ATTENDEES:
DATE:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
PRELIMINARY DATA
1 Stack exit inside diameter (FT) = L^
2 [Stack (or duct) inside diameter (or width) at each transmissometer location (FT)] x 2 « L,
3 Calculated OPLR « LX/L,
4 Source-cited OPLR value
5 Source-eked zero automatic calibration value (% opacity)
* Source-cited span automatic calibration value (% opacity)
[IF UNAVAILABLE, INPUT THE FACTORY ASSIGNED SPAN VALUE.]
[GO TO CONVERTER CONTROL UNIT/DATA RECORDER LOCATION.]
!f£fJ?JJ?A™.^P?*?'"03L??™* A"0 "A™ W™ 'OPACITY AUDIT.*
FAULT LAMP
ON OFF
T FAULT [Low AGC current]
• OVER RANGE [Effluent opacity exceeds optical density range setting]
CONTT3OL UNtT CONFIGURATION CHECK
9 Original position of 'Measurement Switch*
[TURN THE 'MEASUREMENT SWITCH TO THE "20% OPACITY- POSITION.]
[TURN THE 'MODE* SWITCH TO THE 'ZERO* POSITION.]
10 Panel meter zero calibration value (% Op)
11 Opacity data recorder zero calibration value (% Op)
SPAN CHECK
[TURN THE 'MEASUREMENT SWITCH TO THE '100% OPACITY* POSITION.]
[TURN THE 'MODE* SWITCH TO THE 'CALIBRATE* POSITION.]
12 Panel Meter span calibration value (% Op)
13 Opacity data recorder span calibration value (% Op)
[OPTIONAL CHECK: Turn the •MEASUREMENT switch to the 'OPACITY INPUT position
and read the input current from the panel meter 0-20 mA scale.]
14 Panel meter input current value (mA) (Optional)
[TURN THE 'MEASUREMENT SWITCH BACK TO THE '100% OPACITY" POSITION.]
[TURN THE 'MODP SWITCH TO THE 'OPERATE* POSITION AND GO TO THE
TRANSMISSOMETER LOCATION.]
4408 9/91
-------
-------
AUDIT DATA SHEET
LEAR SIEGLER RM-4 OPACITY MONITOR
(Continued)
RETROREFLECTDR DUST ACCUMULATION CHECK
15 Pre-deaning effluent opacity (% Op)
[Open the retroreflector. inspect and clean the retroreflector optical surface and dose the
retroreftector.]
16 Past-deaning effluent opacity {% Op)
fGO TO TRANSCEIVER LOCATION.]
TRANSCEIVER DUST ACCUMULATION CHECK
17 Pre-deaning effluent opacity (% Op)
[Open the transceiver, inspect and dean the primary tens, dean the zero mirror, and
dose the transceiver.]
18 Post-cleaning effluent opacity (% Op)
[OPEN THE TRANSCEIVER CONTROL PANEL.]
FAULT/TEST CHECfr
[PRESS AND HOLD THE "FAULTIEST BUTTON AND READ THE .
TRANSCEIVER METER CURRENT VALUE ON THE 0-20 mA SCALE.]
16 Fault/lest current value (mA)
OPTICAL ALIGNMENT CHECK
PORT O" ™E RIQHT SIDE OP ™E TRANSCEIVER AND OBSERVE
THE POSITION OF THE BEAM IMAGE WITH RESPECT TO THE TARGET CIRCLE.]
20 Image Centered?
[DRAW LOCATION OF THE BEAM IMAGE]
SPAN FILTER PAT^ CflEgK
ttffmOLP FILTER OPTICAL DENSITY PROM THE BOTTOM OF THE TRANSCEIVER
21 Span fitter optical density (O.D.)
CALIBRATION ERROR CHECK
YES
NO
[RECORD AUDIT FILTER DATA.]
% OPACITY
22 LOW
23 MED
24 HIGH
4408 9/91
-------
AUDIT DATA SHEET
DATATEST MODEL 900 TRANSMISSOMETER
OPACITY PERFORMANCE AUDIT DATA SUMMARY
Page 11 of 11
AUDITOR
SOURCE
MODEL 900RM
or MODEL BOOA.
RESULTS CHECKED BY
DATE
UNIT
DATE
AUDFT RESULT
FAULT LAMPS
LAMP OUT
BLOWER OUT
OVER EMISSION
MAINTENANCE
4% DUST
STACK EXIT
CORRELATION ERROR
CITED
M^HMMI^
MEASURED
INTERNAL ZERO ERROR
DATA RECORDER
INTERNAL SPAN ERROR
.DATA RECORDER
TRANSMISSOMETER OPTICAL ALIGNMENT
INITIAL LENS DUSTING
FINAL LENS DUSTING
OPTICAL SURFACE DUST ACCUMULATION
RETROREFLECTOR (RECEIVER)
TRANSCEIVER (TRANSMITTER)
TOTAL
-""
CALIBRATION ERROR ANALYSIS
MEAN ERROR
LOW
CONFIDENCE INTERVAL
LOW
MID
HIGH
i^M^MM
CALIBRATION ERROR
LOW
MID
HIGH
a ERROR BASED ON SIX-M.NUTE AVERAGED DATA. FROM A SINGLE FILTER INSERTION
b VALUES IN BRACKETS ARE RESULTS OF MODEL 900A AUDIT.
K-ll
4408 9/91
-------
SIEGLER RM-4 OPACITY MONITOR
(Continued)
CALCULATION
STACK EXIT CC
52 Source cit
ZERO ERROR (1
53 Panel met
54 Opacity d£
SPAN ERROR p
55 Panel Men
56 Opacity Da
57 Zero currei
OPTICAL SURFA
56 Retrorefled
59 Transceiver
60 Total
61 Low: , .
62 Mid: 1 •
KJ High: 1 -
OF AUDIT RESULTS
JRRELAT10N ERROR (%):
ed (BLANK4) (BLANKS)
(BLANKS)
it Op):
«— m
er (BLANK 10) (BLANKS) •
ita recorder
~ *
(BLANk~11) (BLANK Si "
fc Op):
9r (BLANK~12) (BLANKQ '
X
ita Recorder (BLANK~13) (BLANK S)
-2-
,CE DUST ACCUMULATION (% OP):
^ m
<* (BLANK 15) (BLANK"l5 " "
— m
(BLANK 17) tBLANK 18} "
+
(BLANK 58) (BLANK"^
2 x (BLANK4)
fr -i r -n
1. .,?WNK»» X L (BLANKS - _
j_ 100 J L 100 J —
2 x (BLANK4)
fr -i r -n
(BLANK23) x I (BLANK46)
2 X (BLANK 4) _.
-I n . -f]
(BLANK24) x I (BLANK46)
100 J L 100 J •
C-4
4408 W91
-------
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K-9
-------
LEAR SIEGLER MODEL RM-4 OPACITY MONITOR
PERFORMANCE AUDIT DATA SUMMARY
AUDITOR
SOURCE
RESULTS CHECKED BY
DATE
UNIT
DATE
Auorr RESULT
SPECIFICATION
\VvV\VVs
FAULT
OVER RANGE
STACK EXIT CORRELATION ERROR
INTERNAL ZERO ERROR
DATA RECORDER
INTERNAL SPAN ERROR
DATA RECORDER
ZERO CURRENT ERROR (OPTIONAL)
4%Op
*1 mA
CENTERED
MONITOR ALIGNMENT
OPTICAL SURFACE DUST ACCUMULATION
lETROREFLECTOR
CALIBRATION ERROR ANALYSIS
MEAN ERROR
•MMMM
LOW
\\vv\ssssx
CONFIDENCE INTERVAL
\\ssssssss
CALIBRATION ERROR
LOW
MID
HIGH
ERROR
BASED ON SIX-MINUTE AVERAGED DATA. FROM A SINGLE FILTER
INSERTION.
C-6
4406 9/91
-------
AUDfT DATA SHEET
DATATEST MODEL 900 TRANSMISSOMETER
Page7of 11
CALIBRATION FRRQR CHECK - MODEL goo*
[RECORD AUDIT FILTER DATA.J
1-23
FILTER
LOW
MED
SERIAL MO
%OPACfTV
1-25 HIGH
[INSTALL THE AUDIT JIG ON THE TRANSMISSOMETER.]
RLTCfif THE AUDIT nLTERS FROM ™E PROTECTIVE COVERS. INSPECT AND CLEAN EACH
cfJt™^0 RECORD THE EFFLUENT OPACITY VALUE I
BY
^
[REMOVE THE FILTER. REPLACE THE BLANK FILTER. AND RECORD THE EFFLUENT OPACITY.]
REPEAT THIS PROCESS FIVE TIMES.]
EFFLUX
LOW
HIGH
EFFLUENT
LOW
ALLOW 13 MINUTES EACH FOR AN ADDITIONAL RUN OF THE
EFFLUENT MID EFFLUENT
HIGH
[REMOVE AUDIT JIG AND CLOSE TRANSCEIVER.]
[RETURN TO CONTROL UNIT LOCATION.]
[PERFORM THE FINAL ZERO COMPENSATION CHECK IN ITEM 26.]
LENS DUSTWn CHECK reiM^
26 Final lens dusting value (% Op)
(MV) / 100
K-7
4408 9/91
-------
AUDIT DATA SHEET
DYNATRON MODEL 1100 OPACITY MONITOR
SOURCE IDENTIFICATION: CORPORATION:
PROCESS UNIT/STACK IDENTIFICATION: PLANT/SITE:
AUDITOR: . . REPRESENTING:
ATTENDEES: . REPRESENTING:
. REPRESENTING:
— REPRESENTING:
— REPRESENTING:
DATE: __
PRELIMINARY DATA
1 Stack exit inside diameter (FT) - Lg
2 [Stack (or duct) inside duuneter (or width) at the transmissomeler location (FT)] x 2 * L,
3 Calculated 'M' Factor * Lx /L,
4 Source-cited *M* Factor value
5 Source-cited zero automatic calibration values (% opacity)
6 Source-cited span automatic calbration value (% opacity)
[GO TO CONTROL UNIT / DATA RECORDER LOCATIONJ
[INSPECT THE DATA RECORDING SYSTEM AND MARK WITH 'OPACITY
AUDIT.' AUDITORS NAME. AFFILIATION. DATE. SOURCE. PROCESS
UNIT/STACK IDENTIFICATION. AND THE TIME OF DAY.]
FAULT LAMP CHECKS
ON OFF
7 LAMP [Insufficient measurement lamp output]
S WINDOW [Excessive dust on transceiver optics]
» AIR FLOW [Insufficient purge air flow]
CONTROL UNIT CHECKS
10 Automatic calibration time (cycle time) knob position
[Turn CYCLE TIME knob to 'MANUAL' position.]
11 Meter display knob position
[Turn METER DISPLAY knob to 'OPACITY position, tf necessary.]
ZERO CHECK
PRESS ZERO/SPAN SWITCH.]
12 Panel meter zero calibration value (% Op)
13 Opacity data recorder zero caibralion value (% Op)
4406 9/91
D-l
-------
AUDFT DATA SHEET
DATATEST MODEL 9X TRANSMISSOMETER
Page 5 of 11
— =====
LENS DUSTING (% Op):
59 initial
(BLANK 15)
60 Final
(BLANK 26)
OPTICAL SURFACE DUST ACCUMULATION
61 Retroreftector — — — ___
(BLANK 18)
62 Transceiver _ _
(BLANK 20)
63 Total _
(BLANK 61)
CALCULATION OF MQDFI 900RM CALIBR^
EXTT CORRELATION AND ZERO OFFSET CO
64 Low: , I,. ~ (BLANK 23)
L_ . 100
65 MM- 1. L " "(BLANK 24)"
L 100
n-
E* U&. 1- L (BLANK 25)
L 100
— .
•
l(*0p):
(Bl AUK 10|
(BLANK 21) r-
m
TION gBRQR RESULTS MtO PRf^fPPUftn
flRECTION OF AUDTT PITERS (% OP):
(BLANK 12)"
."1 r -nl
J (BUNK^,
J L 100 J
(BLANK 12)" _
."] r -nl
(BLANK<7)
L ™
(BLANK 12)" —
~l r ™n
7BLANK47)
K-5
4408
-------
AUDIT DATA SHEET
DYNATRON MODEL 1100 OPACITY MONITOR
(Continued)
(REMOVE THE AUDIT FILTERS FROM THE PROTECTIVE COVERS. INSPECT AND CLEAN
EACH FILTER.)
(INSERT A FILTER. WAIT APPROXIMATELY 2 MINUTES. AND RECORD THE OPACITY
VALUE REPORTED BY THE OPACITY DATA RECORDER. REPEAT THE PROCESS 5 TIMES
FOR EACH FILTER.]
(IF THE JG ZERO VALUES CHANGE BY MORE THAN 1.0% OPACITY DURING ANY OF THE
RUNS. READJUST THE JG ZERO TO THE ORIGINAL VALUE AND REPEAT THE RUN.]
2ERO LOW MID HIGH ZERO
(RETURN TO CONTROL UNIT LOCATION.]
CONTROL UNIT ADJUSTMENT RES
oESET7HE CONTROI- UNIT CALIBRATION TIMER AND METER DISPLAY
KNOBS TO THE POSITIONS INDICATED IN THE CORRESPONDING BLANKS.] UR>KIAT
Automate Calbration Timar BLANK NO
Mater Display n
(OBTAIN A COPY OF THE AUDIT DATA FROM THE OPACITY DATA RECORDER AND
ENSURE THAT THE DATA CAN BE CLEARLY READAND INTERPRETED°
(READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA,]
K, ^^""^ INTEGRATED DATA ARE ALSO AVAILABLE. ALLOW 13 MINUTES EACH FOR
AN ADDITIONAL RUN OF THE ZERO. LOW. MID. HIGH. AND ZERO READINGS.]
ZERO LOW MID HIGH ZERO
LOW MID HIGH
25 * 27 28 28.
*n m*
** 52 33_
** * » 37.
38 » 40 41.
42 «- 44 45.
PIX-MINUTE AVERAGE DATA. IF APPLICABLE,]
40 ff ^» ».». *
*' . . 46 40 go
4406 9/91
D-3
-------
AUDFT DATA SHEET
DATATEST MODEL 900 TRANSMISSOMETER
Page 3 of 11
CALIBRATION FRROR CHFCK - MODEL goo Ruf flG PBOCCPURC)
{OPEN THE TRANSCEIVER AND INSTALL THE AUDIT JIG
(RECORD AUDIT FILTER DATA.]
FILTER
23 LOW
24 MED
25 HIGH
SERIAL NO
%OPAcrrv
E RLTERS FROM ™EIR PROTECTrVE COVERS.
INSPECT AND
A,«FILTER IN THE JIG- WArT APPROXIMATELY 2 MINUTES PER FILTER
FOR A CLEAR RESPONSE, AND
OPACITY DATA RECORDER.
EFi? ¥£% VALUES CHANGE BY MORE THAN 1 .0% OPACITY DURING ANY OF THE
RUNS. READJUST THE JIG ZERO TO THE ORIGINAL VALUE AND REP^TTHE RU^.f
ZERO
LOW
MID
HIGH
ZERO
^^ "MINUTES "* «* «ADDITION«-RUN»i«
ZERO
LOW
MID
HIGH
ZERO
[REMOVE AUDIT JIG AND CLOSE TRANSCEIVER.]
[RETURN TO CONTROL UNIT LOCATION.]
LENS DUSTING CHECK fPlNAI
[MEASURE THE VOLTAGE ON TEST POINT 3 OF PC-5 IN MILLIVOLTS DIVIDE THIS VAJ I IP
BY 100 TO CALCULATE THE LENS DUSTING IN PERCENT' oHSrvJ
26 Final tens dusting value (% Op) *
[OBTAIN A COPY OF THE AUDIT DATA FROM THE OPACfTY DATA
ENSURE THAT THE DATA CAN BE CLEARLY READ WD
K-3
4406 9*1
-------
N
<
<
HIGH RANGE
DIFFERENCP
i
Z
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ig
-------
DATATES'
- " -'A ........ A SHEET
: 1 3 EL IK C 1 RAH I! 5 M 1SSOMETER
Pagii 1 c r 1 1
SOURCE IDENTIFICATION:
PROCESS UNIT/STACK IDENTIFICATION:.
AUDITOR:
ATTENDEES:
CORPORATION:
PLANT/SITE
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
DATE
1 Stack exit inside diameter (ft) «LX
2 [Stack (or duct) inside diameter (or width) at the transmissorneter location (ft) « L,
3 Cateulated correction factor .LX/LJ
4 Source-cited correction factor value
5 Source-cited zero automatic calbraibn values (% opacity)
6 Source-cited span automatic calibration value (% opacity)
==
[GO TO DATA RECORDER LOCATION.]
ff r n*5F2?DING SYSTEM AND ***** W™ -OPACITY AUDIT.' AUDITOR'S NAME
AFFILIATION. DATE. SOURCE. PROCESS UNIT/STACK IDENTIFICATION. AND THE ^ME OF DAY.]
[GO TO CONTROL UNIT LOCATION.]
FAULT LAMP INSPECTION
7 Lamp out [Drastic reduction in measurement beam]
8 Blower out [Status of purge air blower]
9 Over emissJon[Exceeding high present alarm value]
t a
10 Maintenance [Exceeding intermediate |
11 4% Dust [Dust accumulation exceeds 4% opacity]
lue]
ON
OFF
gPHTRPL. UNfT CHECKS FTP BF DOME om v BY nifALiFiPP PCP.
12 Correction factor measurement (optional)
4WIO SS^01*1 FACT°R IS ** MEASURED DIRECTLY. ENTER THE VALUE IN BLANK
(MV)/1000,
ZERO CHECK
[TURN ON THE 'ZERO CALIBRATION- SWITCH INSIDE THE CONTROL UNIT.]
[READ THE ZERO CALIBRATION VALUE FROM THE PANEL METER AND THE DATA RECORDER.]
13 Panel meter zero cafbration value (% Op)
14 Opacity data recorder zero calibration value (% Op)
K-l
4406 6/B1
-------
AUDIT DATA SHEET
DYNATRON MODEL 1100 OPACITY MONITOR
(Continued)
INCREMENTAL CAL ERROR
CALIBRATION ERROR CHECK flNCREMPMTAI PROCEDURE!
^ "«»« SHOULD BE USED ONLY WHEN THE
K3£!K^ ~ owcnv «
[THE RATED OPACITY VALUES OF THE AUDIT FILTERS MUST INCLUDE AN ASSUMED
NOMINAL OPACITY VALUE FOR THE TRANSCEIVER PROTECTIVE WINDOW.)
[RECORD AUDIT FILTER DATA.]
FILTER
SERIAL NO
% OPACITY
1-21
1-22
1-23
LOW
MID
HIGH
SHSS£ JS22SLTERS FROM PROTECT1VE COVERS. INSPECT. AND CLEAN EACH FILTER 1
AND RECORD ™E °PACI7Y VALUE REPORTED FROM "WE
REPICE 7HE ^^SCBVER PROTECTIVE WINDOW AND RECORD THE
REPEAT THIS PROCESS FIVE TIMES FOR EACH FILTER.]
EFFLUENT
LOW
EFFLUENT
MID
EFFLUENT
HIGH
E^f '*:M™1! INTEGRATED DATA ARE ALSO AVAILABLE. ALLOW 13 MINUTES EACH
FOR AN ADDITIONAL RUN OF THE EFFLUENT LOW. MID. AND HIGH READING?]
EFFLUENT
LOW
EFFLUENT
MID
EFFLUEMT
HIGH
[CLOSE THE TRANSCEIVER HOUSING.]
[RETURN TO CONTROL UNIT LOCATION.]
D-7
4406 9/91
-------
LAND COMBUSTION MODEL 4500
OPACITY MONITOR PERFORMANCE AUDIT DATA SUMMARY
AUDITOR
SOURCE
RESULTS CHECKED BY
DATE
UNIT
DATE
PARAMETER
FAULT LAMP
FAULT
STACK EXIT
CORRELATION ERROR
INTERNAL SPAN ERROR
CITED
MEASURED
PANEL METER
DATA RECORDER
PANEL METER ,
DATA RECORDER
MONITOR ALIGNMENT ANALYSIS
ZERO COMPENSATION
OPTICAL SURFACE DUST
ACCUMULATION
RETROREFLECTOR
TRANSCEIVER
BLANK
NO.
>V^^N
7
54
55
56
57
58
50
21
GO
SSSNSS;
61
62
CALIBRATION ERROR ANALYSIS KX^SX^
MEAN ERROR
LOW
MID
HIQH
LOW
MID
HIQH
LOW
MID
HIQH
R^^
I **
I 76*
I 68
I ^
I 78m
k^W
AUDIT RESULT
s>^\s>^^sSSSX
^NS^sSXX>\^s>\>
\^\S^XSSS>NS^
K^^SS^
\\\\\\\\\\\\N
70
"
72
P^\N^\\\\\\\\\\\V
73
74
75
SPECIFICATION
\\^N^SNs><\NvN
OFF
*2%
*4%0p
*4%Op
*4%Op
N^SSSSS>vsvs
• 2% Op
«2%Op
*4%Op
^^NSSSS
N^S^S^V
>!js\^vs^sN^v;
^SSS^^^x
^S^^SSSS:
x^^^^c^Nvvvvo
N\\V\XV\XsX
s\\\\v\v\x
NN>X>sS>vs\sS
vvvv^v^^
^^WSX^x
SSS^^^vSS!
\W\\\\\V\
«3%Op
• 3% Op
s3%Op
ERROR
BASED ON SIX-MINUTE AVERAGED DATA, FROM A SINGLE FILTER INSERTION.
J-8
4408 9/91
-------
to
CM
CO
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CD
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CD
2
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CD
9
CD
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CO
2
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D-9
-------
AUDIT DATA SHEET
LAND COMBUSTION MODEL 4500 OPACITY MONITOR
(Continued)
ZERO COMPENSATION (% OP):
60
(BLANK 12)
OPTICAL SURFACE DUST ACCUMULATION (% Op):
61 Ratroreftector «. _ - _
62 Transceiver
63 Total
(BLANK 17)
(BLANK 19)
(BLANK 61)
(BLANK 18)
(BLANK 20)
(BLANK 62)
OPLR AND ZERO OFFSET CORRECTION OF AUDIT FILTERS (% OP):
64 Low:
1 -
(BLANK 24)
100
2 x (BLANK 13)
:] -f
(BLANK 48)
100
_ •
x 100
63 Mid:
1 .
E1"
_
(BLANK 25)
100
2 x (BLANK 1*3)*
J -F
(BLANK 48)
100
_ •
X 100
-66
High:
1 -
2 X (BLANK 13)
1-
(BLANK26)
100
(BLANK 48)
100
1
JJ
X 100 -
J-6
4406 9/91
-------
DYNATRON MODEL 1100 OPACITY MONITOR
PERFORMANCE AUDIT DATA SUMMARY
(INCREMENTAL CAL ERROR PROCEDURE)
AUDITOR
SOURCE
RESULTS CHECKED BY
DATE
UNIT
DATE
PARAMETER
FAULT LAMPS
LAMP
WINDOW
AIRFLOW
STACK EXIT CORRELATION ERROR
INTERNAL ZERO ERROR PANfcL METER
DATA RECORDER
INTERNAL SPAN ERROR PANEL METER
DATA RECORDER
MONITOR ALIGNMENT ANALYSIS
OPTICAL SURFACE DUST ACCUMULATION
RETROREFLECTOR
TRANSCEIVER
TOTAL
CALIBRATION ERROR ANALYSIS
MEAN ERROR
LOW
MID
HIGH
CONFIDENCE INTERVAL
LOW
MID
HIGH
CALIBRATION ERROR
LOW
MID
HIGH
BLANK
NO.
sS>vNv^xvs
7
8
9
51
52
53
54
55
20
sSSSSS>
58
57
58
ssSvsS^s
^^S^NXN^S^
1-83
1-92 •
1-84
1-93*
1-65
1-94 •
\s\"\vssvS
1-66
1-67
1-88
*^NSSXS>
1-89
1-90
1-91
AUDIT RESULT
xC^^N>^s>NSN
X^^xSS^sS^NSS
^^^^^^^^^^^^^^
S^^^^^^^^^^^^
^S^^^^^^^^v^^;
\\\\\\\\\\\\\
SPECIFICATION
s>^NNSN>NS!
OFF
OFF
OFF
*2%
*4%Op
*4%Op
*4%Op
±4%Op
CENTERED
s^^^vssSSS
«2%0p
c2% Op
*4% Op
NvsNsNSSNsN^
S^N^s^sS^s^
sS^$^$;
;^S>W$^s
h\>NSS>sSSSS
^^sSSXSNS
sSSS^SS^
^S^^s^S^
SSSSsSss^
VOOvOv\X^
^^vooow
v^^$^
^^NSS^s
«3%Op
*3% Op
a ERROR BASED ON SIX-MINUTE AVERAGED DATA. FROM A SINGLE FILTER INSERTION.
D-ll
4408 9/91
-------
AUDIT DATA SHEET
LAND COMBUSTION MODEL 4500 OPACITY MONITOR
(Continued)
i. INSPECT AND
SSyJ"?J*££L»PROMMATELY 2 MINUTES PER FILTER
[REPEAT THE PROCESS 5 TIMES FOR EACH FILTER.]
THRUN HT . -0* O™01™ DURINQ ANY OF
THE RUNS. READJUST JG ZERO TO THE ORIGINAL VALUE AND REPEAT THE RUN.]
ZERO
LOW
HIGH
ZERO
ZERO
LOW
MID
HIGH
[REMOVE AUDIT THE JIG AND CLOSE THE TRANSCEIVER.]
REACTTVATF ZERO eOMPP^^-n^fi
27 Zero compensation function reactivated?
[ENTER
CALJBR
[RETURN TO CONTROL UNIT LOCATION.]
ZERO
YES
NO
RESET CONTROL
Parameter
Calibration FrwiiMncy
Output Range 1
Output Range 2
BLANK NO,
14
15
16
J-4
4406 0/91
-------
THERMO ENVIRONMENTAL INSTRLIMILIVTS Vu3l)lil. 400 TRANSMISSOMETER AND
MODE;. 50(1 COM1 HOI. UNFT
SOURCE IDENTinCATION:.
PROCESS UNIT/STACK IDENTIFICATION:.
AUDITOR:
CORPORATION:
PJWT/STTE __
ATTENDEES:
DATE
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
PRELIMINARY DATA
1 Stack exit inside diameter (FT)« Lx
2 Stack (or duct) inside diameter (or width) at the transmissorneter location (FT)«L<
3 CalculatedSTR- Lx/Lt
Sourae-ched STR value
Souroe-ched zero automatic caEbration value (% opacity)
Source-cited span automatic calibration value (% opacity)
[GO TO DATA RECORDER LOCATION.]
PNSPECT THE DATA RECORDING SYSTEM AND MARK WITH -OPACITY
AUDIT-, AUDITOR'S NAME. AFFILIATION, DATE, SOURCE, PROCESS
UNIT/STACK IDENTIFICATION. AND THE TIME OF DAY.J
fGO TO CONTROL UNIT LOCATION.]
FAULT L
7 CAL FAIL [Excessive zero and/or apart error]
8 DIRTY WINDOW [Excessive dirt on transceiver optics]
9 PURGE AIR [insufficient purge ar flow]
10 STACK POWER [No power to tmnsmisaometer]
1 1 LAMP FAILURE pnsuffioienl measuremenl lamp inlemfty]
12 ALARM [Effluent opacity exceeds source selected limit]
ON
OFF
ZERO
[PRESS THE •2ERCVCAL- SWITCH.]
[READ THE ZERO CALIBRATION VALUE FROM THE PANEL
METER AND THE DATA RECORDER]
13 Panel meter zero caEbration value (% Op)
14 Opacity data recorder zero catibration value (% Op)
SPAN CHECK
PRESS THE -SPAN/CAL- SWITCH.]
[READ THE SPAN CALIBRATION VALUE FROM THE PANEL
METER AND THE DATA RECORDER.]
15 Panel Meter span calibration value (% Op)
16 Opacity data recorder span caibralion value (% Op)
[GO TO TRANSMISSOMETER LOCATION.]
E-l
4406 0/01
-------
AUDIT DATA SHEET
LAND COMBUSTION MODEL 4500 OPACITY MONITOR
(Continued)
ZEBCLCQMPENSATION CHECK
PRESS THE "SYSTEM DATA' KEY. PRESS THE "ENTER' KEY UNTIL THE ZERO COMPENSATION
VALUE IS DISPLAYED.]
12 Zero compensation value (% Op)
OPLR CHECK AMP CONTROL UNIT ADJUSTMENTS
[PRESS THE -CONSTANTS' KEY. ENTER THE NUMBER 10 AS THE ENTRY CODE USING THE "YES'"
(A) KEY AND PRESS THE -ENTER' KEY. PRESS THE 'ENTER- KEY UNTIL THE OPLR IS DISPLAYED.]
13 Measured OPLR
[IF THE OPLR IS NOT MEASURED, TRANSPOSE THE VALUE IN (BLANK 4) TO (BLANK 13).]
PRESS THE 'ENTER' KEY UNTIL THE AUTOMATIC CALIBRATION FREQUENCY IS
DISPLAYED.]
14 Original automatic calbralion frequency setting
EfJ ™E AUTOMAT1C CALIBRATION FREQUENCY TO -00- USING THE "YES' (A) AND
NO (T) KEYS.]
[PRESS THE -ENTER' KEY UNTIL THE OUTPUT RANGE 1 SETTING IS DISPLAYED.]
15 Original output range 1 setting
[SET OUTPUT RANGE 1 TO 100% USING THE "YES' (A) AND *NO' (T) KEYS.]
PRESS THE -ENTER' KEY UNTIL THE OUTPUT RANGE 2 SETTING IS DISPLAYED.]
16 Original output range 2 setting
[SET OUTPUT RANGE 2 TO 100% USING THE "YES" (A) AND "NO" (T) KEYS.]
[GO TO TRANSMISSOMETER LOCATION.]
RETROREFLECTOR DUST ACCUMULATE CHT^
17 Pre-deaning effluent opacity (% Op)
[Open the retroreflector. inspect and dean the retroreflector optical surface and dose
retroreftedor.] ^^' ^**
1 • Post-deaning effluent opacity (% Op)
[Go to transceiver location.]
J-2 '
4406 9/91
-------
AUDIT DATA SHEET
THERMO ENVIRONMENTAL INSTRUMENTS MODEL 400 TRANSMISSOMETER AND
MODEL 500 CONTROL UNIT
(Continued)
=^=
(REMOVE THE AUDIT FILTERS FROM THE PROTECTIVE COVERS. INSPECT AND CLEAN EACH FILTER.)
[INSERT A FILTER IN THE JIG. WAIT APPROXIMATELY TWO MINUTES AND RECORD THE OPAOTY
VALUES REPORTED BY THE OPACITY DATA RECORDER. REPEAT THE PROCESS 5 TIMES FOR EACH
• IL J cn.j
ZERO LOW MID
HK3H ZERO
[IF SIX-MINUTE INTEGRATED DATA ARE ALSO AVAILABLE ALLOW 13 MINUTES EACH FOR
AN ADDITIONAL RUN OF THE ZERO. LOW. MID. HIGH
ZERO LOW MID
HIGH ZERO
^ AUDrT JIGt
[RETURN TO CONTROL UNIT LOCATION.]
[OBTAIN A COPY OF THE AUDIT DATA FROM THE OPACITY DATA
[READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA.J
LOW MID HIGH ZERO
25 ......... » ......... V ......... 26. _ 29
• • • • » •»•»•»«••«<
30 --------- SI _________ 32 _____ _ ___ 33 ______
34 ......... * ......... 36 ......... 37 ...... \
38 --------- » ___ _ _____ 40 _________ 41_ _
42 ......... « ......... 44 ......... 45 ...... m
ISIX-MNUTE AVERAGE DATA, IF APPLICABLE.!
46 --- ...... «7 ......... 4« ....... 49 50
E-3
4406 B/91
-------
APPENDIX J.
Land Combustion Model 4500 Audit Data Forms
-------
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-------
APPENDIX F.
Thermo Environmental Instruments
Model 1000A Audit Data Forms
-------
AUDIT DATA SHEET
UNITED SCIENCES, INC. MODEL 500C OPACITY MONITOR
(Continued)
[REMOVE THE AUDIT FILTERS FROM THE PROTECTIVE COVERS. INSPECT AND CLEAN EACH FILTER.]
(INSERT EACH FILTER IN THE AUDIT JIG. WAIT APPROXIMATELY TWO MINUTES AND RECORD THE
OPACITY VALUES REPORTED BY THE OPACITY DATA RECORDER. REPEAT THE PROCESS 5 TIMES FOR
EACH FILTER.]
[IF THE JG ZERO VALUE CHANGES BY MORE THAN 1.0% OPACITY DURING ANY OF THE RUNS READJUST
THE JIG ZERO TO THE ORIGINAL VALUE AND REPEAT THE RUN.] ««=*UJU!»
ZERO
LOW
MID
HIGH
ZERO
[IF SIX-MINUTE INTEGRATED DATA ARE AVAILABLE. ALLOW 13 MINUTES EACH FOR AN
ADDITIONAL flUN OF THE ZERO. LOW. MID. HIGH. AND ZERO READINGS.]
ZERO
LOW
MID
HIGH
ZERO
- CLOSE ^D SECURE THE TRANSCEIVER.
MOVE THE 'RUN/TEST SWITCH TO THE 'RUN' POSITION CLOSE
AND SECURE THE J-BOX]
[RETURN TO THE DATA RECORDER LOCATION.]
[OBTAIN A COPY OF THE AUDIT DATA FROM THE OPACITY DATA
RECORDER AND ENSURE THAT THE DATA CAN BE CLEARLY READ
AND INTERPRETED.]
[READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA,]
ZERO
LOW
MID
25
26.
30.
34
HIGH
ZERO
27.
31.
35
28
32.
36
29.
33.
37
41
[SIX-MINUTE AVERAGE DATA. IF APPLICABLE.]
47
90
4408 9/91
1-3
-------
AUDHT DATA SHEET
THERMO ENVIRONMENTAL INSTRUMENTS MODEL 1000A
(Continued)
RETROREFLECTOR DUST ACCUMULATION CHECK
9 Pre-deantng effluent opacity (% Op)
[Inspect and dean optical window.]
10 Poat-deaning effluent opacity (% Op)
[Go to transceiver bcation.]
TRANSCEIVER DUST ACCUMUUmON CHECK
11 Pre-deaning effluent opacity (% Op)
[Inspect and dean optical window.]
12 Post-deaning effluent opacity (% Op)
CALIBRATION ERRQR CHECK
[INSTALL THE FILTER HOLDER ASSEMBLY ON THE RETROREFLECTOR.]
[AVOID EYE CONTACT WITH THE UV LIGHT SOURCE]
[RECORD THE AUDIT FILTER DATA.]
El-IEB SFRIAI MO
13 LOW
14 MED
15 HIGH
[REMOVE AUDIT FILTERS FROM PROTECTIVE COVERS, NSPECT. AND CLEAN EACH FILTER.]
[RECORD THE EFFLUENT OPACrTY VALUE FROM THE OPACITY DATA RECORDER.]
[REMOVE THE FILTER AND RECORD THE EFFLUENT OPACITY.]
[REPEAT THIS PROCESS FIVE TIMES FOR EACH FILTER]
EEN
MJD. EFFLUENT HIGH
EEJ'X-MINUTE INTEGRATED DATA ARE ALSO AVAILABLE, ALLOW 13 MINUTES EACH
FOR AN ADDITIONAL RUN OF THE EFFLUENT LOW. MID. AND HIGH READING?]
EEELUEHI UM EFFLUFNT • MJD. EFFUJFMT HIGH PFFUIFMT
[CLOSE THE RETROREFLECTOR HOUSING.]
[RETURN TO CONTROL UNFT LOCATION.] p.
4406 W9^
-------
. ...~^ ~ AUDFT DATA SHEET
UNITED SCIENCES, INC. MODEL 500C OPACITY MONITOR
SOURCE IDENTIFICATION:
PROCESS UNIT/STACK IDENTIFICATION:.
AUDITOR:
ATTENDEES:
CORPORATION:
PLANT/SITE
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
DATE:
PRELIMINARY DATA
1 Stack exit inside diameter (FT) « Lx
2 Stack (or duct) inside diameter (or width) at the trensnwsometer location (FT)
3 Calculated STR « LX/L,
4 Source-cfted STR value
8 Source-cited zero automatic calibration value (% opacty)
« Source-cited span automatic calibration value (% opacity)
~~
[GO TO DATA RECORDER LOCATION.]
DATA ACOin^-nON srSTTry f;Hp^^
MARK WITH
' 7 Data recorder zero calibration value (% Op)
• Data recorder span calibration value (% Op)
[GO TO CONTROL UNIT LOCATION.]
FAULT LAMP CHECKS
9 INST MALF (conuift manual or source peraonnel lor
10 CALFAIL [zero/span error]
11 PURGE FAIL finsuffiooot purge air ftowj
12 STACK PWRFAJL[no power to transmiMOfnMer]
ON
OFF
fMOVE THE MODE SWITCH TO THE ZERO POSITION AND
READ THE ZERO CALIBRATION VALUE FROM THE PANEL METER.]
13 Panel meter zero calibration value (% Op)
DIRT COMSATION
^
Dirt compensation value (% Op)
SPAN CHg
?Sl?JIiEeoODE SWf TCH 7D ™E SPAN POSITION AND
READ THE SPAN CALIBRATION VALUE FROM THE PANEL METER.]
1 5 Panel Meter span calfcration value (% Op)
[RETURN THE MODE SWITCH TO THE 'NORMAL' POSITION.]
16 STR value
- TRANSPOSE ™E V^UE RECORDs)
[GO TO THE TRANSMISSOMETER LOCATION.]
4408 9/91
-------
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F-4
-------
ENVIROPLAN MODEL CEMOP-281 OPACITY MONITOR
PERFORMANCE AUDIT DATA SUMMARY
AuorroR
SOURCE
RESULTS CHECKED BY
DATE
UNfT
DATE
PARAMETER
FAULT LAMPS
BLOWER FAILURE
FILTER BLOCK
WINDOW
FAULT
STACK EXIT CORRELATION ERROR
INTERNAL ZERO ERROR PANEL METER
DATA RECORDER
INTERNAL SPAN ERROR PANEL METER
DATA RECORDER
OPTICAL ALIGNMENT ANALYSIS
OPTICAL SURFACE DUST ACCUMULATION
RETROREFLECTOR
TOTAL
CALIBRATION ERROR ANALYSIS
MEAN ERROR
MD
HIGH
BLANK
NO.
NXSNSN
7
8
9
10
51
52
53
54
55
21
S^v^sSSJ
56
57
56
^\^XSN
s^vSNSSsS
62
71 •
63
72*
64
1 73*
CONFIDENCE INTERVAL kSNSNXS
AUDIT RESULT
s^SNNSSSSSSNX
SPECIFICATION
N^s^s^S^S
OFF
OFF
OFF
OFF
*2%Op
*4%Op
*4%0p
I *4%0p
| * 4%Op
I CENTERED
^s>^sXs^^NS^
S^^v^vS^s^^
t>^NSSS^
<2%Op
• 2% Op
\Vv\\\Vx5?
>^s^^ss^^ss^^^^^s^3^
l\^^S^
K^KXxV^
^^^^^^^^^^^^;
^ 65
HIGH
CALIBRATION ERROR N
LOW
MID
HIGH
1
f
^^;
68
69
70
:^w^w^>
^V^s^v^S^S
S^N^sN^sJsNsN,
sSSSSNNNNX
v^^S^v^
^^w^
^Sw^^
v\\\\\\\\\V
\Vv\\x\xv\
^$^$
<3%0p
*3%Op
a ERROR BASED ON SIX-MINUTE AVERAGED DATA. FROM A SINGLE FILTER INSERTION.
H-6
4408 9/91
-------
, * r;\ V -OYMENrTAL INSTRUMENTS MODEL 1000A
(Continued)
STACK EXTT CORRELATION ERROR (%):
87
(BLANK 4)
(BLANK 3
(BLANKS)
ZERO ERROR (% Op):
(BLANK7
SPAN ERROR (% Op):
89 Opacity Dala Recorder
(BLANKi)
OPTICAL SURFACE DUST ACCUMULATION (% Op):
90 Retmreflector
92 Tctal
(BLANK9
(BLANK 10)
(BLANK"00)
(BLANKV)
F-6
4406
-------
M..-T " .'J/i"A S-'EET
ENVIROPLAN MO1DI-L. CIEMO. >-231 OPACITY MONITOR
j'CkiniJn ltd)
CALCULATION OF AUDIT RESULTS
*
STACK EXIT CORRELATION ERROR (%):
si
ZERO ERROR (% Op):
52 Panel Meter
53 Opacity Data Recorc
SPAN ERROR (% Op):
54 Panel Meter
55 Opacity Data Record
OPTICAL SURFACE DUST
56 Retroreflector
57 Transceiver
SB Total
3PT1CAL PATHLENGTH CC
>FFSET CORRECTION OF
» Low: ,.,.""
|_L
0 Mi* 1-1-
L LI-
£*"" _
(BLANK 4) (BLANK 3f *
(BLANKS) — '
6-25 "/BLANlTl* " ~4-° ~ " ~ ~ ~.~ - - -
L (W-ANKIS) J (BLANKS)
tor
(BLANK 14) (BLANK Sj "
6-25 'fBLANK iffl " "4'° ~ »,
L RRECTION FACTOR AND ZERO
AUDPT RLTERS:
(BLANK 4j
"I p -T
(BLANK22) x I (BLANK45) |
100 J L 100 J
(BLANK 4j
5LANK23) x f ~ " iBLANk^" ~ "1
100 J L 100 J
BLANK 4)
(BLANK24) | . | fflLANK^T " |
100. _ J L 100 J
•
\
X 100 «
x 100 «
X 100 *
^^
H-4
4408 8/91
-------
APPENDIX G.
Thermo Environmental Instruments
Model D-R280 AV Audit Data Forms
-------
AUDIT DATA SHEET
ENVIROPLAN MODEL CEMOP-281 OPACITY MONITOR
(Continued)
SPAN CHECK
15 Panel meter span calibration value (mliiamps)
16 Opacity data recorder span calibration value (% Op)
[GO TO TRANMISSOMETER LOCATION.]
RETROREFLECTDR DUST AC^IMULATIOM CHfCK
17 Pre-cleaning affluent opacity (% Op)
[Inspect and clean optical surface.]
1i Post-deaning effluent opadly (% Op)
[GO 70 TRANSCEIVER LOCATION.]
IB Pre-deaning effluent opacity (% Op)
[Inspect and clean optical surface.]
20 Post-cleaning effluent opacity (% Op)
OPTICAL ALIONMEMTCHPrif ropnoNAt )
[LOOK THROUGH ALIGNMENT SIGHT AND DETERMINE IF BEAM IMAGES ARE CENTERED.]
21 Images Centered?
[DRAW LOCATION OF IMAGES IN SIGHT.]
YES
NO
CALIBRATION ERROR CHFrir fj,G PBOffFn!fRn
REA^!^^
[MAKE THE FINAL JG ZERO ADJUSTMENTS BASED ON OPACITY DATA FROM THE DATA RECORDER.]
[RECORD AUDIT FILTER DATA.]
FILTER
22 LOW
23 MED
24 HIGH
SERIAL MO
3LDPAC1TY
4406
H-2
-------
14 Internal span calibration value (milEampe)
15 Data recorder span calibration value (% Op)
[GO TO TRANMISSOMETER LOCATION.]
BTmOREFLFCTPR n.tgf ^cUMU
18 Pre-deaning affluent opacity (% Op)
[Inspect and clean the optical surface.]
17 Post-cleaning effluent opacity (% Op)
[GO TO TRANSCEIVER LOCATION.]
TRANSCFfVFR DUST iftffl >M. rLA710N
18 Pre-deaning effluent opacity (% Op)
[Inspect and clean the optical surface and the zero mirror.]
19 Post-cleaning effluent opadty (% Op)
[LOOK THROUGH THE ALIGNMENT SIGHT AND DETERMINE
20 Images Centered?
IF THE BEAM IMAGES ARE CENTERED.]
YES
NO
[DRAW LOCATION OF IMAGES IN SIGHT.]
CALIBRATION ERROR ftHFrK rj,G PQ/?frFr?! fFT
[MAKE RNAL JIG ZERO ADJUSTMENTS BASED ON
21 Jig zero value from data recorder (% Op)
[RECORD AUDIT FILTER DATA.]
FILTER
22 LOW
23 MED
24 HIGH
OPACITY DATA FROM THE DATA RECORDER.]
SERIAI Mfl
% OPACITY
G-2
4406
-------
APPENDIX H.
Enviroplan Model CEMOP-281 Audit Data Forms
-------
THERMO ENVIRONMENTAL. INSTRUMENTS D-R280AV OPACITY MONITOR
(Continued)
CALCULATION OF AUDtT RESULTS
STACK EXIT CORRELATION ERROR (%):
51
ZERO ERROR (% Op):
52 Panel meter
S3 Opacity data record*
SPAN ERROR (% Op):
54 Panel Meter
55 Opacity Data Recorc
OPTICAL SURFACE DUS'
56 Retroreflector
57 Transceiver
SB Total
OPTICAL PATHLENGTH C
OFFSET CORRECTION Q
"Low: , . L
L li-
•o Mi
-------
<*x
^
Z
^
•Mill
1
S 5 5 5 !
i i i f !
ocj a S S 3 2
~
i S r - ? "
S > CM
. § zf '
; g ax « | :
i i • • 1 * ?
U .u1 K § _I _S
* p P o o o
S
(D
fe
CM
b
X
" in
N Z
CM-J g W_
Mfc
b
CM ^,
T °J ? ^
=! I
a jj' > WJ
5 ~* w
e a o ^ ^_^
5 . • STT
? _• -• z _, _,
u> «., 1^ S -H ^-*
Z f£ p g o o
D
s.
s.
3
K
^
II
1
1 ^
. w
• 1 ^
. J 1 ll
o
T i
N ^ 1
eco *J
l : ; ?
UJ X X
' • 1 " • II «~ I,
X = ui1 u.1 u.1 -? *
o oooo uT uT
• S ?2
K
g "
e ^
o
-s UI X
8» i I i
• ^^ ^^ i
mm ||j
7T ^
| ^ "I |f
| * J § 1
5 S Z Z Z 3 3
•— < uj ui ui S" S"
w o o o o uT uT
S S ~
w 10^
I
g-
^
~* s.
m. 1
= J 71
8*1 ^
« -ii 5
fi iz I »
• i " • • i^ ,
B _i -i -i -" -J
J j w ui ui 8- s-
"3^00 uT uT
§
-------
THERMO ENVIRONMENTAL INSTRUMENTS D-R280AV OPACITY MONITOR
PERFORMANCE AUDIT DATA SUMMARY
AUDITOR
SOURCE
RESULTS CHECKED BY
DATE
UNFT
DATE
AUDIT RESULT
SPECIFICATION
BLOWER FAILURE
FILTER BLOCK
WINDOW
PACK EXIT CORRELATION ERROR
INTERNAL ZERO ERROR
DATA RECORDER
INTERNAL SPAN ERROR
DATA RECORDER
*4%Op
CENTERED
OPTICAL ALIGNMENT ANALYSIS
OPTICAL SURFACE DUST ACCUMULATION
CALIBRATION ERROR ANALYSIS
MEAN ERROR
LOW
CONFIDENCE INTERVAL
LOW
MID
HIGH
\ssss\v\v
CALIBRATION ERROR
LOW
MID
HIGH
• ERROR BASED ON SIX-MINUTE AVERAGED DATA, FROM A SINGLE RLTER INSERTION.
G-6
4406 9/91
-------
AUDIT DATA SHEET
THERMO ENVIRONMENTAL INSTRUMENTS D-R280AV OPACITY MONITOR
(Continued)
5™^ 7HE AUD'T FILTERS moM ™E PROTECTIVE COVERS. INSPECT. AND CLEAN EACH
FILTERl WAIT APPROXIMATELY 2 MINUTES. AND RECORD THE OPACITY VALUE
REPORTED BY THE OPACITY DATA RECORDER. REPEATTHE PROCESS 5 TIMES FOREACH FILTER.)
[IF THE JG ZERO VALUE CHANGES BY MORE THAN 1 .0% OPACITY DURING ANY OF THE RUNfi
READJUST THE JG ZERO TO THE ORIGINAL VALUE AND REPEAT THE RUN.] '
ZERO
LOW
MID
HIGH
RF SIX-MINUTE INTEGRATED DATA ARE AVAILABLE. ALLOW 13 MINUTES EACH FOR AN
ADDITIONAL RUN OF THE ZERO. LOW. MID. HIG^^ZERO READINGS.]
ZERO
ZERO
LOW
MID
HIGH
[REMOVE THE AUDIT JG. CLOSE THE TRANSCEIVER HEAD AND THE WEATHER COVER.]
(RETURN TO CONTROL UNIT LOCATION.]
ZERO
CONTROL UNIT AD JUSTMEMT pf ffFT
BLANK 5? ***' RESET ™E °PACITY RANQE SWI7CH TO ™E POSI'nON INDICATED IN
(READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA.]
ZERO
LOW
MID
25
HIGH
26.
30.
34
38
42
ZERO
27.
31
28,
32.
36.
40
•
44
29.
33.
37.
41.
48
PIX-MINUTE AVERAGE DATA. IF APPLICABLE.]
48
47
80
4406 9/91
G-3
-------
AUDIT DATA SHEET
ENVIROPLAN MODEL CEMOP-281 OPACITY MONITOR
SOURCE IDENTIFICATION:
PROCESS UNIT/STACK IDENTTFICATION:.
AUDITOR:
ATTENDEES:
DATE:
CORPORATION:
PLANT/SITE:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
nun
PRELIMINARY DATA
1 Stack exit inside diameter (FT)« Lx
2 Stack (or duct) inside diameter (or width) at tra
3 Calculated optical patMength correction factor » LX/L,
4 Sourer-died optical pathiength correction factor
S Source-eked zero automatic calibration value (% opacky)
• Source-eked span automatic calibration value (% opacity)
Merkxttk
>(FT)-L,
fGO TO CONTROL UNIT DATA RECORDER LOCATION.]
PNSPECT DATA RECORDING
FAULT LAMP CHECK^
7 BLOWER [Loss of purge air blower power]
• FILTER pnadequate purge air flow]
6 WINDOW {Excessive dirt on transceiver wndow]
FAULT [Additional fault has occured. Note fault code on
panel meter and consult the instrument manual.]
10
ON
OFF
INSTRUMENT RANGE CHECK
11 I nstrument range setting
fPress the 'RANGE" button and record the instmmenl
range. Increase range if too low.]
ZERO CHFqft
[PRESS THE 'CALJBR' BUTTON ON THE CONTROL PANEL.]
12 Internal zero value (mHiampe)
[WATT TWO MINUTES FOR AUTOMATIC CHANGE TO EXTERNAL ZERO MODE.]
13 Panel meter zero calibration value (mlliamps)
14 Opacity data recorder zero cafbration value (% Op)
(WAIT TWO MINUTES
FOR AUTOMATIC CHANGE TO EXTERNAL SPAN MODE.]
4406 0/91
H-l
-------
THERMO ENVIRONMENTAL INSTOUME^MolH M280AV OPACHY MONITOR
SOURCE IDENTIFICATION
PROCESS UNIT/STACK IDENTIFICATION:.
AUDITOR:
ATTENDEES:
DATE
CORPORATION:
PLANT/SITE:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
Stack exit inside diameter (FT)« L,
s>iacn exn mside diameter (FT)« Lx
2 Stack (or duct) inside diameter (or width) at the traiisnieec^er location (FT) « L,
3 Calculated optical pathlength correction factor. LX/L,
« Source-died optical pathtengthcocmdion factor
« Source-cited zero automatic calibration value (% opacfty)
6 Source-ded span automatic caibnUwn value (% opacity)
fGO TO CONTROL UNIT / DATA RECORDER LOCATION.]
FAULT LAMP CH^CftS
7 BLOWER FAILURE (Loss of purye air blower power]
• FILTER BLOCK Pnadequate purge air How]
« WINDOW (Excessive din on transceiver wndow]
ON
OFF
10 Opacity range switch position
[Turn RANGE SWITCH to position '4'.]
1 1
PRESS THE CALIBRATION BUTTON ON THE CONTROL PANEL.)
Internal zero value (milEamps)
(WAIT TWO MINUTES FOR AUTOMATIC CHANGE TO EXTERNAL ZERO MODE]
12 Panel meter zero calibration value (miliampe)
13 Data recorder zero calibration value (% Op)
fWAIT TWO MINUTES
FOR AUTOMATIC CHANGE TO EXTERNAL SPAN MODE.]
4406 9/91
G-l
-------
AUDFT DATA SHEET
ENVIROPLAN MODEL CEMOP-281 OPACITY MONITOR
(Continued)
[REMOVE THE AUDIT FILTERS FROM THE PROTECTIVE COVERS. INSPECT. AND CLEAN EACH FILTER.]
ZERO
LOW
MID
HIGH
(IF SIX-MINUTE INTEGRATED DATA ARE ALSO AVAILABLE ALLOW 13 MINUTES EACH Pne>
AN ADDITIONAL RUN OF THE ZERO. LOW. MD/HON/ANO ZERO* EAD?Nc£f
ZERO
LOW
MID
HIGH
IREMOVE THE AUDIT JG. CLOSE THE TRANSCEIVER HEAD AND THE WEATHER COVER.)
{RETURN TO CONTROL UNIT LOCATION.]
ZERO
ZERO
CONTROL
RESET7HE °PACITY "»** WWTCH TO THE POSITION INDICATED IN
READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA.]
ZERO
LOW
MID
25
HIGH
29.
30.
94
27.
31.
35
28,
32.
36.
40
ZERO
29.
33.
37.
41 _
45
PIX-MINUTE AVERAGE DATA. IF APPLICABLE.]
47
80
H-3
4406 9/91
-------
o. INSTRUMENTS MODEL 1000A
OPACfTY MONITOR PERFORMANCE AUDIT DATA SUMMARY
AUDITOR
SOURCE
RESULTS CHECKED BY
DATE
UNIT
DATE
AUDIT RESULT
SPECIFICATION
STACK EXIT CORRELATION ERROR
-^—————-^—«^
INTERNAL ZERO ERROR
1
INTERNAL SPAN ERROR
OPTICAL SURFACE DUST ACCUMULATION
RETROREFLECTOR
TRANSCEIVER
TOTAL
MMMI^BM
CALIBRATION ERROR ANALYSIS
MEAN ERROR
LOW
\\X\\\N
\SSSS\SSN
\XXXXNXXXXXXXXXXXX
CONFIDENCE INTERVAL
LOW
MID
HIGH
NSSSSSSSX'
\s\vvv\vv
CALIBRATION ERROR
LOW
MID
HIGH
ERROR
BASED ON SIX-MINUTE AVERAGED DATA. FROM A SINGLE FILTER
INSERTION.
F-7
4406 9/91
-------
fit
«
<
UIU
2S
zz
^^
Z z 1
0 w *"*
• *T
j i
> oT"
1 i
1 1^1
o o o
-S
UI
S
. z
C? o -
g * ;
c — n
ui z
i - J
" i • "
Z 3 iu ui i
o o o o <
fc
,
i *
'i
• *i^
y
N «
z z
JJ —
\ *"*'
p
U
(E
C
a
oc
CD
IJ
<
U
S2]
zu
« d
o o o
Q o
I 1. 1
g« J
2 •
B j ^ -^
^ UJ UJ U>
S o o o
co, to
UJ UJ
-------
M
<
<
UIUI
Ot
ZZ
X
in
d
• ^^^
— !», — *. N
Z z
• 2
C * —,
ec — |
!« 2
| !| J
• • •
• H
2 2
8-^" -T* .* S UJ IM UJ
0 w « e5 S S o
s
u
2
s;
UJ
I
o
UI UI
CD
ff
s
CM —
^"
g
-
I '!
UI
-J uj Z -j _
^ ^8^0
o
• IK
_l -J
Uj UJ UJ
> o
(7
r-.
f
u7
-------
APPENDIX I.
United Sciences, Inc Model 500C Audit Data Forms
-------
AUDIT DATA SHEET
THERMO ENVIRONMENTAL INSTRUMENTS MODEL 1000A
(Continued)
READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA.]
LOW
16
17
23
28
34
35
40
«6
EFFLUPMT
18
24
30
36
MID
19
31
37
EFFLUENT
20
32
ISK-MINUTE AVERAGE DATA (IF APPLICABLE))
HIGH
21
27
33
30
45
S3
CORRECTION OF AUDIT FILTERS:
SO
5,
52
54 L«r
E
2 x (BLANK4)
(BLANK 13)
100
•]
2 x (BLANK4)
100
56 Hioh:
E
2x (BLANK)
(BLANK 15)
100
•]
F-3
4408 0/91
-------
^^ AUDIT DATA SHEET
UNITED SCIENCES, INC. MODEL 500C OPACITY MONITOR
(Continued)
TRANSCEfVFR DUST ACm ly^
17 Prt-daaning affluent opacity (% op)
1i Post-cleaning effluent opacity (% Op)
[GO TO RETROREFLECTOR LOCATION.)
RETRQRFR FCTOR DUST ftr^ ^MULATIOM t^f^
[OBTAIN THE PRE-CLEANINQ EFFLUENT OPACITY READING.J
19 Pre-deaning effluent opacity (% Op)
•
20 PaeNctaaning affluent opacity (% Op)
JLAR IMAGE OF THE OPEN
21 Image centered?
(DRAW IMAGE.]
YES
NO
PETURKTOTHERETBOREFLBCTOBLOCATON. OOS6 AND SECURE IHi RE7BOREFLECTOR,
SA1'°N ^-^"^ WE
« ""NOTES PLACE WE
[RECORD AUDIT FILTER DATA.J
FILTFR
22 LOW
23 MED
24 HIGH
SEB1ALNO
% OPACITY
4406
T-?
-------
THERMO ENVIRONMENTAL llfSH :l. I I-NTS MODEL 1000A
SOURCE IDENTIFICATION:
PROCESS UNIT/STACK IDENTIFICATION:.
AUDITOR:
ATTENDEES:,
DATE
CORPORATION:
PLANT/SITE
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING: .
PRELMNARY DATA
1 Stack exit inside diameter (FT)« Lx
2 [Stack (or duct) inside diameter (or width) at the trwwmasomeM
3 Calculated 'SEC* Factor « Lx /L,
4 Source-cited "SEC" Factor value
5 Source-cited zero automatic calibration value (% opacity)
6 Source-cited span automatic calibration value (% opacity)
tfion(FT)]x2«Lt
[GO TO DATA RECORDER LOCATION ]
ZERO CUP CK
THE -RO- POSH-ION. WAIT THREE MINUTES,
7 Opacity data recorder zero caJbralon value (% Op)
SPAN CHECK
8 Opacity data recorder span calibration value (% Op)
F-l
4406
-------
UNITED SCIENCES, INC. MODEL 500C OPACITY MONITOR
(Continued)
CALCULATtOK
STACK EXITC
51
ZERO ERROR (
32 Panel Me
S3 Opacity C
SPAN ERROR f
54 Panel Mel
55 Opacity D
OPTICAL SURF/
56 Transceive
57 Retroreflecl
50 Total
•ATHLENGTH Ah
W Low: ,.
» Mid: 1-
1 High: 1 -
I— *•
ORRELAT1ON ERROR (%):
PLANK 4) "(BLANK 3~ ~
(BLANK3) -J
*0p):
(BLANK 13) (BLANKS) •
>ata Recorder
~ c
(BLANK 7j (BLANKS) —
*0p):
• *
(BLANK 15) (BLANK 6) •
ata Recorder ^ ^ fflLANKO " "
LCE DUST ACCUMULATION (% OP):
(BLANK 17) (BLANK 18) " • —
_ •
* (BLANK 1^ (BLANK2$ .
- . + •
(BLANK56) (BlANlTsT) .
ID ZERO OFFSET CORRECTION OF AUDFT FILTERS:
^ "(BLANkTer
(BLANK22) . fflLAN-K^" ~ I
u. -J L 100 J —
(BLANKTef
fr--- n r -fil
(BLANK23) K (BLANK 45)" ~ ]
L " 'inn "
(BLANK 16)
-i p -n"|
• (BLANK24) X L (BLAN-K4-5)- - 1
J L '100
1-4
4408 9/91
-------
PERFORMANCE' AUWT niu* ":;:.IIIIMARY
AuorroR
SOURCE
RESULTS CHECKED BY
AUDIT RESULT
SPECIFICATION
FAULT LAMPS
CALFAIL
DIRTY WINDOW
PURGE AIR
STACK POWER
LAMP FAILURE
ALARM
•^^M«^m
STACK EXIT CORRELATION ERROR
INTERNAL ZERO ERROR
DATA RECORDER
INTERNAL SPAN ERROR
DATA RECORDER
MONITOR ALIGNMENT ANALYSIS
OPTICAL SURFACE DUST ACCUMULATION
RETROREFLECTOR
—^—•———
TRANSCEIVER
MBMBHMM
TOTAL
^—»^»
CALIBRATION ERROR ANALYSIS
MEAN ERROR
•H^^^H
LOW
±4% Op
CENTERED
\\sss\v\\
\\SsSS\\SN
NSSSSNSN
\Vs\S\Vs\
CONFIDENCE INTERVAL
LOW
MID
HIGH
•MM^^Mi
CALIBRATION ERROR
LOW
MID
HIGH
« ERROR BASED ON SIX-MINUTE AVERAGED DATA FROM A SINGLE FILTER INSERTION.
E-6
4408 0/01
-------
UNITED SCIENCES, INC. MODEL 500C
OPACITY MONITOR PERFORMANCE AUDIT DATA SUMMARY
AuorroR
SOURCE
RESULTS CHECKED BY
DATE
UNIT
DATE
PARAMETER
FAULT LAMPS
INSTMALF
CALFAIL
PURGE FAIL
STACK PWR FAIL
STACK EXIT CORRELATION ERROR
INTERNAL ZERO ERROR PANEL METER
DATA RECORDER
DIRT COMPENSATION
INTERNAL SPAN ERROR PANEL METER
DATA RECORDER
MONITOR ALIGNMENT ANALYSIS
OPTICAL SURFACE DUST ACCUMULATION
TRANSCEIVER
RETROREFLECTOR
TOTAL
CALIBRATION ERROR ANALYSIS
MEAN ERROR
LOW
MID
HIGH
CONFIDENCE INTERVAL
LOW
MID
HIGH
CALIBRATION ERROR
LOW
MID
HIGH
BLANK
NO.
N^S^S^v
9
10
11
12
51
52
53
14
54
55
21
vsssSsss\^S
56
57
56
^sSSSS^
vSSsSSsS>
62
71 •
63
72*
64
73«
"^NSNN^
65
66
67
^^S^S
66
69
70
AUDIT RESULT
XS^^^SN^NNNS>
^s^s^N^sN^v^^s^
X^S^s^s^v^^
SSNSSSks\S>\svsS
^^>^^^
^^^^^^^^^s:
SPECIFICATION
\\x\vx\\xs
OFF
OFF
OFF
OFF
±2%
*4%Op
*4%Op
*4%Op
*4% Op
*4%Op
CENTERED
^V^NS^X^
*2%Op
<2%Op
• 4% Op
SN^S^vN^sN^
N^S^N^NsN^
^SSS^SSSSS
^N>^W>;
^^N^^\
^SSSSSSNSSJ
oSc^^^sSv
"WOOOOOOO
^WOOW
S$^
^^^N
v^SSSSSsSS
^SSSSSSS>s
x3%Op
<3%Op
«a%0p
» ERROR BASED ON SIX-MINUTE AVERAGED DATA. FROM A SINGLE FILTER INSERTION.
4406 9/91
1-6
-------
MODEL 400 TRANSMISSOMETER AND
LHiUbW CONTROL UNfT
CALCULATION OP Atmrr nf s^ Ts
STACK EXIT CORRELATION ERROR (%):
51
ZERO ERROR (% Op):
52 Panel Meter
53 Opacity Data Recorder
SPAN ERROR (% Op):
54 Panel Meier
55 Opacity Data Recorder
(BLANK 4)
(BLANK 3)
(BLANK 3}
x100<
(BLANK 13)
"(BLANK~14)
(BLANKS)
(BLANKS)'
(BLANK 15)
~(BLANK~16)
(BLANKS)
"(BLANK sT
OPTICAL SURFACE DUST ACCUMULATION (% OP):
56 Retroreflector
57 Transceiver
58 Total
(BLANK 17)
(BLANK~19)
(BLANK 18)
~(BLANK*20)
(BUNKS?)
PATHLENGTH AND ZERO OFFSET CORRECTION OF AUDIT PITERS:
59 Low:
1 -
(BLANK 4)
(BLANK 22)
(BLANK 45)
100
100
x 100
Mid:
1-
(BLANK 4)
(BLANK 23)
100
:]
(BLANK 45)
100
•
x 100
High:
1 -
£""
^
(BLANK 24)
100
(BLANK 4)
] -F
(BLANK 45)
100
1
JJ
"
x 100
E-4
4408 9/91
-------
,« >,
LAND COMBUST ON MC I) EL 4f C(. OPACITY MONITOR
SOURCE IDENTIFICATION:
PROCESS UNIT/STACK IDENTIFICATION:.
AUDITOR:
ATTENDEES:
DATE-
CORPORATION:
P1ANT/SITE:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
Stack act inside diameter (FT)« Lx
2 fSUKMordua) inside di^er (or wkfth) at tta^
3 Calculated OPLR.Lw/L,
" I
4 Source-cited OPLR value
« Source-cited zero automatic calibration value (% opacity)
• Source-cited span automatic calibration value (% opacity)
fit unavailable, input the factory assigned span value.]
[GO TO DATA RECORDER LOCATION.]
ES^^SKSSSS^^
[GO TO CONTROL UNIT LOCATION.)
AND THE T.ME OFY.,
FAULT LAMP CHECK
7 FAULT [One or more monitor faufc* detected.]
[ENTER ADDITIONAL FAULT INFORMATION BELOW. (Optional)]
ON
OFF
• Panel meter span calibration value (% Op)
• Data recorder span calibration value (% Op)
10 Panel meter zero calibration value (% Op)
11 Data recorder zero calibration value (% Op)
J-l
4408 9/91
-------
AUDfT DATA SHEET
THERMO ENVIRONMENTAL INSTRUMENTS MODEL 400 TRANSMISSOMETER AND
MODEL 500 CONTROL UNFT
(Continued)
RETRQREFLECTQR PUCT ACCUMUL1T1OM CH.FftK
17 Pre-cleaning effluent opacity (% Op)
r' lnfipect •^ deiin ** '*IW
.]
1i Po«
-------
AUDIT DATA SHEET
LAND COMBUSTION MODEL 4500 OPACITY MONITOR
(Continued)
TRANSCEIVER DUST ACCUMUL AT1OM CHECK
19 Pre-daaning effluent opacity (% Op)
20
[Open the tnuwcerver. Inspect and clean the primary kern and zero minor, and cbeethe
transceiver.]
Post-cleaning affluent opacity (% Op)
RESET THE ZERO COMPENSATION VALUE BY HAVING AN ASSISTANT AT THE
CONTROL UNIT LOCATION INITIATE A MANUAL ZERO AND SPAN CALIBRATION
CYCLE. THE COMPLETE CYCLE WILL TAKE APPROXIMATELY 3.5 MINUTES J
OPTICAL ALIQMMEMT CHECK
[TURN THE FUNCTION SWITCH CLOCKWISE TO THE "VISIER' POSITION.]
t22Ll')?SJll~EWING PORT O" ™E RIQHT HAND SIDE ^ WE TRANSCEIVER. AND
OBSERVE THE POSITION OF THE BEAM IMAQE WITH RESPECT TO THE BLACK CIRCLE.]
21 Image Centered?
YES
NO
ESZygSSSSUSF,i^SS^SKr"1"' APPE*RS " ™
DEFEAT ZERO COMPgMSATinM
22 Zero compensation function defeated?
YES
NO
CALIBRATION ERROR CHECK
[OPEN THE TRANSCEIVER AND THE J-BOXJ
E^SS^L?1:7^ OPTICAL DENSITY VALUE FROM THE FRONT SIDE OF THE
THANSCHVER.J
23 Span filler value p.D.)
[RECORD AUDIT FILTER DATA,]
FILTER
24 LOW
25 MED
26 HIGH
SERIAL NO
% OPACITY
4406 9/91
-------
APPENDIX E.
Thermo Environmental Instruments
Model 400 Audit Data Forms
-------
AUDIT DATA SHEET
LAND COMBUSTION MODEL 4500 OPACITY MONITOR
(Continued)
(READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA,]
ZERO LOW
28 29
33
37
41
45 _
MID
HIGH
ZERO
30
34
38
42
48
ISIX-MINUTE AVERAGE DATA, IF AVAILABLE.]
49
51
31
35
39
43
47
52
CALCULATION OF AUPtTRPSU. TS
STACK EXIT CORRELATION ERROR (%):
32
38
40
53
54 Source cited (BLANK 4) (BLANK 3)
——~~———————————— X100 !
"(BLANKS)
«5 Measured (BLANKJaT *
"(BLANKS)
ZERO ERROR (% Op):
58 Panel meter - - -mr .T..T - -- *---.-..
(BLANK 10) (BLANKS)
57 Opacity data recorder _
(BLANK"11) " " (BLANKST
(PAN ERROR (% Op):
(8 Panel Meter
(BLANKS)" " " (BLANKS?
16 Opacity Data Recorder
(PLANKS)" " " (BLANKST
J-5
4406 9/91
-------
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-------
§
ii
-------
AUDfT DATA SHEET
DYNATRON MODEL 1100 OPACITY MONITOR
(Continued)
INCREMENTAL CAL ERROR
CONTROL UNIT ADJUSTMENT RESET
[IF NECESSARY. RESET THE CONTROL UNIT CALIBRATION TIMER AND METER DISPLAY
KNOBS TO THE POSITIONS INDICATED IN THE CORRESPONDING BLANKS.]
KNOB
Automatic Calibration Timer
Metar Display
BLANK NQ
10
11
[OBTAIN A COPY OF THE AUDIT DATA FROM THE OPACITY DATA RECORDER AND
ENSURE THAT THE DATA CAN BE CLEARLY READ AND INTERPRETEDJ
[READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA.]
EFFLUENT
LOW
EFFLUENT
MID
EFFLUENT
HIGH
,.25
1-26
,.27
,.28
1-29
'-30
1,33
1-35
,.39
M1
,45
I-47
WO
1-53
1-54
ISIX-MINUTE AVERAGE DATA (IF APPLICABLE)]
1-55
1-56
1-57
1-56
1-50
1-60
1-61
FACTOR CORRECTION OF AUDIT FILTER (TRANSMITTANCE):
2 x (BLANK 4)
1-62 Low:
(BLANK 1-21)
100
I-63 Mid:
E
2 x (BLANK 4)
(BLANK I-22)
100
1-64 High:
L JBLANKI-lsT
L 100
2 x (BLANK 4)
D-8
4406 9/91
-------
APPENDIX K.
Datatest Models 900A and 900RM Audit Data Forms
-------
DYNATRON MODEL 1100 OPACITY MONITOR
PERFORMANCE AUDIT DATA SUMMARY
(JIG PROCEDURE)
AUDITOR
SOURCE
RESULTS CHECKED BY
— DATE
_ BATE
PARAMETER
FAULT LAMPS
LAMP
WINDOW
AIR FLOW
STACK EXIT CORRELATION ERROR
INTERNAL ZERO ERROR PANEL METER
DATA RECORDER
INTERNAL SPAN ERROR PANEL METER
DATA RECORDER
MONITOR ALIGNMENT ANALYSIS
OPTICAL SURFACE DUST ACCUMULATION
RETROREFLECTOR
TRANSCEIVER
TOTAL
CALIBRATION ERROR ANALYSIS
MEAN ERROR
LOW
MID
HIGH
CONFIDENCE INTERVAL
LOW
MID
HIGH
CALIBRATION ERROR
LOW
MID
HIGH
BLANK
NO.
sSXS>^
7
8
0
51
52
53
54
55
20
AUDIT RESULT
^^^>^^^^^^^^\^
^sS^^^^^s^^x^N^N^^^^^^
56
57
56
;>^SSN!
ssS^Ss^
^^^s^s^^^^^^^^^
^^S^^s^^^^^^^^^
62 I
71 • |
63 I
72* I
64 |
73« I
\x\xxxk\xx\xxx\xx\v
65 I
66 I
67 I
XXXXX^XXXXXXXXXXXX
68 |
60 |
70 |
SPECIFICATION
^^NS>v^
OFF
OFF
OFF
*2%
*4%Op
*4%Op
CENTERED
^^SSSS^s
«4%Op
^ISSSSSS^
\X\X\X\NX^
^^^
>$$$$$$$$$;
^$$^
^$$^N
^S^^
^^^
^^^
^^^
^^^
VOOOOO^N>
^^^
«3%Op
*3% Op
• 3% Op
• ERROR BASED ON SIX-MINUTE AVERAGED DATA, FROM A SINGLE FILTER INSERTION.
D-6
44OB 9/91
-------
AUDIT DATA SHEET
DATATEST MODEL 900 TRANSMISSOMETER
Pcge2of 11
LENS DUSTING CHECK ntimAt}
(MEASURE THE VOLTAGE AT TEST POINT 3 ON PC-5 IN MILLIVOLTS.]
PVIDE THIS VALUE BY 100 TO CALCULATE THE LENS DUSTING IN PERCENT OPACITY.]
15 Initial lens dusting value {% Op) >
(MV)/100.
SPAN CHECK
TURN OFF THE "ZERO CALIBRATION- SWITCH AND TURN ON THE "SPAN CALIBRATION- SWITCH.]
[READ THE SPAN CALIBRATION VALUE FROM THE PANEL METER AND THE DATA RECORDER]
16 Panel meter span cafixation value (% Op)
17 Opacity data recorder span caibration value (% Op)
(TURN OFF THE "SPAN CALIBRATION" SWITCH.] ' -
[GO TO TRANSMISSOMETER LOCATION.]
RETRQREn FCTQR fOR RFCFiVEm BUST A.CTMULATIQII r^FTTK
18 Pre-deaning effluent opacity (% Op)
~
18 Post-deaning effluent opacity (% Op)
[GO TO TRANSCEIVER LOCATION.]
TBANSCEIYFR fQR TRANSMFTTFR^ DUST Arr.,^ f, ATIQM
20 Pre^eaning effluent opacity (% Op)
21 PosJ-deaning effluent opacity (% Op)
OPTICAL ALIGNMENT CHECR
22 Image centered?
YES
NO
PRAW LOCATION OF BEAM IMAGE.]
K-2
4406 0/D1
-------
,-'A'"AS•-"=.;=.'-
DYNATRON MODE! I JIM* O=A-ITY MONITOR
.ltd)
CALCULATION OF AUDfT RPSUt TB
STACK EXIT CORRELATION ERROR (%):
31
ZERO ERROR (% Op):
52 Panel meter
53 Opacity data recorder
(BLANK 4)
(BLANK 3
(BLANKS)
X100
(BLANK 12)
(BLANK 13)
(BLANKS)
SPAN ERROR (% Op):
54 Panel Meter
55 Opacity Data Recorder
(BLANK 14)
"(BLANK~15)
(BLANKS)
(BLANK Q
OPTICAL SURFACE DUST ACCUMULATION (% Op):
56 Retrorefiector
57 Transceiver
58 Total
(BLANK 16)
(BLANK~18)
(BLANK 17)
"(BLANtTlfli
(BLANK 56)
(BLANlsT)
•M- FACTOR AND ZERO OFFSET CORRECTION OF AUDIT FILTERS:
59 Low:
,.
E
2 x (BLANK)
(BLANK22)
100
.] ,f
100
x 100
BO Mid:
1 -
I
(BLANK 2*3)"" " '
100
2 x (BLANK)
] •[
(BLANK 4s
•I
X 100
1 High:
1 -
E
2 x (BLANK)
******
:] ,[
<•
X 100
D-4
4408
-------
AUDIT DATA SHEET
DATATEST MODEL 900 TRANSMISSOMETER
Page 4 of 11
FINAL CALIBRATION ERROR DATA - MODEL 900RII
[READ AND TRANSCRIBE RNAL CALIBRATION ERROR DATA.)
ZERO
LOW
MID
HIGH
27
28
32
36
40
ZERO
29
33
37
41
45
30
34
38
42
46
[SIX-MINUTE AVERAGE DATA. IF APPLICABLE]
48 49
ttLCULATION QF AUDIT RFSUITS - MODELS SQORU ^P mft
5TACK EXfT CORRELATION ERROR (%):
3 Source cited (BLANK 4) (BLANK 3)
'" x100i
"(BLANKS)
« Measured 7BLANK 12" " * " "(BLA'NK 3" -ww
i x100i
(BLANKS)
RO ERROR (% Op):
Panel meter IpTAMiT.,^ ~
(BLANK 13) (BLANKS)
Opacity data recorder
~(BLANk~14) ~ ~ (BLANK 5j
W ERROR (% Op):
Panel Meter
~(BLANK~16) " " (BLANK 6)
Opacity Data Recorder
~(BLANK~17) " "
31
35
39
43
47
K-4
4406 9/91
-------
AUDIT DATA SHEET -
DYNATRON MODEL 1100 OPACITY MONITOR
(Continued)
14 Panel meter span calibration value (% Op)
15 Opacity data recorder span cafbraiion value (% Op)
[GO TO TRANSMISSOMETER LOCATION.]
RETROREFLECTOR DUST ACCUMULATION. CH.F.7K
16 Pre-deaning effluent opacity (% Op)
[Remove, inspect, dean, and replace the protective window.)
17 Post-cleaning effluent opacity (% Op)
[Go to transceiver location.]
TRANSCEIVFR DUST Arrt ,u, fL A71QM eHPffg.
18 Pre-deaning effluent opacity (% Op)
fRemove. inspect, clean, and replace the protective window.]
19 Post-cleaning effluent opacity (% Op)
OPTICAL At IfiNMEKT PMPri^ f^pT]^Mfi| }
20 Image Centered?
PRAW ORIENTATION OF THE RETROREFLECTOR PORT IN ALIGNMENT CIRCLE.]
CALIBRATION FRROR enprir rlf(p pRocirpt^^
REMOVE THE TRANSCEIVER PROTECTIVE WINDOW.]
YES
NO
™E 7RANSCBVER PROTECTIVE WINDOW AND RECORD THE PROTECTS WINDOW
21
[REMOVE THE TRANSCBVER PROTECTIVE WINDOW.]
[RECORD AUDIT RLTER DATA.] "wvwj
F1LTFR
22 LOW
23 MED
24 HIGH
SERIAL NO
% OPACITY
4406 SV91
n-?
-------
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-------
APPENDIX D.
Dynatron Model 1100 Audit Data Forms
-------
EFFLUENT
FINAL CALIBRATION ERROR DATA - MODEL 900RM
[READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA.]
EFFLUENT LOW
*"** 1-27 1-28
1-32 „_____. K33 144
••38 _ . W8 MO
M4 _ , MS
1-50 _ , W1
1-56
AVO.T DATA SHEET
t-*SSJATES1 ^:IDEL SOO TRANSMISSOMETER
MODEL 900A <;•!,. BRATION ERROR PROCEDURE
Page 8 of 11
k35
MO M1
MS M7
1-52 1^3
[SIX-MINUTE AVERAGE DATA. IF APPLICABLE.]
EFFLUENT LOW EFFLUENT
^ . K58 (.59 ^^
1-63
MID
EFFLUENT
HIGH
U36
M2
MID
5TACK EOT CORRELATION OF AUDfT FILTER (TRANSMfTTANCE)
(-31
W7.
U3
M9
EFFLUENT
HIGH
Low:
(BLANK 12)'
(BLANK 1-23)
100
Mid:
E
(BLANK 12)'
(BLANK t-24)
100
High:
(BLANK t-25)
100
•1
(BLANK 12)'
K-8
4406
-------
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-------
AUDIT DATA SHEET
LEAR SIEGLER RM-4 OPACITY MONITOR
(Continued)
ZERO
..,_.
MID
HIGH
ZERO
LOW
REMOVE AUDIT JG AND CLOSE TRANSCEIVER.)
[RETURN TO CONVERTER CONTROL UNIT LOCATION.]
MID
HIQH
ZERO
ZERO
ZERO CURRFNT CHECK fflpTlfrMfll}
RXffS^^
25 Zero current value, mA (OPTIONAL)
[READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA.]
ZERO
LOW
26
MID
27.
81.
35
HIQH
32.
38.
40
39.
37.
41 m
45
47
PIX-MINUTE AVERAGE DATA. IF APPLICABLE.]
-- * 80
ZERO
30.
34
51
4406 9/91
------- |