EPA-6OO/8-87-O25
Technical Assistance Document:
Performance Audit Procedures for Opacity
Monitors
Prepared by-
Steven J. Plaisance
James W. Peeler
OEM/Engineering Division
Entropy Environmentalists, Inc.
EPA Contract No. 68-02-4125
Work Assignment Nos. 140Aand 182A
and
EPA Contract No. 68-02-4442
Work Assignment No. 11
EPA Project Officer: Thomas J. Logan, Quality Assurance Division
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Environmental Monitoring Systems Laboratory
Research Triangle Park, North Carolina 27711
April 1987
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Disclaimer
This material has been funded wholly or in part by the U. S. Environmental
Protection Agency under Contract Numbers 68-02-4125 and 68-02-4442 to Entropy
Environmentalists, Inc. It has been subject to the Agency's review, and it has
been approved for publication as an EPA document. Mention of trade names or
commerical products does not constitute endorsement or recommendation for use.
ii
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Abstract
This manual contains monitor-specific performance audit procedures and data
forms for use in conducting audits of installed opacity continuous emission
monitoring systems (GEMS's). General auditing procedures and acceptance limits
for various audit criteria are discussed. Practical considerations and common
problems encountered in conducting audits are delineated, and recommendations
are included to optimize the successful completion of performance audits.
Performance audit procedures and field data forms were developed for six
common opacity GEMS's: (1) Lear Siegler, Inc. Model RM-41; (2) Lear Siegler
Inc. Model RM-4; (3) Dynatron Model 1100; (4) Thermo Electron, Inc. Model 400-
(5) Thermo Electron, Inc. Model 1000A; and (6) Enviroplan Model D-R280 AV.
These procedures were designed to be performed by a single auditor. 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 opacity
CEMS's with multiple transmissometers and combiner devices. In addition,
several approaches for evaluating the zero alignment or "clear-path" zero
response have been described. The zero alignment procedures have been included
sxnce this factor is fundamental to the accuracy of opacity monitoring data
even though the zero alignment checks cannot usually be conducted during a
performance audit.
iii
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CONTENTS
Disclaimer
Abstract '*.''*'*
Figures '.'.'.'.'.'.'.'.'.'.'.'.'.'.'.. v
1. Introduction j«
1.1 Background r '.'.'.'.'' 1-1
1.2 Use of This Manual !!!''*'!'!*''*''!''' 1-2
1.3 Approach and Limitations ^_o
2. General Audit Procedures. 2-1
2.1 Practical Considerations 2-1
2.2 Pre-Audit Information '!'!*'' °2-3
2.3 Performance Audit Procedures ...!!!*' 2-4
3. Performance Audit Procedures for Lear Siegler, Inc.
Opacity Monitors o_^
3.1 Lear Siegler, Inc. Model RM-41 Transmissometer and Model 611"'
Control Unit o i
3.2 Lear Siegler, Inc. Model RM-4 Transmissometer \ '3-18
4. Performance Audit Procedures for Dynatron Opacity Monitor 4-1
4.1 Dynatron Model 1100 Transmissometer '.'.'.'.'.'.'. 4-1
5- Performance Audit Procedures for Thermo Electron (Contraves Goerz)
Opacity Monitor c_]_
5.1 Thermo Electron (Contraves Goerz) Model 400 Transmissometer
and Model 500 Control Unit K-I
6. Performance Audit Procedures for Thermo Electron (Environmental
Data Corporation) Opacity Monitor g_]_
6.1 Thermo Electron Corporation (Environmental Data Corporation)"*
Model 1000A _ 6_±
7. Performance Audit Procedures for Enviroplan (Thermo Electron
Corporation) Opacity Monitor 7.^
7.1 Enviroplan (Thermo Electron Corporation) Model D-R280 AV
"Durag" 7_±
8. Performance Audit Procedures for Opacity CEMS With Combiners 8-1
8.1 Calculation of Stack-Exit Opacity for Combiner Systems '.'.'.'.8-1
8.2 General Audit Procedures 8-4
9. Zero Alignment Checks q_±
9.1 Off-Stack Zero Alignment '.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.^-1
9.2 On-Stack Zero Alignment .*'!.'.'' 9-2
9• 3 Alternate Zero Alignmetn Approaches '.9-3
(Continued)
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Appendices
Appendix A.
Appendix B.
Appendix C.
Appendix D.
Appendix E.
Appendix F.
CONTENTS (continued)
Lear Siegler, Inc. Model RM-41 Audit Data Forms
Lear Siegler, Inc. Model RM-4 Audit Data Forms
Dynatron Model 1100 Audit Data Forms
Thermo Electron (Contraves Goerz) Model 400
Audit Data Forms
Thermo Electron (EDO) Model 1000A Audit Data Forms
Enviroplan (Thermo Electron) Model D-R280 AV "Durag
Audit Data Forms
A-l
B-l
C-l
D-l
E-l
F-l
v
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2-1.
3-1.
3-2.
3-3-
3-4.
3-5-
3-6.
3-7.
4-1.
5-1.
5-2.
7-1-
7-2.
7-3.
7-4.
9-1.
FIGURES
Opacity Audit Data Form '.
Arrangement of LSI RM-41 Transceiver and Retroreflector Components.
LSI RM-41 Control Unit (Model 611) '
LSI RM-41 Control Unit Circuit Board Arrangement
LSI RM-41 Transceiver
LSI RM-41 Junction Box
Arrangement of LSI RM-4 Transceiver and Retroreflector Components..
LSI RM-4 Converter Control Unit
Dynatron 1100 Transceiver and Retroreflector Arrangement
Arrangement of Thermo Electron (Contraves Goerz) Model 400
Transceiver and Retroreflector
Thermo Electron (Contraves Goerz) Model 500 Control Unit.
Arrangement of Enviroplan (Thermo Electron) Model D-R280 AV
Transceiver and Retroreflector
Enviroplan (Thermo Electron) Model D-R280 AV Control Unit.
Enviroplan (Thermo Electron) Model D-R280 AV Transmissometer
Components
Enviroplan (Thermo Electron) Model D-R280 AV Junction Box.
Zero Alignment Jig
2-4
3-2
3-3
3-7
3-11
3-13
3-19
3-20
4-2
5-2
5-3
7-2
7-3
7-7
7-9
9-5
VI
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SECTION 1
INTRODUCTION
1.1 BACKGROUND
In 1975, the U. S. Environmental Protection Agency (EPA) first promulgated
specific requirements for several source categories subject to the Standards of
Performance for New Stationary Sources 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 these actions, Federal, state, and local air
pollution control agencies have expanded the applications of opacity continuous
emission monitoring systems (CEMS's) by adopting monitoring requirements for
additional source categories, 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. Data on excess
emissions are most often used as an indication of whether proper operation and
maintenance practices for process and control equipment are being used.
However, the opacity monitoring data may also be evaluated by the control
agency as an indication of: (1) the degree of compliance with applicable
opacity standards, (2) particulate emission levels, and (3) 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 CEM data are of
concern to both control agency and source representatives. In almost all
cases, the source/owner or operator is required to demonstrate that the opacity
GEMS 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 opacity CEMS becomes operational, and serves to
ensure that the monitoring system is properly installed and is capable of
providing reliable data.
EPA regulations and 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 response of the opacity CEMS at two points
at least once each day. These checks are usually performed at zero opacity and
an upscale point referred to as the span check through the use of an internal
device that simulates a zero opacity condition and an internal filter that
obscures a known quantity of the light beam. (Some opacity CEMS's substitute a
low range opacity check for the zero 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 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 opacity CEMS, 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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Audits of CEMS's may be conducted in order to assess the quality of data
provided by CEMS's 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 acquired by the opacity monitoring system.
Since it is not feasible to obtain independent effluent measurements for
comparison with the measurements provided by an installed opacity monitor, a
series of checks of the individual monitoring system components is conducted.
Based on the results of these checks, an assessment of the performance of the
entire monitoring system can be made.
Audits of opacity CEMS's may be conducted by either the control agency or
source personnel. Performance audits may be conducted by the control agency to
assess the quality of opacity monitoring data, at sources selected randomly, or
at sources where opacity monitoring problems or high levels of excess emissions
are indicated in quarterly excess emission reports. Performance audits may also
be conducted by source personnel (or other company representatives) on a routine
basis, as part of a quality assurance program, or when specific concerns arise
regarding the validity of the opacity monitoring data. A performance audit
provides a relatively simple and quick method of obtaining an objective
evalution of opacity monitor performance, regardless of who conducts the audit.
1.2 USE OF THIS MANUAL
This manual provides detailed procedures for conducting performance audits
of opacity CEMS's. This manual updates and replaces the information and
procedures contained in an earlier document "Performance Audit Procedures for
Opacity Monitors," (EPA 340/1-83-010, January 1983). The audit procedures were
revised based on experience gained in conducting several hundred opacity GEMS
audits and during other EPA studies that involved the evaluation of opacity GEM
reliability at particular sources. ' The revised audit procedures more
adequately address practical considerations and problems that are encountered in
conducting audits. The revised procedures address changes in contemporary
monitoring instrumentation, additional types of monitors, and new audit devices
and methods for certain monitors. In many cases, revisions to the audit
procedures have been made to eliminate the collection of unnecessary or
irrevalent data and to simplify the audit procedures. These changes also
significantly reduce the amount of time necessary to conduct a performance
audit. This manual also provides updated guidance for the interpretation of
audit results. Revisions of acceptance limits for some audit critera are
included that reflect changes in applicable EPA regulations and/or additional
experience with opacity CEMS's.
The procedures in this manual have been developed with the goal of
simplifying the technical aspects of opacity CEMS's so that performance audits
can be conducted by a single person who has a basic understanding of monitor
1Peeler, J. W. GEMS Pilot Project: Evaluation of Opacity CEMS
Reliability and QA Procedures, Volume I. EPA-340/l-86-009a, U. S.
Environmental Protection Agency. May 1986.
2Peeler, J. W., and Quarles, P. Summary Report: A Pilot Project to
Demonstrate to Feasibility of a State Continuous Emission Monitoring System
(CEMS) Regulatory Program. EPA-340/1-86/007. U. S. Environmental Proetection
Agency. June 1986.
1-2
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operation. 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 a discussion of
general opacity monitor audit procedures and the evaluation of audit results.
Sections 3 through 7 each provide monitor--Opcoxric information and annotated,
step-by-step audit procedures for various monitors. Much information is
provided in those sections so that relatively inexperienced personnel can
conduct audits by carefully following the instructions; however, some amount of
field training is recommended. Also provided in the appendices to this
document are monitor-specific data forms (coded to correspond with the step-by-
step instructions). Use of these data forms will assist the auditor in
recording all of the necessary information and in calculating the audit
results.
Section 8 of this manual describes performance audit procedures for use in
evaluating opacity CEMS's that include multiple duct mounted transmissometers
and a combiner device for computing the equivalent combined stack-exit
opacity. A generic approach is presented for conducting audits of opacity
CEMS's with combiners. These procedures require that the auditor understand
the monitor-specific audit procedures for opacity CEMS's with a single
transmissometer. Section 9 of this manual discusses several approaches for
checking the zero alignment of the opacity monitoring system. Although the
zero alignment checks cannot usually be conducted during a performance audit,
these procedures are included because of the importance of the zero alignment
to the accuracy of the opacity monitoring data.
The uninitiated auditor may find some of the discussions in Sections 1 and
2 of this manual somewhat overwhelming at first. However, review of these
materials after working through the monitor-specific information for at least
one monitor should eliminate confusion regarding the basic approach and
terminology.
1.3 APPROACH AND LIMITATIONS
Opacity CEMS performance audits involve a series of checks of individual
monitoring system components and/or factors affecting the operational status or
accuracy of the opacity measurements. The first of these checks are performed
from the monitor control unit/data recording location, which is usually
installed in the boiler or process control room. Subsequent checks must be
performed at the transmissometer installation location on the stack or duct.
In general, performance audit procedures involve the following consecutive
checks:
(1) Monitor Component Analysis
• An attempt is made to verify the accuracy of the pathlength correction
factor used to convert measurements obtained at the monitoring location
to the equivalent opacity that would be observed at the stack exit.
Ideally, two issues are considered: (a) whether the proper dimensions
were used in establishing the pathlength correction factor, and (b)
whether the value of the pathlength correction factor used by the
monitor is consistent with the calculated value. However, it is not
always possible to address these issues during a performance audit
because of practical constraints.
1-3
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• Fault lamp indicators on the monitor control unit are checked to
determine whether the monitor is operating within preset limits.
Usually, these limits are established by the monitor manufacturer;
however, for some monitors, the user may select activiation limits for
the fault circuits.
• Various internal electronic checks are performed in accordance with the
recommendation of the monitor manufacturer to determine the operational
status of the monitor. These checks are performed using the controls
and meters of the monitoring system; use of external electronic test
equipment is generally beyond the scope of the performance audit.
• The responses of the opacity GEMS permanent data recorder and (if
applicable) the control unit panel meter to the zero (or low range) and
span check values are determined.
(2) Transmissometer Maintenance Analysis
• The optical alignment of the transmissometer (transceiver and
reflector) components 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.
• The dust accumulation on optical surfaces 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
apparent opacity 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 at some
sources.
(3) Calibration Error Analysis
• The calibration linearity and the accuracy of the monitor's opacity
measurements relative to a series of neutral density filters and to the
monitor's own zero value are determined. For most monitors, this test
is performed using an audit device that simulates clear-path conditions
and allows insertion of the filters into the light path. For other
monitors, the calibration error determination is accomplished by
evaluating the monitor response to the superposition of audit filters
and the effluent opacity. In either case, neutral density filters must
be inserted into the light path of the transmissometer, and the
corresponding response of the monitoring system is determined from the
permanent data recorder.
Although the purpose of the performance audit is to provide a basis for
evaluating the accuracy and precision of the monitoring data, 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 tb*> oKoor-oe of such problems, the opacity
measurements are assumed to be accurate.
1-4
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It is emphasized that the results of the calibration error check of an
installed opacity GEMS do not provide a measure of the absolute accuracy of the
monitoring data 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 zero opacity response of the monitor. A determination of the absolute
accuracy of an opacity CEMS can only be accomplished by combining the results
of a performance audit (e.g., accuracy of monitoring data relative to the
simulated zero value) with the results of an independent zero alignment check
(e.g., determination of the degree of agreement between the simulated zero
response and true zero response of the monitor under clear-path conditions).
Normally, the zero alignment check cannot be conducted during a perforamnce
audit (see Section 9)•
Second, the results of the calibration error check do not include the
measurement bias that is due to the accumulation of particulate material on the
optical windows of the transmissometer, since the windows are cleaned prior to
conducting the calibration error test. To estimate the accuracy of the opacity
measurements prior to the audit, superposition of the results of the calibra-
tion error check and the dust accumulation checks would be necessary.
Consideration of zero and span errors would not be necessary, provided that no
adjustments to the monitor are made during the audit.
1-5
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SECTION 2
GENERAL AUDIT PROCEDURES
This section provides an overview of opacity CEMS performance audit
procedures as a supplement to the monitor-specific procedures detailed in
Sections 3 through 7. Practical considerations affecting opacity CEMS
performance evaluation programs are addressed. Information that should be
acquired before the audit is conducted 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 below since questions
regarding these matters occur very frequently.
Manpower - Performance audits may be conducted by one person or by a team
consisting of at least two people. If one person performs the audit, a
sufficient period of time must be allowed to elapse after each action taken at
the actual monitoring location {e.g., cleaning of windows, insertion of
filters, etc.) to allow the monitoring system to obtain and record the proper
response. This period would be approximately two minutes for monitors
recotding instantaneous opacity data on strip chart recorders.. For an opacity
CEMS that records only 6-minute averages, a period of 13 minutes must elapse
between each action that the auditor performs, since it is not possible for an
auditor at the monitoring location to determine when the 6-minute period
begins. Conducting an audit under these circumstances would require the lone
auditor to remain at the monitoring location for at least 5 hours. Since this
is obviously impractical, the audit should be performed by two people in those
very unusual cases where the CEMS cannot display instantaneous or short term
averages. A second drawback of having one person conduct opacity CEMS audits
is that the auditor has no real-time feedback to indicate when specific steps
in the audit should be repeated because of the uncertainty of particular
results. Thus, only after the audit is complete can the auditor ascertain if
any or all of the checks at the monitoring location 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
feedback problems, assuming that effective communication between the two
locations is established. (The person recording the measurements at the
control unit does not have to be trained in auditing monitors, since recording
of 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 act as, the second person. Personnel at
most sources are usually willing to provide this assistance. However, control
agency representatives who plan to conduct audits in this manner should request
the assistance of plant personnel in advance of the audit to make sure that
personnel are available and willing to perform specific activities. Also, the
auditor should check to ensure that the plant representative determines the
monitor responses from the appropriate data recording device and that he
interprets and records the values correctly.
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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 assume the availability or use of such equipment; they should
discuss the need for such equipment with plant personnel in advance or provide
their own equipment.
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.
However, it is imperative that non-plant personnel obtain clearance to use such
equipment prior to its use at any stationary source. In some cases, use or
even possession of radios in the plant control room is prohibited, since these
radios may. interfere with instrumentation or control signals necessary to
operate the plant safely. The consequence of unauthorized use of radios can be
very significant.
Computer System Operations - Some plants are equipped with computerized
data acquisition systems. The operation and control of such systems may be
complex, and the output format may be confusing when first encountered.
Control agency personnel who are conducting performance audits should not
expect to fully understand how such systems operate. Plant personnel should be
requested to enter necessary control commands to facilitate acquisition of the
appropriate output. An explanation sufficient to allow the auditor to obtain
the necessary monitor responses from the computer output should be obtained,
or the auditor should request that source personnel determine the monitor
responses from the computer output for each step of the audit.
Equipment Damage Liability - Auditing of opacity GEMS's presents a
situation where there is a very remote chance that the monitoring equipment
could be damaged. Control agency personnel should determine, in advance, their
agency's policy with respect to assuming such liability. In the event that
relevant policy prevents the assumption of such liability, control agency
personnel should adopt a "hands off" posture and have qualified plant personnel
perform the audit under their direct supervision. Plant personnel should be
notified in advance of this situation so that appropriate personnel will be
available at the time the audit is conducted.
Organizational and Labor Constraints - The auditor should be mindful of
protocol with respect to plant organizational interaction. Because the
operation and maintenance of the opacity CEMS's and reporting of opacity data
may involve personnel from the corporate environmental department, as well as
plant environmental operations, instrumentation, and maintenance departments,
the auditor should plan to conduct a brief initial meeting with representatives
of 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 of his actions resulting from
union limitations. For example, the auditor may not be allowed to press
buttons or even touch the monitor controls. Also, break, meal, and quitting
times may be rigidly enforced, thereby restricting the auditor's access to
plant equipment and personnel.
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Preserving Objectivity - Regardless of whether control agency personnel or
source representatives conduct the audit, it is advantageous to all parties to
take several simple steps to preserve the objectivity of the auditors.
Therefore, the correct 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, as corrected to
stack exit conditions, 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 is available typically in source files. Prior
to an audit, it is necessary only to extract the information from the agency
records. During the audit, the information should be verified and updated as
necessary. If the auditor cannot acquire information on the source from
existing files, then he should utilize the opacity audit data form (Figure 2-1)
to compile the necessary information prior to or during the audit. This 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:
Critical Information; Tells the auditor at-a-glance 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, both by the corporate name and the plant or station name. The
plant mailing address and telephone number, are included, and the person at the
plant indentified as the principal contact is identified and his telephone
number is included. This information facilitates communications with plant
personnel responsible for the opacity monitors.
Corporate Contact; Many source organizations have corporate personnel charged
with overseeing environmental activities in the satellite facilities.
Typically, these persons should be notified as to audit plans and should
receive copies of audit results. Therefore, their names, addresses, and
telephone numbers should be included.
Additional Contacts; Source personnel concerned with monitor operation,
maintenance, calibration, servicing, or data reduction should be identified as
encountered. This information will aid the auditor in acquainting himself with
the source's monitoring program. Also, it may be necessary to contact some of
these individuals to answer specific questions as they arise.
Source Data; Information about the unit, its output capacity, and fuel and
pollution control equipment is included to provide a basis for a description of
the plant. The output capacity should be that from the most recent permit, in
the same units as specified in the permit. Because communications between'the
opacity data recorder and transmissometer locations are vital in facilitating
the completion of an audit by a lone auditor, the auditor should determine in
advance if the source can supply communications equipment (radios, telephone,
etc.) and an employee to take preliminary reading from the opacity data
recorder during the transmissometer portion of the audit.
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CRITICAL INFORMATION:
PERSON TO CONTACT UPON ARRIVAL:.
AT (GATE. OFFICE. ETC.):
FINAL AUDIT DATE:
TIME:
UNIT *
MONITOR TYPE:.
SOURCE NAME:.
OPACITY AUDIT DATA FORM
DATE:.
INDIVIDUAL SUPPLYING INFORMATION AND HIS AFFILIATION:.
SOURCE IDENTIFICATION:
CORPORATION:.
PLANT OR STATION NAME:.
PRINCIPAL CONTACT:
PLANT MAILING ADDRESS:.
TELEPHONE
PLANT TELEPHONE
CORPORATE CONTACT:
NAME:
TITLE:.
MAILING ADDRESS:.
TELEPHONE
ADDITIONAL CONTACTS:
1. NAME:.
AFFILIATION:.
TELEPHONE «:
2. NAME:
AFFILIATION:
TELEPHONE *:
3. NAME:
AFFILIATION:.
TELEPHONE •:
Figure 2-1. Opacity Audit Data Form
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OPACITY AUDIT DATA FORM (CONTINUED)
SOURCE DATA:
UNIT *:.
FUEL: _
OUTPUT (MW):.
AIR POLLUTION CONTROL EQUIPMENT:.
TYPICAL EFFLUENT OPACITY :.
.(FROT1 PERMIT)
AVAILABILITY Of COMMUNICATIONS (RADIO. TELEPHONE, ETC.) BETWEEN MONITOR LOCATION AND CONTROL ROOM:
AVAILABILITY OF PERSONNEL TO TAKE READINGS FROM OPACITY DATA RECORDER DURING AUDIT:
MONITOR LOCATION:
MONITOR LOCATION (STACK/DUCT):
(UPSTREAM).
DISTANCE FROM NEAREST FLOW OBSTRUCTION: _
HEIGHT (IN FEET): (TO MONITOR) ______
ACCESS TO SAMPLING LOCATION (LADDER, STAIRS, HOIST, ELEVATOR): __
STACK/DUCT INSIDE DIAMETER: (AT MONITOR LOCATION).
(DOWNSTREAM)
.(TOTAL STACK)
. (STACK EXIT)
MONITOR DATA:
MANUFACTURER/MODEL *:
MONITOR PRESET STACK EXIT CORRECTION FACTOR (BY MONITOR MANUFACTURER):
MONITOR ZERO AND SPAN VALUES (BASED ON MOST RECENT CALIBRATION):
COMBINER SYSTEM IN USE ?
. (ZERO).
DATA RECORDING/LOGGING SYSTEM:,
DATA FORMAT USED IN REPORTING TO A.Q. AGENCY (6-MIN/DAILY AVGS.):
AVAILABILITY OF INSTANTANEOUS MONITOR OUTPUT RECORD (METER, STR1PCHART. OR COMPUTER):
. (SPAN)
RECENT REPAIRS/MODIFICATIONS/CALIBRATIONS:
SOURCE EMPLOYEE MOST FAMILIAR WITH THE MONITORING SYSTEM:.
Figure 2-1. (continued)
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OPACITY AUDIT DATA FORM (CONTINUED)
COMMENTS:
MONITOR LOCATION SCHEMATIC
OPACITY DATA SYSTEM SCHEMATIC
Figure 2-1. (continued)
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Monitor Location; The monitor location should be specified with respect to
height and distances from upstream and downstream flow disturbances, in order
to produce a schematic drawing of the monitor within the effluent 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 form the basis of 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 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 and zero and span
values should be identified either prior to or at the outset of the audit.
Because the zero and span values may change due to clear path calibration
results, 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 stripchart,
circular chart, and/or computer. Frequently, sources employ a combination of
chart 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 source personnel be available to
reset the control unit integrator to produce instantaneous opacity data for the
duration of the calibration error analysis. Also, the auditor should 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 him to identify possible problems that
may be encountered. Also, he should obtain the name of the source person most
knowledgable about the operation and maintenance of the monitor so that this
person could be consulted for additional information.
Comments; The auditor should include general comments about the source or
monitor that will facilitate the audit.
Monitor Location Schematic; The auditor should sketch the effluent system,
including the heights and distances associated with the monitor location and
upstream and downstream flow disturbances. The schematic should include stack
exit and monitor location dimensions.
Opacity Data System Schematic; The auditor should sketch the flow of opacity
data from the transmissometer to the control unit and to the opacity data
recorder. The sketch should show the content and format of the data (e.g.,
double-pass transmittance, instantaneous path opacity, six minute averaged
stack exit opacity), as well as the system components (e.g., transmissometer,
control unit, stripchart recorder, computer, printer, etc.).
2.3 PERFORMANCE AUDIT PROCEDURES
The following discussions identify and define the specific parameters that
are evaluated during a performance audit, describe how these parameters are
measured, and indicate acceptable limits for the various criteria. Additional
suggestions and methods for evaluating various parameters are provided for
those areas where problems are frequently encountered.
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Opacity monitor performance audits provide an accurate, reliable indication
of monitor performance through a simple, quick field test procedure which can
be performed by a single technician who has a basic understanding of monitor
operation. Specialized equipment necessary for a typcial audit includes a
monitor-specific reflector ("audit jig") which is used to simulate clear stack
conditions, materials for cleaning the optical surfaces exposed to the
effluent, and a set of three calibrated neutral density filters to evaluate the
calibration error of the monitor. All of the equipment required for an opacity
monitor performance audit can be transported in a small suitcase. The auditor
should also have safety equipment, including a hard hat, safety glasses,
hearing protection, and any specialized equipment necessitated by the
particular plant environment.
The audit procedures are organized sequentially according to the location
of the monitoring system components (moving 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
cases it is advantageous for multiple personnel to be involved in conducting
the audit. The general audit procedures and acceptable limits for the various
criteria are described below.
2.3.1 Stack Exit Correlation Error
Typically, the cross-stack optical pathlength of the installed opacity
monitor is not equal to the diameter of the stack exit. To obtain a true stack
exit opacity value, the measured opacity at the monitor location is corrected
to stack exit conditions through the use of a pathlength correction factor.
Ideally, the stack exit correlation error is the percent error of the
pathlength correction factor used by the GEMS, relative to the correct
pathlength correction factor calculated from actual dimensions. The stack exit
correlation error should not exceed +2 percent.
Determining both the actual and the correct pathlength correction factors
is often difficult in practice. Measurement of the monitoring pathlength and
the stack exit diameter is usually not possible; blueprints showing con-
struction details are often not readily available at the source. The problem
associated with determining the monitor pathlength and stack exit dimensions
can be minimized by requesting the information in advance so that source
personnel have time to locate the information. In addition, the
flange-to-flange separation distance of the transceiver and reflector
components should be requested. This information helps to identify the
majority of problems that are likely to be encountered in the calculation of
the pathlength correction factors, since by far the most common mistake is the
use of the flange-to-flange separation distance in place of the depth of
effluent (stack or duct internal 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 pathlength for
conducting off-stack, clear-path calibrations of the opacity monitor.) Unless
there is an obvious error or question, the dimension provided by the source
personnel should be used, and the auditor should calculate the correct value of
the pathlength correction factor using the equations provided in the
monitor-specific sections.
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The auditor must attempt to determine the value of the pathlength
correction factor that is used by the opacity GEMS. Two approaches may be
used: (1) the auditor may be able to determine the value of the correction
factor preset by the manufacturer, or (2) the auditor may be able to measure
the pathlength correction factor in some cases.
The value of the pathlength correction factor preset by the manufacturer is
sometimes indicated on the control unit, or is sometimes included in the
documentation provided with the monitor. However, this information is
sometimes unavailable or is undecipherable because several different values are
found with no clue as to which one was finally used by the manufacturer. In
such cases, it is not possible to determine whether the correct value was used
by the monitor manufacturer. If the correction factor cannot be determined
directly as described below, the audit report should indicate that the stack
exit correlation error was not determined, and the correct value of the
pathlength correction factor should be used in 'all subsequent audit
calculations.
Any error associated with the value of the pathlength correction factor
will result in a systematic, non-linear bias in the mean differences obtained
for the low, mid, and high range calibration error checks. (In the absence of
other problems, errors in the pathlength correction factor will result in
increasing errors with increasing opacity.) When the audit results indicate
such a bias, the auditor can, as a troubleshooting technique, calculate the
value of the pathlength correction factor that would provide a zero value mean
difference for the mid range filter, and then use this pathlength correction
factor for recalculating the low and high range calibration error check
results. If the systematic bias in the calibration error results is removed,
it is likely that the problem with the monitor is due to an error in the
pathlength correction factor. It is emphasized 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
pathlength correction factor becomes significantly more complicated, if not
impossible. Therefore, it is strongly recommended that the other problems be
resolved prior to attempting to determine if the pathlength correction factor
is wrong.
In some cases it is possible to measure the pathlength correction factor
using the same procedures that are used by the monitor manufacturer for the
initial set-up of the instrument. As an example, for the Lear Siegler RM4l
opacity monitor, the pathlength correction factor can be determined by removing
the opacity circuit board from the control unit and measuring the resistance of
the Rg potentiometer using a digital voltmeter or equivalent device. The value
of the OPLR is then calculated as the resistance across R,- 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, since
such diagnostic procedures are beyond the scope of the audit and involve the
use of equipment that may be unfamiliar to the control agency auditor. Where
applicable, procedures for measurement of the pathlength correction factor are
included in the monitor-specific sections that follow.
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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, but 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, this
simple rule does not always account for malfunctions in the fault indicator
circuitry or for a burned-out or missing lamp bulb.
Many contemporary, computerized data handling systems are capable of
performing a variety of self-diagnostic tests and of displaying "error
messages," "flags," or GEMS malfunctions/faults in the permanent record. The
availability of such 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 GEMS operation.
2.3.3 Auxiliary Electronic Checks
Some opacity CEMS's provide access to various electronic signals or
circuits which are indicative of the monitor operational status through 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 such signals are the Lear Siegler RM-41 reference signal and the
Dynatron Model 1100 M lamp voltage, both of which are critical parameters in
the operation of the respective monitors. Monitor-specific procedures are
provided for the evaluation of these parameters in Sections 3 through 7 of this
manual. For other monitors, the auditor should refer to the operator's manual
for the identification of important parameters and corresponding test
procedures.
2.3.4 Panel Meter Checks
Most opacity CEMS's are equipped with an analog or digital panel meter on
the control unit. Some CEMS's are also equipped with an analog meter at the
transceiver location which may be useful as a reference for making adjustments
to the monitor. Checks of the accuracy of the panel meter may be performed for
each type of measurement which can be displayed on the panel meter (i.e.,
opacity and optical density for most monitors and input current signals for
some monitors}. The panel meter correction factors are the ratio of the panel
meter responses to the specified values for the opacity filter, input signal,
or optical density filter. Results within +_ 2 percent (ratios within the range
of 0.98 to 1.02) are considered acceptable.
The determination of panel meter factors should be deleted (1) for all
parameters that are not normally monitored or used to assess monitor
performance by source personnel (e.g., optical density for most sources), and
(2) when source personnel refer to other measurement output devices (e.g.,
strip chart recorders, computer ont^nts, and digital voltmeters) when they
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perform calibration adjustments for the monitoring system. However, when source
personnel use the panel meter to determine when adjustments are necessary or to
perform the actual adjustments, the appropriate panel meter scale factors should
be determined. Specific recommendations regarding the determination of panel
meter accuracy are provided in each monitor-specific section c° this manual.
2.3-5 Zero and Span Errors
The zero and span errors are the percent opacity differences between the
rated opacity values of the simulated zero device (or low range check) and
interal span filter and the corresponding opacity OEMS responses, respectively.
The opacity GEMS responses must be determined from the permanent data recorder
that provides the basis for emissions data reported to the applicable control
agency. (The zero and span errors are the same as the results of the required
daily zero and span checks, except that they are performed during the audit
rather than on the normal schedule.)
The previous performance audit procedures manual specified a zero (or low
range) and span error acceptance limit of +_ 2% opacity. At the time the manual
was written, these limits were consistent with the applicable EPA regulations
(40 CFR 60.13), which required adjustment of the opacity GEMS when the
day-to-day zero drift exceeded the limits of Performance Specification 1. When
EPA promulgated revisions to Performance Specification 1 (Federal Register, Vol.
48, No. 62, March 30, 1983, PP. 13322-13339), the drift limits of Performance
Specification 1 for the 24-hour zero and calibration drift test did not change.
However, when EPA promulgated revisions to Performance Specifications 2 and 3
(for S02, NO , C02, and 0_ monitors) and revisions to 40 CFR 60.13 (Federal
Register, Vol. 48, No. 102, May 25, 1983, pp. 23608-23616), the requirement to
adjust GEMS calibration was relaxed; adjustment is now required when the zero or
calibration drift exceeds twice the applicable performance specification limit.
Thus, for sources subject to EPA regulation, adjustment of opacity GEMS
calibration is now required only when the drift exceeds + 4$ opacity. For
sources subject to state or local requirements, the acceptance limits for zero
and span errors should be consistent with the applicable regulations.
2.3.6 Zero Compensation Limit
Some opacity CEMS'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 (zero compensation) accounts for dust accumulation on the optical
surfaces of the transceiver. The acceptable limit for zero compensation is
+_ 0.018 OD, which is equivalent to +_ 4# opacity, both before and after cleaning
of the optical surfaces of the transmissometer. This value is consistent with
the limitation imposed by EPA regulations contained in 40 CFR 60.13 (d)(l):
"For continuous monitoring systems measuring opacity of emissions,
the optical surfaces exposed to the effluent gases shall be cleaned
prior to performing the zero and span drift adjustments except that
for systems using automatic zero adjustments. The optical surfaces
shall be cleaned when the cumulative automatic zero compensation
exeeds 4 percent opacity."
A reduced compensation limit should not be applied to the "post cleaning"
value due to the sensitivity of this parameter.
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2.3-7 Monitor Alignment Error
The optical alignment of the transceiver and reflector components is
critical in maintaining accurate opacity measurements. Misalignment of
the beam can cause erroneously high opacity readings, because a
significant portion of the measurement beam is not returned to the
transceiver. Most opacity monitor manufacturers include provisions for an
optical alignment check, either as a standard feature or as an option.
Monitor alignment errors are indicated by an off-center light beam.
2.3.8 Optical Surface Dust Accumulation
The amount of dust found on the optical surfaces of the transmis-
someter is quantified (in units of percent opacity) by recording the
effluent opacity before and after each window is cleaned. The optical
surface dust accumulation is excessive if the total reduction in apparent
opacity (i.e., the sum of transceiver and reflector dust accumulation)
after cleaning of the optical surfaces exceeds 4 percent opacity.
The results of this check may be adversely affected by fluctuations in
the effluent opacity over the time period required to clean the windows
and obtain the opacity measurements. The auditor should be careful in
obtaining instantaneous opacity measurements that represent the effluent
opacity; in some cases, average values may provide more representative
results. In addition, when the windows are very clean at the time the
audit is conducted, the auditor may actually increase the particulate
matter on the optical surfaces rather than decrease it. The auditor
should use the following procedures:
(a) For monitors with zero reflectors (e.g., Lear Siegler RM-4, RM-41,
RM-4200, etc.), the auditor should clean the reflective side of the
zero mirror when cleaning the transceiver window. Also, if the
monitor is equipped with automatic zero compensation, the zero
compensation should be reset after cleaning of the transceiver
window (before cleaning of the zero reflector) and reset again
after cleaning of the zero reflector, if possible. If this is not
practical, the zero compensation should be reset after the cleaning
of both the transceiver and zero reflector windows. Resetting of
the zero compensation between cleaning of the optical surfaces
provides an indication of whether dust has accumulated on each of
the surfaces, independently. Since the biases introduced into the
effluent opacity measurements from dust accumulation on the two
optical surfaces are in opposite directions, the auditor must be
careful in comparing changes in the zero compensation level with
apparent changes in the effluent opacity.
(b) For all monitors, the auditor should check that the apparent
effluent opacity decreases after the cleaning of each optical
surface. (This is usually not practical if only one person
performs the audit.) An increase in the apparent effluent opacity
indicates that either (1) effluent opacity fluctuations have
affected the results, or (2) the auditor has done an inadequate job
in cleaning the optical surfaces. When an increase in the apparent
effluent opacity occurs, the auditor should reclean the.optical
surfaces and recheck the effluent opacity.
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(c) For all monitors, an apparent increase in the effluent opacity
after cleaning of an optical surface provides a negative result for
the quantity of dust accumulated 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
The calibration error check involves the comparison of the monitor responses
to the known opacity values for three reference neutral density filters. (The
values of the neutral density filters are corrected to stack exit conditions
using the same pathlength correction factor that is used by the opacity GEMS.)
For most monitors, this check is performed using an audit device that simulates
clear-path conditions and allows insertion of the filters into the light path.
The audit device is adjusted to provide the same zero response as the monitor's
internal zero device. For other monitors, the calibration error check is
performed by conducting an incremental calibration (i.e., superimposing the
audit filters and the effluent opacity). For both types of calibration error
checks, three filters are each placed in the light path five times. The low,
mid, and high range calibration error results are computed as the mean
difference and 95 percent confidence interval for the differences between the
expected and actual responses of the monitor. The calibration error check
results are acceptable if the calculated results for all three filters are less
than or equal to 3 percent opacity.
The following additional procedures are applicable to calibration error
checks:
(a) For all checks performed using a "clear path" audit device, the audit
device is installed and adjusted to provide the zero response, and then
each of three filters is placed in the light path five times. The
calibration error results will be affected if the zero value provided
by the audit device changes during the course of the 15 filter
measurements. (Vibration at the monitoring location or the auditor
accidentally bumping the iris adjustment lever of the audit device can
cause such a change; these situtions occur quite frequently.)
Therefore, at a minimum, the zero value produced by the audit device
should be checked at the end of the calibration error test. If the
difference between the "post test" and "before test" zero values is
greater than 1 percent opacity, then the entire test should be
repeated. For practical purposes, it is recommended that the auditor
recheck the audit device zero value after each set of three filter
measurements to make sure the zero value is stable. This practice
allows the auditor to discover a problem sooner, and therefore requires
that fewer measurements be repeated after the problem is corrected.
(b) For calibration error checks using "incremental calibration," the audit
procedure involves superimposing a series of audit filters on the
effluent opacity. The calculation procedure requires that the average
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of "before" and "after" effluent opacity readings be mathematically
combined with the filter value in 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 check results. Short term effluent opacity spikes
present the greatest problem. Therefore, each instantaneous effluent
opacity measurement and each filter measurement must be obtained from
the digital panel meter as quickly as possible. Two-way communications
between the monitoring location and the control unit location are
required in this situation. When using this procedure, it is
advantageous for the auditor to watch the panel meter for about 15
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 particular monitor responses to the audit filters deviate by more
than 1 to 2 percent opacity from the mean response to the filter, the
audit procedures should be repeated. When the "before" and "after"^
effluent opacity measurements vary by more than 2 to 3 percent opacity,
the audit procedures should also be repeated. It is usually possible
to get 5 reasonable measurements of each filter in 7 or less attempts.
The decision to accept or reject particular filter measurements is
subject to the auditor's discretion. Where great difficulty is
encountered in conducting the test, it is appropriate to relax the
calibration error specification. It is suggested that where such
difficulty is 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) where possible. If the permanent data
recorder cannot display such measurements, the calibration error
measuremetnts can be obtained from the control unit panel meter or by
use of a temporary output device such as a DVM, provided that two or
more people perform the audit, and that communications between the
control unit/data recorder location and transmissometer location are
possible. This procedure is adequate for determining the accuracy and
precision of the opacity monitor. An auxiliary check involving only
one 6-minute average response for each of the three audit filters is
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 positive biases 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 at least every six months and checked more
frequently if they appear damaged.
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SECTION 3
PERFORMANCE AUDIT PROCEDURES FOR LEAR SIEGLER, INC. OPACITY MONITORS
3.1 LEAR SIEGLER, INC. MODEL RM-41 TRANSMISSOMETER AND MODEL 611 CONTROL UNIT
3.1.1 GEMS Description
The RM-41 opacity GEMS consists of three major components: the transmis-
someter, the air-purging and shutter system, and the Model 6ll control unit.
The transmissometer component consists of a transceiver unit mounted on one
side of a stack or duct and a retroreflector 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 the control unit.
Figure 3-1 illustrates the general arrangement of the transceiver and
retroreflector units on the stack, and provides further details of the chopped,
dual-beam measurement technique. The light from the measurement lamp passes
through a perforated rotating wheel which "chops" it into discrete pulses to
minimize interference from ambient light. Next, the lamp beam is split into
measurement and reference beams, with the reference beam being reflected to the
photodetector and the measurement beam passing out of the transceiver and
across the stack or duct. After being reflected back through the effluent, the
measurement beam strikes the photodetector which also receives the reference
beam. The reference beam signal is monitored continuously by the automatic
gain control (AGC) circuit, which compensates for changes in lamp intensity so
that the reference signal remains constant. Since the AGC circuit affects both
the reference signal and the measurement signal amplitude equally, lamp
intensity changes are theoretically elimiated from the measurement signal.
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 the transceiver unit and one for the retroreflector
unit; each system has a blower providing filtered air.
The shutters (optional) automatically provide protection for the
transceiver and retroreflector exposed optical surfaces from smoke, dust, and
stack gas. Whenever the purge airflow decreases below a predetermined rate
(due to blower motor failure, clogged filter, broken hose, or stack power
failure), the servo mechanism holding the shutter open is deactivated by an
airflow sensor installed in the connecting hose between the air-purge blower
and 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.
The control unit (Figure 3-2) converts the double-pass transmittance output
from the transceiver, in conjunction with the reference amplitude output, to
linear optical density which is corrected to stack exit conditions. The
resultant stack exit optical density is converted to instantaneous, single-pass
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Transceiver Unit
Smoke Channel
Reflector Unit
Figure 3-1. Arrangement of LSI KM-41 Transceiver and
Retroreflector Components
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RM-41 VISIBLE EMISSION MONITORING SYSTEM
FAUUT MONITORS
AIR RM-41 OPTICAL
PURGE SENSOR DENSITY
CONTROL-uwr _
LearStegterlnc
Figure 3-2. LSI EM-41 Control Unit (Model 611)
3-3
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stack exit opacity. Many control units contain an optional integrator circuit
card which compiles the above opacity data and calculates a discrete average
over an integration period that is set by the source (typically six minutes).
This function may not be used at facilities employing a computer to reduce and
record opacity data because the computer may 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 stream at the monitor location, or the "path" optical
density. In order to provide stack exit opacity data, the path optical density
must be corrected by multiplying by the ratio of the stack exit diameter to the
measurement pathlength. This ratio is called the "optical pathlength ratio" by
Lear Siegler, and is abbreviated as the "OPLR." This value is set within the
control unit circuitry and the correction is automatically applied to the path
optical density mesasurements. The following equations illustrate the
relationships between the OPLR, path optical density, and exit opacity.
OP =
x
where:
OP = stack exit opacity (%)
OPLR = x = optical pathlength ratio
Lt
L = stack exit inside diameter (ft)
x
L = measurement pathlength (ft) = two times the
effluent depth at the monitor location
OD = transmissometer optical density (path)
3.1.2 Performance Audit Procedures
Preliminary Data
1. Obtain the stack exit (inside) diameter and transmissometer
measurement pathlength (two times the stack or duct inside diameter
or width at monitor location) and record on blanks 1 and 2,
respectively, of the Lear Siegler RM-41 Performance Audit Data
Sheet.
* 2.
3.
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order to reliability: (1)
physical measurements; (2) construction drawings; (3) opacity
monitor installation/ certification documents; and (4) source
personnel recollections .
Calculate the OPLR, (divide the value on blank 1 by the value on
blank 2) , and record the value on blank 3-
Record the source-cited OPLR value on blank 4.
Note: The OPLR is preset by the manufacturer using information
supplied by the source. The value recorded in blank 4 should be
that which the source personnel agree should be set inside the
monitor. Typically, this value is cited from monitor installation
or certification data, as well as from service reports,,
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4. Obtain the present values that the monitor should measure for the
zero and span calibrations and record on blank 5 and blank 6,
respectively.
Note: These values are set during monitor calibration, and therefore
may not be equal to values recorded at installation and/or
certification. Records of the zero and span values resulting from
the most recent monitor calibration should exist.
Control Unit Checks
5- Inspect the opacity data recorder (strip chart or computer) to
ensure proper operation. Annotate the data record with the
auditor's name, plant, unit, date, and time.
Fault Lamp Checks
The following list describes the fault lamps that are found on the Lear
Siegler Model 611 control unit panel. 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 FILTER fault lamp on blank J.
Note: An illuminated FILTER fault lamp indicates that the transceiver
and/or retroreflector purge air flow rate is reduced, either because a
blower may not be working properly or one of the purge air filter
elements is dirty, thereby reducing the airflow. This fault does not
preclude the completion of the audit.
7. Record the status (ON or OFF) of the SHUTTER fault lamp on blank 8.
Note: An illuminated SHUTTER fault lamp indicates that one of the
protective shutters is blocking the optical path; therefore, no
measurement of the stack opacity is being made. The performance audit
can continue, but the shutter 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 on blank 9.
Note: An illuminated REF fault lamp indicates a reference signal
decrease which may be due either to a fault in the automatic gain
control (AGO) 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 on 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
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primary lens and the zero mirror). Exceeding the zero compensation
limit may bias the opacity data, as well as the zero and span
calibration values.
10. Record the status (ON or OFF) of the OVER RANGE fault lamp on blank
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, 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
(note the original range before changing) on the optical density
circuit board located in the control unit (see Figure 3~3)•
Control Unit Adjustment Checks
11. Open the control unit and remove the main power fuse.
Note: The following checks should be performed only by qualified
personnel and with the approval of source personnel.
12. Locate and pull the GAL TIMER circuit board inside the control unit
(see Figure 3~3) and record the position of the SI switch on blank
12.
Note: The SI switch has six positions.
13. Rotate the SI switch to the sixth position, if necessary, and
replace the board.
Note: This adjustment will deactivate the automatic calibration
timer, thereby preventing the initiation of a calibration cycle
during the audit that may result in damage to the zero mirror
mechanism.
14. Locate and pull the optical density board and record the position of
the SI switch on blank 13.
15. Rotate the SI switch to the fifth position, if necessary, and
replace the board.
Note: This adjustment will expand the optical density measurement
range to its maximum, ensuring that all audit filter values will
fall within the monitor's optical density measurement range.
16. Locate and pull the opacity board and record the position of the SI
switch on blank 14.
17. Rotate the SI switch to the fifth position, if necessary, and
replace the board.
3-6
-------
S/N
CAL TIMER
POS
MRS
OFF
TP2 '
SIGNAL
GNO
COMPI
DENSITY
POS
RANGE
0.09
0.18
0.45
ago
1.80
E
B.
L>
CAL TIMER a RECV'R OPTICAL
POWER SUPPLY W/AUTO ZERO DENSITY
____^?
OPACITY
POS
1
2
3
4
5
%
10
20
3O
50
10O
RESPONSE
FAST A
32
SLOW f
OPLR (R6)l
LEXTT/2Lls«Asl
A
I
S2
HIGH LEVELI
ALARM |
SET PONT ^
HIGH LEVEL
ALARM
DELAY
r
R34S
LOW LEVEI
ALARM
SET POINT
ALARM
DELAY
3.
r
OPACITY
ALARM
1
I
1
1
SPARE
Figure 3-3. Lear Siegler RM41 Control
Unit Circuit Board Arrangement
3-7
-------
18.
19.
Note: This adjustment will ensure that the range of the opacity
output signal from the control unit to the data recorder is at its
maximum value of 0 to 100% opacity.
Optional OPLR check: Measure the resistance across the Rg
Potentiometer in OHMS, divide this value by 400, and write the
result in blank
from blank 4 in blank l4a.
If Rx- is not measured then enter the value
Reinstall the opacity board and the power fuse and close the control
unit panel.
Reference Signal Check
2CK Record the original position on blank 15 of the MEASUREMENT switch
on the control unit panel.
21. Turn the MEASUREMENT switch to the REF position.
22. Record the milliamp current value on blank 16 that is displayed on
the 0-30 scale on the control panel meter.
Note: The reference signal should be within the green area marked
"Reference." A reference value outside the green band may indicate
a malfunction of the AGO or the measurement lamp.
23. Turn Measurement switch to "100$ Op" position.
ZERO CHECK
2"ZJ~
press the
_
mode.
CAL
button on the control panel to initiate the zero
Note: The green OPERATE light should go out when the zero mirror has
moved into the optical path. The yellow CAL light and the green
ZERO light should remain illuminated.
25. Record the zero value on blank 17 displayed on the panel meter.
26. Record the zero value on blank 18 displayed on the data recorder.
Note: The cross-stack zero is simulated by the transceiver zero
mirror. Checking this simulated zero value provides an indication
of the amount of dust on the measurement window and on the zero
retroref lector , as well as an indication of the status of the
electronic alignment of the instrument. It does not, however,
provide any indication of cross-stack parameters, such as the
clear-path zero value.
Zero Compensation Check
27. Turn the MEASUREMENT switch to the COMP position.
28. Record the zero compensation optical density value on blank 19 that
is displayed on the bottom scale of the control panel meter.
Note: The monitor's lamp output is split into two beams:: (1) the
reference beam, which produces the reference signal within the
monitor, and (2) the measurement beam, which passes through the
stack effluent. When the zero mirror is positioned in the
3-8
-------
measurement beam, the beam passes only through the transceiver's
optics, strikes the zero mirror, and is reflected back into the
transceiver. The signal produced by the measurement beam is
compared with the signal from the reference beam; the difference
between the two signals is due to the attenuation of the measurement
beam by dust on the transceiver optics and the zero mirror. The
monitor automatically compensates for this measured difference and
the zero compensation value displayed on the panel meter represents
this difference in terms of optical density (OD).
29. Turn the MEASUREMENT switch to the 100% OPACITY position.
Span Check
7FRO
30. Press the button to initiate the span mode.
SPAN
31. Record the span value on blank 20 that is displayed on the control
panel meter (0-100$ Op scale) and record the span value displayed on
the data recorder on blank 21.
32. Optional input current check: Turn the MEASUREMENT switch to the
INPUT position, and record the control panel meter input current
value on blank 21a that is displayed on the 0-30 scale.
33- Return the MEASUREMENT switch to the 100% OPACITY position.
Note: During the span portion of the calibration cycle, a neutral
density filter is automatically inserted into the measurement beam
path inside the transceiver while the zero retroreflector is in
place. The span measurement provides another check of the monitor
electronic alignment and the linearity of the transmissometer
opacity response.
34. 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 lights are illuminated, as the zero mirror
might stop before it has cleared the measurement beam path.
Retroflector Dust Accumulation Check
35- Record the instantaneous effluent opacity prior to cleaning of the
retroreflector optics on blank 22.
36. Open the retroreflector housing, inspect and clean the
retroreflector optics, and close the housing.
37. Record the post cleaning instantaneous effluent opacity on blank 23.
Go to transceiver location.
3-9
-------
Transceiver Dust Accumulation Check
38. Record the instantaneous effluent opacity on blank 24.
39. Open the transceiver, inspect and clean the optics (primary lens and
zero mirror), and close the transceiver head.
40. Record the post cleaning instantaneous effluent opacity on blank 25.
Note: After the transmissometer optics have been cleaned, the zero
compensation has to 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 assitance of
source personnel.
41. Press the OPERATE button on the control unit.
CAL
42. Turn the MEASUREMENT switch to the COMP position.
43. Record the post cleaning zero compensation value on blank 26.
i,i, r> ^ OPERATE , ^
44. Press the button.
CAL
45. Turn the MEASUREMENT switch to the 100$ opacity position.
Automatic Gain Control Check
46. Determine whether the green light (AGC LED, Figure 3-4) on the
transceiver is illuminated, and check the light status (ON or OFF)
on blank 27.
Optical Alignment Check
47. Remove the protective cover on the transceiver mode switch located
on the bottom right-hand side of the transceiver (see Figure 3~4).
48. Turn the switch one position counter-clockwise until ALIGN can be
seen through the switch window.
49. Determine the monitor alignment by looking through the viewing port
(Figure 3-4) and observing whether the beam image is in the circular
target.
50. Record whether the image is centered inside the circular target (YES
or NO) on blank 28.
51. Draw the orientation of the beam image in the circle on the data
form.
Note: Instrument optical alignment has no effect on the internal
checks of the instrument or on the calibration check using the audit
device; however, if the optical alignment is not correct, the stack
opacity data will be biased high, since all the light transmitted to
the retroreflector is not returned to the detector.
3-10
-------
CAPTIVE SCREWS (3) ALIGNMENT BULL'S EYE WINDOW
LAMP ACCESS DOOR
FAILSAFE SHUTTER ASSY.
FLANGE MOUNTING BOLT (3)
GUIDE RELEASE LATCH (4)
MODE SWITCH
WIRING CABLE TO
"J" BOX
SHUTTER
MEASUREMENT CLEAR ADJUSTMENT
MEASUREMENT OPAQUE ADJUSTMENT
SERIAL if LABEL
Figure 3-4. Lear Siegler RM41 Transceiver
3-11
-------
52. Turn the transceiver mode switch clockwise until OPERATE appears in
the window. Replace the mode switch protective cover.
Span Filter Check
53. Record the span filter's optical density value on blank 29 and the
output current value on blank 30- These values are written on a
nameplate on the underside of the transceiver.
CALIBRATION ERROR CHECK
The calibration error check is performed using three neutral density audit
filters and an audit device (or jig) with an adjustable retroreflector iris to
simulate clear stack conditions. The audit device and neutral density filters
actually determine the linearity of the instrument response with respect to the
current clear-path zero value. This calibration error check does not determine
the actual instrument clear-pack zero, or the status of any cross-stack
parameters.
A true calibration check is performed by removing the on-stack components
and setting them up in a location with minimal ambient opacity, making sure
that the proper pathlength and alignments are attained, and then placing the
calibration filters in the measurement beam path.
54. Install the audit jig by sliding it onto the transceiver projection
lens barrel.
Note: The audit device will not slide on until it is flush with the
lens barrel. Care should be taken not to push it against the zero
mirror or to pinch the wires serving the zero mirror motor.
55. Adjust the audit jig iris to produce a 19-20 mA output current on
the junction box meter (Figure 3~5) to simulate the amount of light
returned to the transceiver during clear stack conditions.
Note: The junction box meter allows the auditor to get the jig 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 0.0$ opacity since the audit
filter correction equations can account for an offset in the jig
zero. Thus, a jig zero value in the range of 0-2$ Op is usually
acceptable.
56. Record the audit filter serial numbers and opacity values on
blanks 31. 32. and 33-
57. Remove the filters from their protective covers, inspect, and ?.f
necessary, clean them.
58. 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 another person at the data recorder location.
59. Insert the low range neutral density filter into the audit jig.
3-12
-------
^ TRANS.
REF-A i /OPACITY
Figure 3-6. Lear Sielger RM41 Junction Box
3-13
-------
60. Wait for 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).
61. Record the monitor's response to the low range neutral density filter.
62. Remove the low range filter from the audit jig and insert the mid
range neutral density filter.
63. Wait the approximately two minutes and record the monitor's response
from the opacity data recorder.
64. Remove the mid range filter from the audit jig and insert the high
range filter.
65. Wait approximately two minutes and record the monitor's response from
the opacity data recorder.
66. Remove the high range filter, wait for approximately two minutes and
record the jig zero value from the opacity data recorder.
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.
67. Repeat steps 58-66 above until a total of five opacity readings are
obtained for each neutral density filter.
68. If six-minute integrated opacity data must be recorded, repeat steps
58-66 above once more, but change the waiting periods to at least 13
minutes.
69. Record the six-minute integrated data.
Note: In order to acquire six-minute integrated opacity data, each
filter must remain in the jig for at least two consecutive six-minute
periods, the first period is invalid because it was in progress when
the filter was inserted. Only at the conclusion of two successive
six-minute integration periods can the monitor's response be
recorded. Thus, a waiting period of 13 minutes or more is
recommended.
70. Once the calibration error check is finished, remove the audit jig,
close the protective cover on the junction box and close the
transceiver head.
Zero Compensation Check
71. Return to the control unit location and initiate the monitor zero mode
hi- pressing the OPERATE/CAL button.
72. Turn the MEASUREMENT switch to the COMP position.
-------
73- Record the zero compensation optical density value from the control
panel meter -0.02 to +0.05 O.D. scale on blank 34.
74. Return the monitor to the operate mode by pressing the OPERATE/CAL
button again.
Control Unit Adjustment Reset
75- Return the CAL timer, optical density, and opacity board SI switches
and the MEASUREMENT switch to their original positions, as recorded
on blanks 12, 13, 14, and 15.
76. Obtain a copy of the audit data from the data recorder.
77- Transcribe the calibration error responses from the data record to
the data form blanks 35 to 60, and complete the audit data
calculations.
3.1-3 INTERPRETATION OF AUDIT RESULTS
This section pertains to the interpretation of the performance audit
analyses peculiar to the RM-41. The interpretation of the more general
analyses is fully discussed in the Section 2.0 of this manual.
Stack Exit Correlation Error Check
The pathlength correction errors on blanks 61 and 62 should be within +2%.
This error expontentially affects the opacity readings, resulting in over-~or
under-estimation of the stack exit opacity. The most common error in computing
the OPLR is the use of the flange-to-flange distance rather than the stack/duct
inside diameter at the monitor location. This error will result in an under-
estimation of the stack exit opacity and can be identified by comparing the
monitor optical pathlength to the flange-to-flange distance, which should be
the greater by approximately two feet.
Control Panel Meter Error (Optional)
The accuracy of the control panel meter is important at sources using the
meter during monitor adjustment and calibration. In such cases, the control
panel meter opacity and input readings are compared to the specified values for
the internal zero and span filter. Errors in the control panel meter should
not affect the opacity data reported by the monitoring system unless the
control panel meter is used to adjust the zero and span functions. The percent
error values associated with the control panel meter are found on'blanks 64,
66, and 67a. 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 determined by 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, the measurement lamp, the photodiode detector, and/or the
preamplifier. A reference signal error greater than 10% is indicative of a
3-15
-------
malfunction in one of these component systems. Because the reference signal is
critical to maintaining the accuracy of the transmissometer opacity
measurements, corrective actions should be taken as soon as possible.
Internal Zero and Span Check
The RM-41 internal zero 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 or mechanical
offset. Excessive dust on the optical surfaces sufficient to cause a
significant zero error also would be indicated by the zero compensation
reading. A malfunction of the transceiver electronics resulting in a zero
error would be indicated by a reference signal error. Instrument span error
may be caused by the same problems that cause zero errors and may be identified
in a similar fashion. Also, a span error may be caused by an inaccurate span
filter value.
If the zero and span errors are due to a data recorder offset, both errors
will be in the same direction and will have the same magnitude. The opacity
data will be offset in the same manner.
Zero Compensation Check
The amount of zero compensation the instrument is generating to compensate
for dust on transceiver optics should not exceed 4$ opacity, which is
approximately equivalent to an optical density of 0.018$. The zero
compensation values recorded on blanks 68, 69, and 70 should not exceed +0.018
OD. Post-cleaning values in excess of this indicate either excessive dust
remaining on monitor optics or a malfunction in the zero compensation
circuitry.
A residual positive zero compensation after a thorough cleaning of
transmissometer optics is normally the result of an incorrect zero compensation
circuit adjustment. If the zero compensation goes negative after the
transceiver optical surfaces are cleaned, it is probable that the zero
compensation circuit was last adjusted at a time when the optical surfaces were
not clean. Often when this situation occurs (adjustments during dirty window
conditions), the internal zero will also have benn adjusted to read 0% opacity,
and thus, the zero will be offset in the negative direction. Under these
conditions, the internal zero and the zero compensation circuit will need to be
adjusted after the optics are cleaned.
Transmissometer Dust Accumulation Check
The total opacity equivalent to the dust on the transmissometer optical
surfaces (blank 73) should not exceed 4$. A dust accumulation value of more
than k% 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 fairly stable {within +2% opacity) before and after the
cleaning of the optical surfaces. If the effluent opacity is fluctuating more
than +2%, the dust accumulation analysis should be omitted.
3-16
-------
Calibration Error Check
Excessive calibration error results (blanks 83, 84, and 85) are indicative
of a non-linear calibration and/or a miscalibration of the monitor. However,
the absolute calibration accuracy of the monitor can be determined only when
the clear path zero value is known. If the zero and span are not within the
proper range, the calibration check data will often be biased in the same
direction as the zero and span errors. Even if the zero and span errors are
within the proper ranges, the monitor may still be inaccurate due to possible
error in the clear path zero. The optimum calibration procedure involves using
neutral density filters during a clear-stack or off-stack calibration. This
procedure would establish both the absolute calibration accuracy and
linearity. If this procedure is not practical, and if it is reasonable to
assume that the clear path zero is indeed zero, the monitor's calibration
linearity can be set using either neutral density filters or the internal zero
and span values.
3-17
-------
3.2 LEAR SIEGLER, INC. MODEL RM-4 TRANSMISSOMETER
3.2.1 GEMS Description
The RM-4 opacity GEMS consists of three major components: the
transmissometer, the air-purging and shutter system, and the remote control and
data acquisition unit. The transmissometer component consists of a transceiver
unit mounted on one side of a stack or duct and a retroreflector 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 (single-pass, corrected optical density) is transmitted to the
control unit.
Figure 3~6 illustrates the general arrangement of the transceiver and
retroreflector units on the stack, and provides further details of the chopped,
dual-beam measurement technique. In this technique, the reference beam signal
is monitored continuously by the automatic gain control (AGO) circuit, which
compensates for changes in lamp intensity so that the reference signal remains
constant. Since the AGO circuit affects both the reference signal and the
measurement signal amplitude equally, lamp intensity changes are theoretically
elimiated from the measurement signal.
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 the transceiver unit and one for the retroreflector
unit; each system has a blower providing filtered air.
The shutters (optional) automatically provide protection for the
transceiver and retroreflector exposed optical surfaces from smoke, dust, and
stack gas. Whenever the purge airflow decreases below a predetermined rate
(due to blower monitor failure, clogged filter, broken hose, or stack power
failure), the shutter mechanism holding it open is deactivated by an airflow
sensor installed in the connecting hose between the air-purge blower and the
instrument mounting flange. Under stack power failure conditions, the shutters
are reset automatically upon restoration or power to the blowers; however, each
solenoid may have to be reset manually under high negative or high positive
stack pressure conditions.
The converter control unit (Figure 3~7) converts the optical density output
from the transceiver exit opacity by using the ratio of the stack exit diameter
to the stack inside diameter (or duct width) at the transmissometer, commonly
referred to as the optical pathlength ratio (OPLR) by Lear Siegler. 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 span value to be
checked in units of milliampere (Ma) current, opacity and optical density,
respectively. A potentiometer mounted on the converter front panel permits the
adjustment of the optical density zero value to compensate for minor dust
accumulation ~n transceiver optics.
3-18
------- An error occurred while trying to OCR this image.
-------
J2
jriac
A. Mode Switch
B. Measurement Switch
C. Offset Adjustment
D. Response Kate Switch
E. Fault Indicator
F. Over-Range Indicator
G. Panel Meter
H. Range Switch
I. Ratio Adjustment
Jl. Set Point Adjustaent
J2. Sonalert Alarm
J3. Reset Switch
Figure 3-7. LSI RM-4 Converter
Control Unit.
3-20
-------
The opacity monitor measures the amount of light transmitted through the
effluent from the transceiver to the retroreflector and back again. The
transceiver calculates the optical density of the effluent stream at the
monitor location, or the "path" optical density. In order to provide stack
exit opacity data, the path optical density must be corrected by multiplying by
the ratio of the stack exit inside diameter to the stack inside diameter (or
duct width) at the transmissometer, known as the OPLR. The following equations
illustrate the relationships between the OPLR, path optical density, and exit
opacity.
where:
OP - 1 -
x
OP = stack exit opacity (%)
Ji
OD = transmissometer optical density (path)
where:
OPLR = x; optical pathlength ratio
Lt
L = stack exit inside diameter (ft)
X
L = two times the stack inside diameter (or duct
width)
3-2.2 Performance Audit Procedures
Preliminary Data
1. Obtain the stack exit inside diameter and the stack inside diameter
(or duct width) at the transmissometer and record on blanks 1 and 2,
respectively, of the Lear Siegler RM-4 Performance Audit Data Sheet.
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order to 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 on blank 1 by the value on
blank 2), and record the value on blank 3.
3. Record the source-cited OPLR value on blank 4.
Note: The OPLR is preset by the manufacturer using information
supplied by the source. The value recorded in blank 4 should be
that which the source personnel agree should be set inside the
monitor. Typically, this value is cited from monitor installation
or certification data, as well as from service reports.
4. Obtain the present values that the monitor should measure for the
zero and span calibrations and record on blank 5 and blank 6,
respectively.
3-21
-------
Note: These values are set during monitor calibration, and therefore
may not be equal to values recorded at installation and/or
certification. Records of the zero and span values resulting from
the most recent monitor calibration should exist.
Converter Control Unit Checks
5. Inspect the opacity data recorder (strip chart or computer) to
ensure proper operation. Annotate the paper with the auditor's
name, plant, unit, date, and time.
Fault Lamp Checks
The following list describes the fault lamps that are found on the Lear
Siegler RM-4 converter control unit panel. 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 FAULT fault lamp on. blank 7.
Note: An illuminated FAULT fault lamp indicates that the transceiver
AGO 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.
7. Record the status (ON or OFF) of the OVER RANGE fault lamp on
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 Check
8. Record the original position on blank 9 of the MEASUREMENT switch on
the control unit panel.
Zero Check
9. Turn the MEASUREMENT switch to the 20% OPACITY position.
10. Turn the MODE switch on the control panel to the ZERO position to
initiate the zero mode.
11. Record the value on blank 10 displayed on the panel meter
0-20 mA scale.
12. Record the zero value on blank 11 displayed on the opacity data
recorder.
Nrvt-«: Tho "-oss-stack zero is simulated by the transceiver zero
mirror. Checking this simulated zero value provides an indication
of the amount of dust on the measurement window and on the zero
retroreflector, as well as an indication of the status of the
3-22
-------
electronic alignment of the instrument. It does not, however,
provide any indication of cross-stack parameters.
Span Check
13. Turn the MEASUREMENT switch to the 100% OPACITY position.
14. Turn the MODE switch to the CALIBRATE position.
15. Record the span value on blank 12 that is displayed on the control
panel meter (0-100% Op scale) and record the span value displayed on
the opacity data recorder on blank 13.
16. Turn the MEASUREMENT switch to the OPACITY INPUT position
(optional).
17. Record the control panel meter value on blank 1*1 that is displayed
on the 0-20 milliamp scale.
18. Return the MEASUREMENT switch to the 100% OPACITY position.
Note: Steps 16-18 comprise the optional input signal check.
19. Return the mode switch to the OPERATE position.
Note: During the span portion of the calibration cycle, a neutral
density filter is automatically inserted into the measurement beam
path inside the transceiver while the zero retroreflector is in
place. The span measurement provides another check of the monitor
electrical alignment and the linearity of the transmissometer
opacity response.
20. Go to the transmissometer location.
Retroreflector Dust Accumulation Check
21. Record the instantaneous effluent opacity from the opacity data
recorder on blank 15 prior to cleaning the retroreflector optics.
22. Open the retroreflector housing, inspect and clean retroreflector
optics, and close the housing.
23. Record the post cleaning instantaneous effluent opacity on blank 16.
Transceiver Dust Accumulation Check
24.Record the instantaneous effluent opacity on blank 17.
25. Open the transceiver head, inspect and clean the optics (primary
lens and zero mirror), and close the transceiver head.
26. Record the post cleaning instantaneous effluent opacity on blank 18.
Note: After the transmissometer optics have been cleaned, the zero
offset has to 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.
3-23
-------
Fault/Test Check
27. Depress the transceiver Fault/Test momentary-action switch and
record the milliamp value displayed on the transceiver milliampmeter
(0-20 mA) on blank 19.
Note: This combination indicator and momentary-action switch
serving two related functions: 1) When the current within the
instrument AGO circuit falls below 10 milliamperes, the FAULT
indicator lights. 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 fault indication
. (closure) is also transmitted on lead 6 to the remote control room
equipment. When the momentary-action switch is depressed, the
milliampmeter indicates the actual current within the AGC circuit,
which should be between 11 and 16 milliamperes.
Optical Alignment Check
28. Determine the monitor alignment by looking through the viewing port
and observing whether the beam image is in the circular target.
29. Record whether the image is centered inside the circular target (YES
or NO) on blank 20.
30. Draw the orientation of the beam image in the circle on the data
form.
Note: Instrument optical alignment has no effect on the internal
checks of the instrument or on the calibration check using the audit
device; however, if the optical alignment is not correct, the stack
opacity data will be biased high, since all the light transmitted to
the retroreflector is not returned to the detector.
Span Filter Data Check
31. Record the span filter's optical density value on blank 21 from the
front of the transceiver control panel.
CALIBRATION ERROR CHECK
The calibration error check is performed using three neutral density audit
filters and an audit device (or jig) with an adjustable retroreflector and iris
to simulate clear stack conditions. The audit device and neutral density
filters actually determine the linearity of the instrument response with
respect to the current clear-stack zero value. This calibration error check
does not determine the actual instrument clear-stack zero, or the status of any
cross-stack parameters.
A true calibration check is performed by removing the on-stack components
and setting them up in a locatio1"1 with minimal ambient opacity, making sure
that the proper pathlength and alignments are attained, and then placing the
calibration filters in the measurement beam path.
3-24
-------
32. Install the audit jig by sliding it onto the transceiver primary
lens barrel.
Note: The audit device will not slide on until it is flush with the
monitor. Care should be taken not to push it agair.^l 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 to simulate the amount of light returned to the
transceiver during clear stack conditions.
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 0,0% opacity since the audit
filter correction equations can account for an offset in the jig
zero. Thus, a jig zero value in the range of 0-2% Op is usually
acceptable.
34. Record the audit filter serial numbers and opacity values on
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 another person at the data recorder
location.
37- Insert the low range neutral density filter into the audit jig.
38. 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).
39- Record the monitor's 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.
4l. Wait approximately two minutes and record the monitor's responses.
42. Remove the mid range filter from the audit jig and insert the high
range filter.
43. Wait approximately two minutes and record the monitor's response.
3-25
-------
44. 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 ±% 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 37-44 above 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
37-44 above once more, but change the waiting periods to 13 minutes.
4?. Record the six-minute integrated data.
Note: In order to acquire six-minute,averaged opacity data, each
filter must remain in the jig for at least two consecutive
six-minute periods. The first period is invalid because it was in
progress when the filter was inserted. Only at the conclusion of
two successive six-minute integration periods can the monitor's
response be recorded.
48. Once the calibration error check is finished, remove the audit jig,
close the transceiver panel cover and close the transceiver head.
Zero Milliamp Check (Optional)
Note: This is an optional check to evaluate the effects of cleaning
the monitor optics.
49. Return to the control unit location and turn the MODE switch to ZERO
and the MEASUREMENT switch to 20% OPACITY.
50. Record the final zero current value on blank 23.
51. Turn the MODE switch to OPERATE and the MEASUREMENT switch to the
position recorded in blank 9.
52. Obtain a copy of the audit data from the data recorder.
53. Transcribe the calibration error response data from the data
recorder from blanks 26 to 51. and complete the audit data
calculations.
3.2.3 INTERPRETATION OF AUDIT RESULTS
This section pertains to the interpretation of the performance audit
analyses peculiar to the RM-4. The interpretation of the more general analyses
is fully discussed in the introduction of this manual.
Stack Exit Correlation Error Check
The pathlength correction error on blank 52 should be within +2%. This
error expontentially affects the opacity readings, resulting in over- or
3-26
-------
under-estimation of the stack exit opacity. The most common error in computing
the OPLR is the use of the flange-to-flange distance rather than the stack/duct
inside diameter at the monitor location. This error will result in an under-
estimation of the stack exit opacity and can be identified by comparing the
monitor optical pathlength to the flange-to-flange distance, which should be
the greater by approximately two feet.
Control Panel Meter Error (Optional)
The accuracy of the control panel meter is important at sources using the
meter during monitor adjustment and calibration. In such cases, the control
panel meter opacity and input readings are compared to the specified values for
the internal zero and span filter. Errors in the control panel meter should
not affect the opacity data reported by the monitoring system unless the
control panel meter is used to adjust the zero and span functions. 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 determined by
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 a new
value for the input current should be recorded and used in all subsequent
adjustments.
Internal Zero and Span Check
The RM-4 internal zero should be set to indicate 0% opacity and 2.0 mA. A
zero error greater than 4# opacity is usually due to excessive dust
accumulation on the optical surfaces, electronic drift, or data recorder
electronic or mechanical offset. Excessive dust on the optical surfaces
sufficient to cause a significant zero error also would 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 will have the same magnitude. The opacity
data will be offset in the same manner.
Transmissometer Dust Accumulation Check
The total opacity equivalent to the dust on the transmissometer optical
surfaces (blank 60) 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 fairly stable (within +2% opacity) before and after the
cleaning of the optical surfaces. If the effluent opacity is fluctuating more
than +2%, the dust accumulation analysis should be omitted.
Calibration Error Check
The comparison of monitor responses to the opacity values of the neutral
density filters requires that the filter values be corrected to stack exit
conditions and that any zero offset be factored into the corrected filter
value.
3-27
-------
Excessive calibration error results (blanks 70. 71, and 72) are indicative
of a non-linear calibration and/or a miscalibration of the monitor. However,
the absolute calibration accuracy of the monitor can be determined only when
the clear path zero value is known. If the zero and span are not within the
proper range, the calibration check data will often be biased in the same
direction as the zero and span errors. Even if the zero and span errors are
within the proper ranges, the monitor may still be inaccurate due to possible
error in the clear path zero. The optimum calibration procedure involves using
neutral density filters during clear-stack or off-stack calibration. This
procedure would establish both the absolute calibration accuracy and
linearity. If this procedure is not practical, and if it is reasonable to
assume that the clear path zero is indeed zero, the monitor's calibration
linearity can be set using either neutral density filters or the internal zero
and span values.
3-28
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SECTION 4
PERFORMANCE AUDIT PROCEDURES FOR DYNATRON OPACITY MONITOR
4.1 .JDYNATRON MODEL 1100 TRANSMISSOMETER
4.1.1 GEMS Description
The Dynatron Model 1100 opacity CEMS consists of three major components:
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 retroreflector unit mounted on the opposite side. The
Dynatron monitor employs an electonically modulated light source to eliminate
interference from ambient light. The modulated beam is split into reference
and measurement beams with the reference beam going via fiber optics to a
photodetector (see Figure 4-1). The measurement beam crosses through the
effluent to the retroreflector and is reflected back into the transceiver where
it encounters a photodetector identical to the reference detector. Because the
monitor uses the ratio of the reference and measurement signals to determine
opacity, variations in the beam intensity are factored out. The Dynatron
monitor is calibrated internally by turning off the measurement light source
and alternately turning on two calibration light sources, each with a different
neutral density filter in its optical path. When individually viewed by the
photodetectors, these sources produce internal zero and span signals.
The air purging system serves a threefold purpose: (!) it provides an air
curtain to keep protective windows clean; (2) it keeps protective windows from
accumulating condensed stack gas moisture; and (3) it minimizes thermal
conduction from the stack to the instrument. A standard installation has one
air-purging system for the transceiver unit and one for the retroreflector
unit; each system has a blower providing filtered air.
The control unit of the Dynatron Model 1100 has a digital display and a
display selector to select either opacity or optical density. Fault lamps for
"lamp," "window," and "air purge" warn of monitor malfunctions and a selector
knob allows the setting of the automatic calibration frequency. A zero/span
switch allows the monitor to be put into a manual calibration mode. The
control unit integrates the stack exit opacity data on an adjustable time basis
(typically six-minutes).
Dynatron has recently updated the Model 1100 opacity monitor to the Model
1100M. Both monitors are basically identical, but the Model 1100M has a micro-
processor-based digital control unit and a built-in optical alignment sight on
the transceiver. The Model 1100M control unit has only two fault lamps, and
zero, span, and "M" factor values can be displayed on the control unit meter by
manipulating switches inside the control unit. Otherwise, the Models 1100 and
1100M monitors are audited according to the same procedures.
The Dynatron 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 stream at the monitor location, or the "path"
optical density. In order to provide stack exit opacity data, the path optical
density must be corrected by multiplying by the ratio of the stack exit
diameter to the stack inside diameter (or duct width) at the transmissometer
4-1
-------
LIGHT SOURCE
AND PHOTO
ELECTRIC
DETECTOR
AIR PURGE
SYSTEM
STACK OUTLET
L
J
LIGHT BEAM
r
till!
SMOKE OR DUST
REFLECTOR
AIR PURGE
SYSTEM
DIGITAL
DISPLAY
BASIC MONITORING SYSTEM
WEATHER
COVERS
QUICK
DISCONNECT
CABLE KITS
FIELD
INSTALLATION
SUPERVISION
ANALOG
DISPLAY
DATA
RECORDER
EPA
ZERO
SPAN
CHECK
STRIP
CHART
RECORDER
REMOTE
OPERATOR
STATIONS
STACK
EXIT
OUTPUT
CORRELATOR
OPTIONAL ACCESSORIES
ANALOG
AND
RELAY
INTERFACE
KITS
Figure 4-1. Dynatron 1100 Transceiver and Retroreflector Arrangement
4-2
-------
location. This ratio is called the M Factor by Dynatron. The following
equations illustrate the relationships between the M Factor, path optical
density, and exit opacity.
where:
OP = i -
X
OP = stack exit opacity (%)
X.
OD = transmissometer optical density (path)
where:
M = _x = "M" Factor
Lt
L = stack exit inside diameter (ft)
L = measurement pathlength (ft) = two times the stack
inside diameter (or the duct width) at the monitor
location
4.1.2 Performance Audit Procedures
Preliminary Data
1. Obtain the stack exit inside diameter and the stack inside diameter
(or duct width) at the transmissometer and record on blanks 1 and 2,
respectively, of the Dynatron 1100 Performance Audit Data Sheet.
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order to reliability: (1)
physical measurements; (2) construction drawings; (3) opacity
monitor installation/certification documents; and (4) source
personnel recollections.
2. Calculate the M Factor, (divide the value on blank 1 by the value on
blank 2), and record the value oh blank 3.
3. Record the source-cited M Factor value on blank 4.
Note: The M Factor is preset by the manufacturer using information
supplied by the source. The value recorded in blank 4' should be
that which the source personnel agree should be set inside the
monitor. Typically, this value is cited from monitor installation
or certification data, as well as from service reports. For the
Model 1100M monitor, source personnel can adjust switches in the
control unit which will cause the "M" Factor to be displayed on the
panel meter.
4. Obtain the present values that the monitor should measure for the
zero and span calibrations and record on blank 5 and blank 6,
respectively.
4-3
-------
Note: These values are set during monitor calibration, and therefore
may not be equal to values recorded at installation and/or
certification. Records of the zero and span values resulting from
the most recent monitor calibration should exist. Source personnel
can adjust switches in the Model 1100M control unit, which will
cause the present zero and span values to be displayed on the panel
meter.
5. Go to the control unit location and inspect the opacity data
recorder (strip chart or computer) to ensure proper operation.
Annotate the paper with the auditor's name, plant, unit, date, and
time.
Fault Lamp Checks
The following list describes the fault lamps that are found on the Dynatron
Model 1100 control unit panel. Unless otherwise noted, the -audit analysis can
continue with illuminated fault lamps, provided that the source has been
informed of the fault conditions. The Model 1100M monitor control unit has two
fault lamps: "WINDOW" (indicating excessive dust on transceiver window) and
"FAULT" (indicating other internal malfunctions which can be identified by
source personnel through manipulating switch positions within the control
unit).
6. Record the status (ON or OFF) of the LAMP fault lamp on 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 in the lamp voltage.
Because the LAMP fault lamp is obscured by the control unit cover frame,
it is frequently overlooked during cursory inspections.
7. Record the status (ON or OFF) of the WINDOW fault lamp on 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. Monitor opacity data may be biased high by the opacity of
the 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 on 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 monitor optics
and the continued operation of the transmissometer as a result of
exposure to hot, corrosive stack gas. Plant personnel should be
notified immediately of this condition.
9. Record the original position on blank 10 of the AUTOMATIC CALIBRATION
TIME (CYCLE TIME) knob on the control unit panel.
Note: The AUTOMATIC CALIBRATION TIME (CYCLE TIME) knob is used to
adjust the frequency of calibration cycles.
10. Turn the cycle time knob to the MANUAL position.
4-4
-------
11. Record the original position on blank 11 of the METER DISPLAY knob on
the control panel.
Note: The METER DISPLAY knob permits "the selection of either the opacity
or optical density of the stack exit to be displayed on the panel
meter. Optical density data is useful during maintenance and
calibration.
12. Turn the METER DISPLAY knob to the opacity position, if necessary.
Zero Span Check
13. Press the zero/span switch.
Note: The green zero light should go on during the zero period and the
yellow span light should be lit during the span period. The monitor
automatically switches from zero to span after approximately three
minutes. After a similar period in the span mode, the monitor reverts
to normal operation.
14. Record the zero value on blank 12 displayed on the panel meter.
15. Record the zero value on blank 13 displayed on the data recorder.
Note: The cross-stack zero is simulated by the transceiver internal zero
optics. The measurement light source is turned off and a zero light
source is turned on. Checking this simulated zero value provides an
indication of the accuracy of the monitors calibration, assuming that
the clear path zero value is correct, as well as an indication of the
status of the electronic alignment of the instrument. It does not,
however, provide any indication of cross-stack parameters, such as the
present clear path zero or optical alignment.
16. Record the span value on blank 14 that is displayed on the control panel
meter.
17. Record the span value displayed on the data recorder on blank 13.
Note: During the span portion of the calibration cycle, the measurement
light source is turned off and a span light source is illuminated which
has a neutral density filter in its beam path inside the transceiver.
The span measurement provides an upscale check of the monitor's calibra-
tion accuracy with respect to its clear path zero value. Also, when
evaluated in combination with the zero calibration value, the span
permits an evaluation of the linearity of the monitor's calibration.
18. Go to the transmissometer location.
Note: The acquisition of real-time monitor response data requires that
there be communication between the transmissometer location and the
opacity data recorder location. , , ~
Retroreflector Dust Accumulation Check
19. Record the instantaneous effluent opacity prior to cleaning of the
retroreflector protective window on blank 16.
-------
20. Remove, inspect, clean, and replace the retroreflector protective
window.
21. Record the post cleaning instantaneous effluent opacity on blank 17.
Transceiver Dust Accumulation Check
22. Record the instantaneous effluent opacity on blank 18.
23. Remove, inspect, clean, and replace the transceiver protective window.
24. Record the post cleaning instantaneous effluent opacity on blank 19.
Optical Alignment Check
25. If an alignment tube is available, determine the monitor alignment by
looking through the tube and observing whether the beam image is
centered around the retroreflector port on the opposite side of the
stack or duct.
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. The Model 1100 M has an alignment sight on
the transceiver which allows an alignment check when the "target light"
switch is activated.
26. Record whether the image is centered inside the circular target (YES or
NO) on blank 20.
27- Draw the orientation of the retroreflector port in the beam circle on
the 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 all the light transmitted to the
retroreflector is not returned to the detector.
CALIBRATION ERROR CHECK (JIG PROCEDURE)
The calibration error check is performed using three neutral density audit
filters and an audit device (or jig) with an adjustable retroreflector and iris
to simulate clear stack conditions. The jig audit device and neutral density
filters actually determine the linearity of the instrument response with
respect to the current clear-path zero value. This calibration error check
does not determine the actual instrument clear-path zero, or the status of any
cross-stack parameters.
If the audit jig is not available or if the jig cannot be installed in the
transceiver then an incremental calibration error procedure should be used;
This procedure factors out the opacity attributed to the transceiver protective
window and that of the effluent. Due to its complexity and possible
inaccuracy, the incremental calibration error procedure should be used only as
a last resort.
4-6
-------
Note: A true calibration check is performed by removing the
on-stack components and setting them up in a location with minimal
ambient opacity, making sure that the proper pathlength and
alignments are attained, and then placing the calibration filters in
the measurement beam path.
28. Remove the transceiver dirty window detector on the left forward
side of the transceiver. Install the audit jig by inserting it
into the dirty window detector opening (with the iris opening facing
toward the light source) and tighting the thumb screws.
Note: If the transceiver does not have a dirty window detect or if,
for whatever reason, the audit jig will not fit into the available
opening, then the incremental calibration error procedure should be
used.
29. Remove the transceiver protective window.
30. Adjust the audit jig iris to produce a 0-2% opacity value on the
opacity data recorder. This adjustment simulates the amount of
light returned to the transceiver during clear stack conditions.
Note: The audit jig zero adjustment depends on the procedure used in
calibrating the neutral density filters employed in the audit. Some
older filter sets intended for incremental calibration checks of
Dynatron" monitors have an 8-10$ "assumed" window opacity value added
to the actual filter opacity. Thus, a filter marked as "20% Op"
might have a total true opacity of 26% (8% Op + 20$ Op). With the
audit jig zero (without the protective window) being set at 0-2$
opacity as described above, it becomes imperative that the auditor
know the actual opacity of each filter, including any added window
opacity. In general, it is recommended that both assumed filter
values (based on the sum of filter opacity and assumed window
opacity) and actual filter values be known. This information should
be supplied by the firm certifying the filter calibration values.
31. Install the transceiver protective window and record the measured
window opacity value in Blank 21.
32. Remove the transceiver protective window.
33- Record the audit filter serial numbers and opacity values on
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 another person at the data recorder location.
36. Insert the low range neutral density filter into the monitor.
37- Wait for approximately two minutes or until a clear value has been
recorded and displayed on the opacity data recorder.
4-7
-------
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 monitor's response to the low range neutral density
filter.
39- Remove the low range filter from the monitor and insert the mid
range neutral density filter.
40. Wait approximately 2 minutes and record the monitor's responses.
4l. Remove the mid range filter and insert the high range filter.
42. Wait approximately 2 minutes and record the monitor's response.
43. Remove the high range filter, wait approximately 2 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 36-43 above until a total of five opacity readings are
obtained for each neutral density filter.
45.
46. Record the six-minute integrated data, if available.
If six-minute integrated opacity data are recorded, repeat steps
36-43 above once more, changing the waiting periods to 13 minutes.
4?' Once the calibration error check is finished, remove the audit jig,
replace the dirty window detector and the projective window, and
close the transceiver protective housing.
48. Return to the control unit location.
49. If necessary, return the AUTOMATIC CALIBRATION (CYCLE) TIMER, and
the METER DISPLAY knob to their original positions, as recorded on
blanks 10 and 11.
50. Obtain a copy of the audit data from the data recorder.
51. Transcribe the calibration error response data from the data
recorder from blanks 25 to 50. and complete the audit data
calculations .
CALIBRATION ERROR CHECK (Incremental Procedure)
The incremental calibration error check is included herein to address older
Dynatron monitors that do not permit the use of the audit jig. The incremental
calibration error check is performed by substituting three neutral density
4-8
-------
filters in place of the the transceiver protective window. These filters should
include an assumed protective window opacity value of approximately 8% opacity
(or a more appropriate value, as cited by the source or monitor manufacturer).
Thus, a filter with a true total of 26% Op would be "named" as 20% Op. This
check should be performed only when the stack opacity is fairly steady, varying
by no than +2% opacity. The calibration error check provides a determination of
the linearity of the instrument response and the on-stack alignment status,
since it utilizes all of the components of the measurement system. This
calibration check does not provide a test of the actual instrument clear-path
zero.
Only under clear stack conditions will the calibration check provide a check
of the actual instrument zero and instrument calibration. A true calibration
check can also be obtained by removing the on-stack components and setting them
up in an area with minimal ambient opacity, making sure that the on-stack
pathlength and alignment are duplicated.
1-28. Record the audit filter serial numbers and opacity values on blanks
1-21, 1-22, and 1-23
1-29. Remove the low range filter from its protective cover, inspect, and
if necessary clean them.
1-30. Wait approximately two minutes and record the effluent opacity as
indicated by the opacity data recorder.
1-31. Remove the transceiver protective window and insert the low range
neutral density filter.
1-32. Wait 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. Wait 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.
-------
I-4l. 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.
3.3«^ Monitor Response Repeatability
1-44. Repeat the procedures steps 1-31 through 1-43 until a total of five
opacity readings is obtained for each neutral density filter.
1-45• If six-minute integrated opacity data are recorded, repeat steps
1-31 through 1-43 once more, changing the waiting periods to 13
minutes.
1-46. Record the six-minute integrated data, if available.
1-4?« 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.
1-51. Transcribe the calibration error response data from the opacity data
recorder to audit data sheet blanks 1-24 through 1-61.
4.1.3 DYNATRON 1100 PERFORMANCE AUDIT DATA INTERPRETATION
This section pertains to the interpretation of the performance audit data
analyses peculiar to the Dynatron Model 1100 (and also the Model 1100M, where
applicable). The interpretation of the more general analyses is fully
discussed in the introduction of this manual.
Stack Exit Correlation Error Check
The pathlength correction error on blank 51 should be within +2.%. This
error expontentially affects the opacity readings, resulting in over- or
under-estimation of the stack exit opacity. The most common error in computing
the M Factor is the use of the flange-to-flange distance rather than the
stack/duct inside diameter at the monitor location. This error will result in
an under-estimation of the stack exit opacity and can be identified by
comparing the monitor optical pathlength to the flange-to-flange distance; cne
flange to flange distance should be the greater by approximately two feet.
4-10
-------
Control Panel Meter Error Check
The accuracy of the control panel meter is important at sources using the
meter during monitor adjustment and calibration. In such cases, the control
panel meter opacity readings are compared to the specified values for the
internal zero and span. Errors in the control panel meter should not affect
the opacity data reported by the monitoring system unless the control panel
meter is used to adjust the zero and span functions. The percent error values
associated with the control panel meter are found on blanks 52 and 5^- 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 determined
by using the internal zero and span values, any change in the specified values
for the zero or span will cause an erroneous assessment of the control panel
meter errors. The zero and span values 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 Dynatron Model 1100 monitor internal zero is typically set to indicate
2-10$ opacity because the monitor will not indicate negative opacity values. A
zero error greater than 4% opacity is usually due to electronic drift, or data
recorder electronic or mechanical offset. Excessive dust on the optical
surfaces sufficient to cause a significant zero error also would be indicated
by the dirty window fault lamp. Instrument span error 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 have the same magnitude. The opacity
data will be offset in the same manner.
Transmissometer Dust Accumulation Check
The total opacity equivalent to the dust on the transmissometer optical
surfaces (blank 58) should not exceed k%. A dust accumulation valve of more
than 4$ opacity inidicates 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 fairly stable (within +2% opacity) before and after the
cleaning of the optical surfaces. If the effluent opacity is fluctuating more
than +2%, the dust accumulation analysis should be omitted.
Calibration Error Check
Excessive calibration error results (blanks 68, 69. and 70 or blanks 1-89.
1-90. 1-91) are indicative of a non-linear calibration and/or a miscalibration
of the monitor. However, the absolute calibration accuracy of the monitor can
be determined only when the clear path zero value is known. If the zero and
span are not within the proper range, the calibration check data will often be
biased in the same direction as the zero and span errors. Even if the zero and
span errors are within the proper ranges, the monitor may still be inaccurate
due to possible error in the clear path zero. The optimum calibration proce-
dure involves using neutral density filters during clear-stack or off-stack
calibration. This procedure would establish both the absolute calibration
4-11
-------
accuracy and linearity. If this procedures is not practical, and if it is
reasonable to assume that the clear path zero is indeed zero, the monitor's
calibration linearity can be set using either neutral density filters or the
internal zero and span values.
4-12
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SECTION 5
PERFORMANCE AUDIT PROCEDURES FOR
THERMO ELECTRON (CONTRAVES GOERZ) OPACITY MONITOR
5.1 THERMO ELECTRON (CONTRAVES GOERZ) MODEL 400 TRANSMISSOMETER AND MODEL 500
CONTROL UNIT
5.1.1 GEMS Description
The Thermo Electron, Inc. (formally the Contraves Goerz) Model 400 opacity
GEMS consists of three major components: the transmissometer, the air-purging
system, and the Model 500 control unit. The transmissometer component consists
of a transceiver unit mounted on one side of a stack or duct and a retrore-
flector 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.
Figure 5-1 illustrates the general arrangement of the transceiver and
retroreflector units on the stack. The transceiver uses a single lamp single
detector system, employing both internal and external choppers. The internal
chopper modulates the measurement beam to eliminate interference from ambient
light. The external three-segmented chopper produces alternating calibration
and stack opacity measurements. Also, since the external chopper is exposed to
stack conditions, it automatically compensates for dust accumulation on
transceiver optics. The output signal from the transceiver (double-pass,
uncorrected transmittance) is transmitted to the control unit.
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 the transceiver unit and one for the retroreflector
unit; each system has a blower providing filtered air.
The Model 500 digital control unit (Figure 5-2) converts the double-pass
transmittance output from the transceiver to linear optical density
measurements which are corrected according to the ratio of the stack exit
diameter to the transmissometer pathlength, referred to as the stack taper
ratio (STR). The resultant stack exit optical density is converted to
instantaneous, single-pass stack exit opacity. The control unit also contains
an integrator which compiles the above opacity data and calculates a discrete
average over an integration period that is set by the source (typically six
minutes). This function may not be used at facilities employing a computer to
reduce and record opacity data because the computer may perform the
integration. Also, the Model 500 control unit has a lamp test button that
lights all fault and control lamps, and the STR setting can be checked by
manipulating a switch inside the control unit.
5-1
-------
AKI VALVE
'CALIBRATION
TEST KIT
MOULDED COVER
MOULDED
COVER /
RETRO
ALIGNMENT
TOOL
-f—55-T.
L JUOMC J^
Figure 5-1.
Arrangement of Thermo Electron (Contraves Goerz) Model 400
Transceiver and Retroreflector.
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
TRANSM1SSOMETER
SIGNAL
MODEL 500
TRANSMISSOMETER
REMOTE DISPLAY
O O O
EXIT PATH AVG.
O
O.D.
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
I INOPERATIVE
LIGHT
SOURCE
Figure 5-2. Thermo Electron (Contraves Goerz)
Model 500 Control Unit
5-3
-------
The following equations illustrate the relationships between the STR, path
optical density, and exit opacity.
,-(STR)(OD)
where:
OP =1-10
•X.
OP = stack exit opacity (%)
STR = stack taper ratio = x/L
L = stack exit inside diameter (ft)
L = measurement pathlength (ft) = the stack or
duct inside diameter at the monitor location
OD = transmissometer optical density (path)
5.1.2 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 and record on
blanks 1 and 2, respectively, of the Thermo Electron (Contraves
Goerz) Model 400 Performance Audit Data Sheet.
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order to reliability: (1)
physical measurements; (2) construction drawings; (3) opacity
monitor installation/certification documents; and (4) source
personnel recollections. The monitor measurement pathlength is the
length of the inside diameter (or width) of the stack (or duct) at
the monitor installation location.
2. Calculate the STR, (divide the value on blank 1 by the value on
blank 2), and record the value on blank 3-
3. Record the source-cited STR value on blank 4.
Note: The STR is preset by the manufacturer using information
supplied by the source. The value recorded in blank 4 should be
that which the source personnel agree should be set inside the
monitor. Typically, this value is cited from monitor installation
or certification data, as well as from service reports. Source
personnel can adjust a switch inside the control unit which will
cause the STR value to appear on the digital display.
4. Obtain the present values that the monitor should measure for the
zero and span calibrations and record on blank 5 and blank 6,
respectively.
Note: These values are set during monitor calibration, and therefore
may not be equal to values recorded at installation and/or
certification. Records of the zero and span values resulting from
the most recent monitor calibration should exist.
5-4
-------
Control Unit Checks
5. Inspect the opacity data recorder (strip chart or computer) to
ensure proper operation. Annotate the paper with the auditor's
name, plant, unit, date, and time.
Fault Lamp Checks
The following list describes the fault lamps that are found on the Model
500 control unit panel. 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 CAL FAIL lamp on blank 7.
Note: An illuminated CAL FAIL lamp indicates that the most recent
monitor automatic zero and/or span calibration values are not within a
preset range.
5. Record the status (ON or OFF) of the DIRTY WINDOW fault lamp on blank 8.
Note: An illuminated dirty window fault lamp indicates that the quantity
of dirt accumulated on transceiver optics has exceeded preset limits.
Such a fault condition can jeopardize the quality of the monitoring data.
6. Record the status (ON or OFF) of the PURGE AIR fault lamp on blank 9.
Note: An illuminated purge air fault lamp indicates that the transceiver
and/or retroreflector purge air flow rate is reduced either because a
blower may not be working properly or one of the purge air filter
elements is dirty, thereby restricting the flow of purge air. This fault
does not preclude the completion of the audit.
7. Record the status (ON or OFF) of the STACK POWER fault lamp on blank 10.
Note: An illuminated stack power fault lamp indicates a lack of power for
the transmissometer. Power must be restored before the audit can
continue.
8. Record the status (ON or OFF) of the LAMP FAILURE fault lamp on 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. However, if the measurement
lamp is replaced the audit should be postponed for several hours to
permit equilibration of the measurement system.
9. Record the status (ON or OFF) of the ALARM fault lamp on Blank 12.
Note: An illuminated alarm fault lamp indicates that the opacity of
the effluent exceeds a value selected by the source. Such a fault
has no effect on the accuracy of the monitoring data or on the
completion of the audit.
5-5
-------
10. Press the GAL 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 illuminated.
11. Record the zero value on Blank 13 displayed on the panel meter.
12. Record the zero value on Blank 14 displayed on the data, recorder.
Note: The cross-stack zero is simulated by the zero reflector segment
of the external chopper. Checking this simulated zero value provides
an indication of the amount of dust on the measurement window and on
the zero retroreflector, as well as an indication of the status of
the electronic alignment of the instrument. It does not, however,
provide any indication of cross-stack parameters.
13. Press the CAL SPAN switch to initiate the span mode.
14. Record the span value on Blank 15 that is displayed on the control
panel meter and record the span value displayed on the data recorder
on Blank 16. Go to the transceiver location.
Note: During the span portion of the calibration cycle, the span
segment of the external chopper is monitored, resulting in an upscale
calibration check. The span measurement provides another check of
the monitor electronic alignment and the linearity of the
transmissometer opacity response.
Retroreflector Dust Accumulation Check
15- Record the instantaneous effluent opacity on blank 17 prior to
cleaning of the retroreflector optics.
16. Open the retroreflector, inspect and clean retroreflector optics, and
close the retroreflector.
17. Record the post cleaning instantaneous effluent opacity on blank 18.
Transceiver Dust Accumulation Check
18. Record the pre-cleaning effluent opacity on blank 19.
19. Open the transceiver, turn off the chopper motor switch, stop the
chopper, clean the primary lens, turn on the chopper monitor switch,
and close the transceiver.
Note: The chopper motor is stopped by turning off the toggle switch
in the lower left corner of the transceiver control panel. This
switch also turns-off the measurement beam.
20. Record on blank 20 the post cleaning instantaneous effluent opacity.
5-6
-------
Optical Alignment Check
21. Determine the monitor alignment by looking through the viewing port
on the back of the transceiver and observing whether the beam image
is in the center of the target cross-hairs.
22. Record whether the image is centered inside the target (YES or NO) on
blank 21.
23. Draw the orientation of the beam image in the circle on the data
form.
Note: Instrument optical alignment has no effect on the internal
checks of the instrument or on the calibration check using the audit
device; however, if the optical alignment is not correct, the stack
opacity data will be biased high, since all the light transmitted to
the retroreflector is not returned to the detector.
CALIBRATION ERROR CHECK
The calibration error check is performed using three neutral density audit
filters and an audit device (or jig) with a built-in retroreflector and iris to
simulate clear stack conditions. The audit device and neutral density filters
actually determine the linearity of the instrument response with respect to the
current clear-stack zero value. This calibration error check does not determine
the actual instrument clear-stack zero, or the status of any cross-stack param-
eters .
A true calibration check is performed by removing the on-stack components
and setting them up in a location with minimal ambient opacity, making sure that
the proper pathlength and alignments are attained, and then placing the
calibration filters in the measurement beam path.
Note: Thermo Electron (Contraves Goerz) supplies an audit jig whose
internal iris setting is fixed for a specific monitor. If the
source has such a dedicated audit device, it should be used in the
audit because its jig zero value has been fixed to correspond to the
given measurement path conditions, and these calibration error
procedures are predicated on this assumption. If such a device is
not available, the auditor should supply a similar device with an
adjustable iris, following the installation of this audit device,
the iris should be adjusted such the jig zero value reads 1-2%
opacity on the opacity data recorder.
24. 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. Care should be taken that the chopper will not
contact the audit jig while in operation. Also do not bend the
chopper blades.
25. Restart the chopper and allow the transceiver 2-3 minutes to
warm-up.
5-7
-------
Note: The jig zero value is based on readings from the data
recorder. The jig zero does not have to be exactly 0.0 since the
audit filter correction equations can account for an offset in the
jig zero. Thus, a jig zero value in the range of 0-2% Op is
typical.
26. Record on Blanks 22, 23, and 24 the audit filter serial numbers and
opacity values.
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 monitor response from the data recorder
requires communication between the auditor at the transmissometer
location and another person at the data recorder location.
29. Insert the low range neutral density filter into the audit jig.
30. 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).
31. Record the monitor's response to the low range neutral density
filter.
32. Remove the low range filter from the audit device and insert the mid
range neutral density filter.
33- Wait approximately two minutes and record the monitor's responses.
3^. Remove the mid range filter from the audit jig and insert the high
range filter, , .._,...
35- Wait for approximately two minutes and record the monitor's
response.
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 checked to determine
the source of the fluctuation, and the 3~filter run should be
repeated.
37- Repeat steps 29-36 above until a total of five opacity readings are
obtained for each neutral density filter.
38. If six-minute integrated opacity data are recorded, repeat steps
29-36 above once more, but change the waiting periods to 13 minutes.
5-8
-------
39- Record the six-minute integrated data.
40. Once the calibration error check is finished, stop the chopper,
remove the audit jig, restart the chopper and close the transceiver
head.
4l. Return to the control unit/data recorder location and obtain a copy
of the audit data from the data recorder.
42. Transcribe the calibration error response data from the data
recorder to Blanks 25 to 50.
5.1.3 THERMO ELECTRON (Contraves Goerz) Model 400 PERFORMANCE AUDIT DATA
INTERPRETATION
This section pertains to the interpretation of the performance audit data
analyses peculiar to the Model 400. The interpretation of the more general
analyses is fully discussed in the introduction of this manual.
Stack Exit Correlation Error Check
The pathlength correction error on Blank 51 should be within +2%. This
error exponentially affects the opacity readings, resulting in over- or under-
estimation of the stack exit opacity. The most common error in computing the
STR is the use of the flange-to-flange distance rather than the stack/duct
inside diameter at the monitor location. This error will result in an under-
estimation of the stack exit opacity and can be identified by comparing the
monitor optical pathlength to the flange-to-flange distance, which should be
the greater by approximately 2-4 feet.
Internal Zero and Span Check
The internal zero should be set to indicate 0% opacity. A zero error
greater than k% opacity is usually due to excessive dust accumulation on the
optical surfaces, electronic drift, or data recorder electronic or mechanical
offset. Instrument span error may be caused by the same problems that cause
zero errors and may be identified in a similar fashion. Also, a span error may
be caused by an inaccurate chopper span segment value.
If the zero and span errors are due to a data recorder offset, both errors
will be in the. same direction and will have the same magnitude. The stack exit
opacity data will be offset in the same manner.
Transmissometer Dust Accumulation Check
The total opacity equivalent to the dust on the transmissometer optical
surfaces should not exceed 4%. A dust accumulation value of more than 4%
opacity may inidicate 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 fairly stable {within +2% opacity) before and after the cleaning of the
optical surfaces. If the effluent opacity is fluctuating more than +2%, the
dust accumulation analysis should be omitted. ~
5-9
-------
Calibration Error Check
Excessive calibration error results (blanks 68, 69, 70) are indicative of a
non-linear calibration and/or a miscalibration of the monitor. However, the
absolute calibration accuracy of the monitor can be determined only when the
clear path zero value is known. If the zero and span are not within the proper
range, the calibration check data will often be biased in the same direction as
the zero and span errors. Even if the zero and span errors are within the
proper ranges, the monitor may still be inaccurate due to possible error in the
clear path zero. The optimum calibration procedure involves using neutral
density filters during clear-stack or off-stack calibration. This procedure
would establish both the absolute calibration accuracy and linearity. If this
procedure is not practical, and if it is reasonable to assume that the clear
path zero is indeed zero, the monitor's calibration linearity can be set using
either neutral density filters or the internal zero and span values.
5-10
-------
SECTION 6
PERFORMANCE AUDIT PROCEDURES FOR THERMO ELECTRON
(ENVIRONMENTAL DATA CORPORATION) OPACITY MONITOR
6.1 THERMO ELECTRON CORPORATION (ENVIRONMENTAL DATA CORPORATION) MODEL 1000A
6.1.1 CEMS Description
The Thermo Electron (formally manufactured by Environmental Data Corpor-
ation or EDC) opacity CEMS consists of three major components: the trans-
missometer, 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 retroreflector unit mounted on the opposite side. The
transceiver unit contains a light source, a photodiode detector, and the opti-
cal, mechanical, and electronic components used in monitor operation and cali-
bration. 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 so that the sig-
nals remain constant. Since the electronic gain compensation affects the zero
and span signals and the measurement signal amplitude equally, all variations
in measurement lamp intensity are concelled out of the measurement signal.
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 the transceiver unit and one for the retrorefleetor
unit; each system has a blower providing filtered air.
The opacity monitor measures the amount of light transmitted through the
effluent from the transceiver to the retroreflector and back again. The
monitor uses this double-pass transmittance to calculate the optical density of
the effluent stream at the monitor location, or the "path" optical density. In
order to provide stack exit opacity data, the path optical density must be
corrected by multiplying by the ratio of the stack exit diameter to the
measurement pathlength. The following equations illustrate the relationships
between this ratio, path optical density, and exit opacity.
where:
OPX = I- i;
OP = stack exit opacity (%)
X
OD = transmissometer optical density (path)
Jx = optical pathlength correction factor
where:
L = stack exit inside diameter (ft)
X
L = measurement pathlength (ft) = two times the
effluent depth at the monitor location
6-1
-------
6.1.2 Performance Audit Procedures
Preliminary Data
1. Obtain the stack exit (inside) diameter and transmissometer
measurement pathlength (two times the stack or duct inside diameter
at monitor location) and record on blanks 1 and 2, respectively, of
the Thermo Electron (EDO) 1000A Performance Audit Data Sheet. If
the monitor uses a slotted tube inside the stack or duct, then the
optical pathlength (Lt) is equal to the length of the slotted
portion of the tube.
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order to reliability: (1)
physical measurements; (2) construction drawings; (3) opacity
monitor installation/certification documents; and (4) source
personnel recollections. The monitor pathlength is two times the
length of the inside diameter of the stack at the monitor
installation location.
2. Calculate the optical pathlength correction factor (divide the value
on blank 1 by the value on blank 2), and record the value on blank 3.
3. Record the source-cited optical pathlength correction factor value
on blank 4.
Note: The optical pathlength correction factor is preset by the
manufacturer using information supplied by the source. The value
recorded in blank 4 should be that which the source personnel agree
should be set inside the monitor. Typically, this value is cited
from monitor installation or certification data, as well as from
service reports.
4. Obtain the present opacity values that the monitor should measure for
the zero and span calibrations and record on blank 5 and blank 6,
respectively.
Note: These values are set during monitor calibration, and therefore
may not be equal to values recorded at installation and/or
certification. Records of the zero and span values resulting from
the most recent monitor calibration should exist.
Monitoring System
This section describes checks to gather the pertinent operating
parameters necessary to ascertain whether the monitoring system is
functioning properly. Since the EDC 1000A does not have a control
unit, the zero and span checks may be performed in the control room,
but only if the source has installed a CAL-INITIATE button.
Otherwise, this check must be performed at the monitoring site.
5. Inspect the opacity data recorder (strip chart or computer) to
ensure proper operation. Annotate the data record with the
auditor's name, plant, unit, date, and time.
6-2
-------
6. If the source has installed a switch to initiate the internal zero
and span functions, initiate the zero and span cycle mode by
pressing this CAL-INITIATE button.
Note: The monitor will remain in the zero mode for approximately
three minutes, after which the span mode will be automatically
initiated. After an additional three minutes, the monitor will
automatically return to normal operation. The cross-stack zero is
simulated by using the zero mirror in the transceiver. The zero and
span checks provide an indication of the status of the electronic
alignment of the instrument. They do not, however, indicate optical
misalignment, or the true cross-stack zero.
?. Record the zero and span responses on blanks 7 and 8, respectively,
that are displayed on the chart recorder.
8. If there is no CAL-INITIATE button in the control room, locate the
MODE switch on the front of the transceiver, next to the
input/output cable.
9. Move the MODE switch to the up position (ZERO).
10. Allow the monitor to operate at least three minutes (thirteen
minutes if the monitoring system processes the data through a
six-minute averaging circuit) for the chart recorder to log the zero
response.
11. Move the MODE switch to the down position (SPAN).
12. Wait another three or thirteen 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 zero and span responses on blanks 7 a and £, respective!; ,
that are displayed on the data recorder. ~
Retroreflector Dust Accumulation Check
15. Record the instantaneous effluent opacity prior to cleaning of the
retroreflector optics on blank 10.
16. Pull up and clean the window that separates the retroreflector from
the stack.
17. Record the post cleaning instantaneous effluent opacity on blank 11.
Transceiver Dust Accumulation Check
18. Record the pre-cleaning effluent opacity on blank 12.
19- Pull up and clean the window that separates the light source from
the stack.
20. Record on blank 13 the post cleaning instantaneous effluent opacity.
6-3
-------
CALIBRATION ERROR CHECK
The calibration error check is performed by installing an EDC filter
holder assembly (P/N 32269) in front of the corner cube retroreflector and then
securing the filter holder assembly by means of two Allen head screws. The
neutral density filter slides (mounted in EDC filter housings) are then placed
into the filter holder assembly in the order described below. This check
should be performed only when the stack opacity is fairly steady. The
calibration check provides a determination of the linearity of the instrument
response and utilizes all of the components of the measurement system. This
calibration check does not provide a test of the actual instrument zero.
A true calibration check is performed by removing the on-stack components
and setting them up in a location with minimal ambient opacity, making sure
that the proper pathlength and alignments are attained, and then placing the
calibration filters in the measurement beam path.
21. Record the audit filter serial numbers and opacity values on
blanks l4. 15. and 16.
22. Remove the low range filter from its protective cover, inspect, and
clean it, if necessary.
23. Wait approximately two minutes and record the effluent opacity as
indicated by the opacity data recorder.
24. Insert the low range neutral density filter.
25. Wait approximately two minutes and record the opacity value
indicated on the opacity data recorder.
26. Remove the low range audit filter, wait approximately two minutes,
and record the indicated effluent opacity value.
27. Remove the mid range filter from its protective cover, inspect, and
if necessary clean it.
28. Insert the mid range audit filter.
29. Wait approximately two minutes and record the indicated opacity value
30.
Remove the mid range filter, wait approximatley two minutes and recoi
the indicated 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 indicated opacity.
34. Remove the high range filter.
35. Wait approximately two minutes and record the indicated effluent
opacity.
6-4
-------
Monitor Response Repeatability
36. Repeat the procedures steps 24 through 35 until a total of five
opacity readings is obtained for each neutral density filter.
37- If six-minute integrated opacity data are recorded, repeat steps 24
through 35 once more, changing the waiting periods to 13 minutes.
38. Record the six-minute integrated data, if available.
39- Remove the filter holder and secure the retroreflector. Return to the
control unit location.
40. Obtain a copy of the audit data from the opacity data recorder.
4l. Transcribe the calibration error response data from the opacity data
recorder to audit data sheet blanks 17 and 5^. and complete the audit
data calculations.
6.1.3 EDO 1000A PERFORMANCE AUDIT DATA INTERPRETATION
This section pertains to the interpretation of the performance audit data
analyses peculiar to the 1000A. The interpretation of .the more general analyses
is fully discussed in the introduction of this manual.
Stack Exit Correlation Error Check
The pathlength correction error on blank 88 should be within +2%, This
error expontentially affects the opacity readings, resulting in over or
underestimation of the stack exit opacity. The most common error in computing
the optical pathlength correction factor is the use of the flange-to-flange
distance rather than the stack/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 pathlength to the flange-to-flange
distance, which should be the greater by approximately 2-4 feet.
Internal Zero and Span Check
The 1000A internal zero 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 or mechanical
offset. Instrument span error may be caused by the same problems that cause zero
errors and may be identified in a similar fashion. Also, a span error may be
caused by an inaccurate span filter value.
If the zero and span errors are due to a data recorder offset, both errors
will be in the same direction and will have the same magnitude. The opacity data
will be offset in the same manner.
Transmissometer Dust Accumulation Check
The total opacity equivalent to the dust on the transmissometer optical
surfaces (blank 93) 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
6-5
-------
is fairly stable (within +_2% opacity) before and after the cleaning of the
optical surfaces. If the effluent opacity is fluctuating more than +2%, the dust.|
accumulation analysis should be omitted.
Calibration Error Check
The comparison of monitor responses to the opacity values of the neutral
density filters requires that the filter values be corrected to stack exit
conditions and that any zero offset be factored into the corrected filter value.
Excessive calibration error results (blanks 82. 83. and 84) are indicative
of a non-linear calibration and/or a miscalibration of the monitor. However, thel
absolute calibration accuracy of the monitor can be determined only when the
clear path zero value is known. If the zero and span are not within the proper
range, the calibration check data will often be biased in the same direction as
the zero and span errors. Even if the zero and span errors are within the propei:
ranges, the monitor may still be accurate due to possible error in the clear pat"
zero. The optimum calibration procedure involves using neutral density filters
during clear-stack or off-stack calibration. This procedure would establish both
the absolute calibration accuracy and linearity. If this procedure is not
practical, and if it is reasonable to assume that the clear path zero is indeed
zero, the monitor's calibration linearity can be set using either neutral density
filters or the internal zero and span values.
6-6
-------
SECTION 7
PERFORMANCE AUDIT PROCEDURES FOR ENVIROPLAN
(THERMO ELECTRON CORPORATION) OPACITY MONITOR
7.1 ENVIROPLAN (THERMO ELECTRON CORPORATION) MODEL D-R280 AV "DURAG"
7.1.1 GEMS Description
The Enviroplan (formally distributed by Thermo Electron) D-280 AV opacity
monitor system consists of four major components: the transmissometer, the
on-stack control unit, the air-purging system, and the remote control unit and
data acquisition equipment. (The most recent version of this monitor is the
Enviroplan Model CEMOP-281; this system is the same as the D-R280, except that
the remote control unit has digital readouts). 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 a light source, a photodiode detector, and
their associated electronics. The on-stack control unit provides a readout of
the milliamp signal from the transceiver and initiates the internal zero and
span checks. Figure J-l illustrates the general arrangement of the
transmissometer transceiver, on-stack control unit, and retroreflector units on
the stack. The transceiver uses a single-lamp, single-detector system to
determine stack opacity. A chopper, located inside the optical compartment,
modulates the light beam to eliminate interference from ambient light. The
modulated beam is alternated between reference and measurement states so that
optical and electronic fluctuations are cancelled out.
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 unit; one
blower providing filtered air.
The remote control unit (Figure 7~2) converts the nonlinear transmittance
output from the tranceiver (a milliamp signal) into linear opacity. It also
corrects the opacity measurement according to the ratio of the stack exit
diameter to the transmissometer pathlength.
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 stream at the monitor location, or the "path" optical
density. In order to provide stack exit opacity data, the path optical density
must be corrected by multiplying by the ratio of the stack exit diameter to the
measurement pathlength. This ratio is called the "optical pathlength
correction factor." The following equations illustrate the relationships
between this ratio, path optical density, and exit opacity.
where:
OP = i - io-
X
OP = stack exit opacity
OD = transmissometer optical density (path)
7-1
-------
o;
VA
5=
s s«
I
*!p°
+j« 3*K
c
::2I
7-2
-------
UJ
o
ca
i
7-3
-------
L
x
Lt
where:
= optical pathlength correction factor
L = stack exit inside diameter (ft)
X
Jt
measurement pathlength (ft) = the
effluent depth at the monitor location
7.1.2 Performance Audit Procedures
Preliminary Data
1. Obtain the stack exit (inside) diameter and transmissometer
measurement pathlength (equal to the stack or duct inside diameter
or width at the monitor location) and record on blanks 1 and 2,
respectively, of the Enviroplan D-R280 AV Performance Audit Data
Sheet,
Note: Effluent handling system dimensions may be acquired from the
following sources listed in descending order to reliability: (1)
physical measurements; (2) construction drawings; (3) opacity
monitor installation/certification documents; and (4) source
personnel recollections.
2.
3.
Calculate the optical pathlength correction factor, (divide the
value on blank 1 by the value on blank 2), and record the value on
blank 3-
Record the source-cited optical pathlength correction factor value
on blank 4.
Note: The optical pathlength correction factor is preset by the
manufacturer using information supplied by the source. The value
recorded in blank 4 should be that which the source personnel agree
Typically, this value is cited
as well as from
should be set inside the monitor.
from monitor installation or certification data,
service reports.
4.
Obtain the present values that the monitor should measure for the
zero and span calibrations and record on blank 5 and blank 6,
respectively.
Note: These values are set during monitor calibration, and therefore
may not be equal to values recorded at installation and/or
certification. Records of the zero and span values resulting from
the most recent monitor calibration should exist.
Control Unit Checks
5. Inspect; the opacity data recorder (strip chart or computer) to
ensure proper operation. Annotate the data record with the
auditor's name, plant, unit, date, and time.
Fault Lamp Checks
The following list describes the fault lamps that are found on the
Enviroplan (Thermo Electron) transmissometer remote control unit front panel.
7-4
-------
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 BLOWER FAILURE fault lamp on
blank 7.
Note: An illuminated BLOWER FAILURE fault lamp indicates no power to the
transceiver or to purge air blowers. If this condition exists, the
audit should be halted and the source should be notified immediately,
since the monitor may be damaged by the stack gases.
7. Record the status (ON or OFF) of the FILTER BLOCK fault lamp on blank 8.
Note: The FILTER BLOCK fault lamp indicates inadequate purge airflow to
maintain optical surface cleanliness. If the FILTER BLOCK fault lamp is
illuminated, the purge air filter element may be dirty or a crimped hose
may be restricting the airflow. Plant personnel should be informed if
this lamp is on so corrective measures can be initiated at the
conclusion of the audit. (This fault lamp is not an indicator of dirt
on the measurement window.)
8. Record the status (ON or OFF) of the WINDOW fault lamp on blank 9.
Note: An illuminated WINDOW fault lamp indicates that the opacity of the
measurement window exceeds the preset limit of 3% opacity. When the
dirty window limit has been exceeded, the opacity data may be biased.
This lamp indicates a need to clean the dirty window surfaces; however,
it only monitors the transceiver window.
Control Unit Adjustment Checks
9. Check the opacity range switch indicator located on the remote control
panel above the ACK/CENTRAL ALARM lamp (see Figure 7-2) to determine the
range selected.
10. Record the range on blank 10.
11. Set the opacity range switch to range "4".
Reference Signal, Zero and Span Checks
12. Initiate the calibration cycle by pushing the CALIBR button on the
control panel.
Note: The green CALIBR lamp will light, and the monitor will
automatically cycle through the internal and external zero and span
modes.
13. Record the internal zero millamp value on blank 11 displayed on the
control panel.
Note: The internal zero simply checks the reference beam inside the
tranceiver and provides a check of the electronic alignment of the
instrument. After two minutes in the internal zero mode, the monitor
will automatically switch to the external zero mode.
7-5
-------
Record the external zero value displayed on the panel meter on blank 12a
and the zero value displayed on the opacity data recorder on blank 12b.
Note: The external zero is simulated by using the zero reflector. The
external zero value displayed on the panel meter provides an indication
of the amount of dust on the transceiver measurement window. The
external zero value displayed on the opacity data recorder is the
monitor zero after compensation for dust accumulation on the transceiver
optics. Neither the panel meter nor data recorder external zero values
provide an indication of dirty window conditions at the measurement
retroref lector, of optical misalignment, or of the true cross-stack
zero. After two minutes in the external zero mode, the monitpr cycles
into the internal span function; the milliamp signal on the control unit
corresponds to the span opacity value.
15. Record the span milliamp value on blank 13 displayed on the control
panel meter, the span percent opacity value on blank
data recorder. Go to the transmissometer location.
displayed on the
Note: The transceiver automatically spans the monitor using the span
filter and the external zero reflector. The span measurement provides
another check of the electrical alignment and the linearity of the
transmissometer response to opacity.
After the completion of the zero and span calibration cycle, the monitor
will automatically return to the stack opacity measurement mode.
Retroref lector Dust Accumulation Check
16. Record the instantaneous effluent opacity prior to cleaning the
retroreflector optics on blank blank 15.
17- Open the transceiver housing, inspect and clean retroreflector optics,
and close the housing.
18. Record the post cleaning instantaneous effluent opacity on blank 16.
Transceiver Dust Accumulation Check
19. Record the pre-cleaning effluent opacity on blank 17.
20. Open the transceiver head, clean the optics (primary lens and zero
mirror) , and close the transceiver head.
21. Record the post-cleaning instantaneous effluent opacity on blank 18.
Alignment Check
22. Determine the monitor alignment by looking through the bull's eye on the
side of the transceiver (Figure 7~3) •
23. Observe whether the images are centered on either side of the cross
hairs and record this information (YES or NO) on blank 19.
7-6
-------
7-7
-------
Note: There are two types of retroreflectors used for the monitor, and
the resulting alignment images are different, as indicated in Figure
7-4. Instrument optical alignment has no affect on the internal checks
of the instrument or the calibration error determination; however, if
the instrument is misaligned, the opacity data will be biased high,
since all the light transmitted to the retroreflector is not returned to
the detector.
Span Filter Check
24. Record the span filter milliamp value on blank 20 and the span filter
opacity value on blank 21, both supplied by the monitor manufacturer.
Note: The span values are recorded on the Instrument Data Sheet supplied
with the monitor. If the manufacturer did not supply the source with
the opacity value of the internal span, the following equation should be
used to compute the span opacity value.
(Blank 21) = 6.25 [(Blank 20) - 4.0]
CALIBRATION ERROR CHECK
The calibration error check is performed using three neutral density audit
filters and an audit device (or jig) with an adjustable retroreflector iris to
simulate clear stack conditions. The audit device and neutral density filters
actually determine the linearity of the instrument response with respect to the
current clear-stack zero value. This calibration error check does not
determine the actual instrument clear-stack zero, or the status of any
cross-stack parameters.
A true calibration check is performed by removing the on~stack components
and setting them up in a location with minimal ambient opacity, making sure
that the proper pathlength and alignments are attained, and then placing the
calibration filters in the measurement beam path.
25. Install the audit jig.
26. Adjust the audit jig iris to produce a 4 mA output current on the
junction box meter (see Figure 7~4) to simulate the amount of light
returned to the transceiver during clear stack conditions.
Note: This allows the auditor to get the jig 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 0.0$ opacity since the audit filter
correction equations can account for an offset in the jig zero.
Thus, a jig zero value in the range of 0-2% Op is usually
acceptable.
27. Record the audit filter serial numbers and opacity values on blanks 22,
23, and 24.
28. Remove the filters from their protective covers, inspect, and if
necessary, clean them.
7-8
-------
TRANSCEIVER
CABLE CONNECTOR
window check
I
ealibr
(&7«F(aT«yS$s4*3E
POWER
FUSE
JUNCTION
TERMINAL
OUTPUT
METER
CALIBRATION
INDICATOR
CHECK/OUTPUT
METER SWITCH
ni
Figure 7-4. Enviroplan (Thermo Electron) Model D-R280 AV
7-9
-------
29. Record the jig zero value from the data recorder on blank 21a.
Note: The acquisition of monitor response from the data recorder
requires communication between the auditor at the transmissometer
location and another person at the data recorder location.
30. Insert the low range neutral density filter into the audit jig.
31. 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).
32. Record the monitor's response to the low range neutral density filter.
33' Remove the low range filter from the audit jig and insert the mid range
neutral density filter.
3^. Wait for approximately two minutes and record the monitor's responses.
35- Remove the mid range filter from the audit jig and insert the high range
filter.
36. Wait for approximately two minutes and record the monitor's response.
37« Remove the high range filter, wait for 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.
38. Repeat steps 30-37 above until a total of five opacity readings are
obtained for each neutral density filter.
39• If six-minute integrated opacity data are recorded, repeat steps 30-37
above once more, but change the waiting periods to 13 minutes.
40. Record the six-minute integrated data.
Note: In order to acquire six-minute averaged opacity data, each filter
must remain in the jig for at least two consecutive six-minute periods.
the first period is invalid because it was in progress when the filter
was inserted. Only at he conclusion of two successive six-minute
integration periods can the monitor's response be recorded.
fyl. Once the calibration error check is finished, remove the audit jig, and
close the transceiver head and the weather cover.
7-10
-------
42.
Final Control Unit Adjustment Reset
Return to the control unit location and reset the opacity range switch
to its original position (Blank 10) , if necessary.
43.
44.
. Obtain a copy of the audit data from the data recorder.
Transcribe the calibration error response data from the data recorder to
data form blanks 25 to 50. and complete the audit data calculations.
7-1.3 ENVIRQPLAN (THERMO ELECTRON) D-R280 AV INTERPRETATION OF AUDIT RESULTS
This section pertains to the interpretation of the performance audit
analyses peculiar to the D-R280AV. The interpretation of the more general
analyses is fully discussed in the introduction of this manual.
Stack Exit Correlation Error Check
The pathlength correction error on blanks 51 should be within +2% This
error expontentially affects the opacity readings, resulting in over- or
under-estimation of the stack exit opacity. The most common error in computing
the optical pathlength correction factor is the use of the flange-to-flangT
distance rather than the stack/duct inside diameter at the monitor location.
This error will result in an under-estimation of the stack exit opacity and can
be identified by comparing the monitor optical pathlength to the ?langLS-
flange distance, which should be the greater by approximately 2-4 feet.
Control Panel Meter Error (Optional)
The accuracy of the control panel meter is important at sources using the
meter during monitor adjustment and calibration. In such cases, the control
panel meter opacity readings are compared to the specified values for the
a?SrihZer° ^ T1 f±lter- Err°rS ±n thS C°ntro1 P**161 meter should not
™S? ^ °PaClty,,data ^ported by the monitoring system unless the control
panel meter is used to adjust the zero and span functions. At sources using
les/SS; pf &\ ' .KhS Panel mSter Sh°Uld be adj'USted so that ^e error fs
less than 2/.. Since the control panel meter error is determined by using; the
span filter, any change in the specified values for the span filte? wiS 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
anTu^f ?f r 6 °Pt^al denSlty ^ °UtpUt current should be ^corded
and used in all subsequent adjustments.
Internal Zero and Span Check
The D-R280 AV internal zero should be set to indicate 0% opacity
(equivalent to 3-7 - 4.3mA). A zero error greater than H% opacity is usually
due to excessive dust accumulation on the optical surfaces, electronic drift
or data recorder electronic or mechanical offset. Excessive dust on the
optical surfaces sufficient to cause a significant zero error also would be
indicated by the difference in the internal and external zero values
Instrument span error may be caused by the same problems that cause zero errors
7-11
-------
and may be identified in a similar fashion.
by an inaccurate span filter value.
Also, a span error may be caused
If the zero and span errors are due to a data recorder offset, both errors
will be in the same direction and will have the same magnitude. The opacity
data will be offset in the same manner.
The external zero displayed on the control unit panel meter is an
indication of the dust deposition upon the zero retroreflector and transceiver
measurement window, and thus, the external zero response (blank 12a), converted
to percent opacity, should equal the amount of dust found on the transceiver
optics (blank 57)• To convert the panel meter mA response to percent opacity,
use the following equation:
Meter response in % opacity =6.25 [(Blank 12a) - (Blank 11)]
If the monitor's internal zero response (blank 11) is within the
recommended range (3-7 mA to 4.3 ma mA), the accuracy to the monitor's external
zero function can be checked through the use of the dust accumulation analysis
results.
Transmissometer Dust Accumulation Check
The total opacity equivalent to the dust on the transmissometer optical
surfaces (blank 58) should not exceed 4$. A dust accumulation value of more
than k% 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 fairly stable (within +2% opacity) before and after the
cleaning of the optical surfaces. If the effluent opacity is fluctuating more
than +2%t the dust accumulation analysis should be omitted.
Calibration Error Check
The comparison of monitor responses to the opacity values of the neutral
density filters requires that the filter values be corrected to stack exit
conditions and that any zero offset be factored into the corrected filter
value.
Excessive calibration error results (blanks 68, 69, and 70) are indicative
of a non-linear calibration and/or a miscalibration of the monitor. However,
the absolute calibration accuracy of the monitor can be determined only when
the clear path zero value is known. If the zero and span are not within the
proper range, the calibration check data will often be biased in the same
direction as the zero and span errors. Even if the zero and span errors are
within the proper ranges, the monitor may still be inaccurate due to possible
error in the clear path zero. The optimum calibration procedure involves using
neutral density filters during clear-stack or off-stack calibration. This
procedure would establish both the absolute calibration accuracy and
linearity. If this procedure is not practical, and if it is reasonable to
assume that the clear path zero is indeed zero, the monitor's calibration
linearity can be set using either neutral density filters or the internal zero
and span values.
7-12
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SECTION 8
PERFORMANCE AUDIT PROCEDURES FOR OPACITY GEMS WITH COMBINERS
The audit procedures described in the previous sections of this manual
presume that the opacity CEMS includes only a single transmissometer which is
installed to view the total emissions from a source. However, at many sources,
the CEMS 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 divided evenly,
routed through twin preheaters, twin ESPs, twin I.D. fans, and subsequently
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 transmissometers for
maintenance and quality assurance activities.
Opacity CEMS'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 duct opacity-measurements
provided by the transmissometers. These devices are typically referred to as
"combiners." The combiner device may a separate device or may incorporate some
or all of the functions normally associated with the monitor control unit.
Performance audits of opacity CEMS'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 7 of this manual.
This Section describes a generic approach for conducting audits of opacity
CEMS'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 (2) the
accuracy of the stack-exit opacity values recorded by the CEMS. To accomplish
this, the auditor must first conduct evaluations of each of the individual
transmissometers using standard audit procedures with minor procedural
modifications to accomodate equipment differences between combiner and single
transmissometer monitoring systems. After the audits of the individual
transmissometers are completed, the accuracy of the combiner system is
determined using either a one-point or a multi-point audit technique, depending
on the type of monitoring system.
8.1 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.
Therefore, several 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
recognized that the various methods for calculating the stack-exit opacity
involve sope assumptions which are not necessarily accurate under all
8-1
-------
conditions. However, the calculation method that is selected, should be
consistent with the design and implementation of the opacity monitoring program
at the facility which is being audited.
The general relationship between multiple duct mounted transmissometer
measurements and stack-exit opacity values is most conveniently expressed in
units of optical density. (Conversions between opacity and optical density
values 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 (8-1):
N
WE
LE
where:
V.A.K. L
111 2L±
(8-1)
V ~ average velocity at measured location or stack-exit
A s cross-sectional area at measurement location or stack-exit
K = idealized constant relating optical density to mass concentration
OD = optical density (single pass)
subscripts:
L = measurement pathlength (e.g., internal duct dimension or stack exit
internal diameter)
E = stack-exit location
i = transmissometer locations; 1.2...N
In practice, the value of the idealized constant "K" cannot be determined, a
function of particle size distribution and other aerosol characteristics.
Therefore, it is generally assumed that for any instant in time, the aerosol
characteristics are constant between the monitoring locations and the stack,
and are the same for all monitoring locations (i.e., Kg = K^ = PL, = K^). Thus,
this factor is eliminated from the general equation.
Additional simplifications of the general equation are usually apparent
where the duct monitoring locations are geometrically similar. This is most
often the case where twin ducts/monitoring locations are simply mirror images
of each other. For the case of two monitoring locations with identical duct
cross sections (i.e.,
becomes:
= L and A.. = A0= A). The general equation
(8-2)
2L VEAE
For most multiple-transmissometer/combiner applications, incompressible
flow may reasonably be assumed (i.e., constant temperature, pressure, and
quality) between the various.measurement and stack-exit locations). Assuming
8-2
-------
incompressible flow and that there is no significant air inleakage, bypass
flow, etc., then continuity requires:
VEAE = A
Thus:
(8-3)
L°D! + V2OD2)
(8-4)
In most cases, measurement of the velocity or volumetric flow rate at the
transmissometer installation locations is not attempted. If the flow rates can
be assumed to be equal in both ducts {i.e., V. = V?), Equation (8-4) can be
simplified to the most commonly used form:
LE (ODl * QD2)
. (8-5)
A filter inserted in the light path at the monitoring location attenuates
the light beam twice in a double pass transmissometer; thus:
°DN ' 2 °DFN
(8-6)
where:
= single pass optical density of the filter inserted at the N
monitoring location
Thus:
ODE=_E_ (ODpl+ODF2)
(8-7)
For Lear Siegler monitors, the factor L /2L is referred to as the "OPLR,", and
for Dynatron monitors this same term is referred to as the "M factor." For
TECO monitors (formally Contraves-Goerz monitors), the term L /L is referred to
as the "STR." These terms are useful for modifying the above equations to be
consistent with the manufacturer's technology.
Equations (8-2), (8-4), and (8-5) may be used to calculate the optical
density at the stack-exit based on the optical density seen by the multiple
transmissometers under the conditions described above. Equation (8-?) 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 form of the equation which is selected should provide for calculation
of the equivalent optical density at the stack-exit as a function of the
8-3
-------
optical density at each monitoring location. The optical density values may be
easily converted to units of opacity as follows:
Opacity., * 1 - 10~ODE
Ei
(8-8)
Conversely, if the opacity values at the monitoring location are known, the
optical density values can be calculated as follows:
ODr
(l-Opacity)
(8-9)
The calculated stack-exit opacity values can be compared to the actual GEMS
responses as described in the single- and multi-point checks described in
Section 8.2.
8.2 GENERAL AUDIT PROCEDURES
8.2.1 Audit Procedures for Individual Duct Transmissometers
Performance audits of each duct-mounted transmissometer must be conducted
using the standard audit procedures for single transmissometer opacity GEMS'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 audit procedures may be necessary in order to
isolate the individual monitors and obtain access to the appropriate signals
and responses. The auditor may need to refer to the operator's manual or seek
assistance from source personnel familiar with the opacity GEMS 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 4l duct-mounted transmissometers are described here. However, the reader is
cautioned that these procedures are not necessarily applicable to other opacity
OEMS with combiners. The analog combiner also serves as the control unit for
both transmissometers and contains several features not included on the typical
RM 4l 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
(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.
In order for the measurements necessary for the audit to be obtained, the
above switches must be positioned correctly. The most important considerations
are as follow:
8-4
-------
* 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 when the
analyzer switch is positioned for the monitor causing the problem.
• Measurements of reference current, zero compensation, or input current
are obtained by placing the measurement select switch in the proper
position {same procedure as used for single RM4l applications). The
analyzer switch must be placed in the position corresponding to the
individual monitor for which these measurements are desired.
Measurements of test functions (e.g., reference current, zero
compensation, or input current) are not meaningful if the analyzer
switch is left in the "exit" position.
• In order for stack-exit opacity measurements to be obtained from the
panel meter, the analyzer switch must be placed in the "exit" position.
To obtain the combined stack-exit opacity, both the A- and B-side
monitors must remain in service. To obtain the stack-exit opacity for
either the A- or B-side monitors independently, the alternate monitor
must be removed from service. When either monitor is removed from
service, the information recorded on the strip chart represents the
independent stack-exit opacity for the monitor remaining in service.
For all opacity CEMS's with combiners, the zero and span errors (and the
opacity scale factor, if applicable) can usually be determined for either
transmissometer independently or for the combined measurement system. Source
personnel will usually evaluate the day to day operation of the GEMS by
observing the combined system calibration, and will check the calibration of
each monitor individually when excessive drift and/or other problems are
indicated. Although a check of the zero and span errors for each
transmissometer provides the best information for comparison with the
calibration error test results, the results of a combined system calibration
provide an adequate assessment of performance when the total zero or span drift
is small. It is extremely unlikely that a major zero or span shift in one
monitor would be completely offset by an opposite and equal shift in the other
monitor. Thus, it is very unlikely that a correct value for the combined
system calibration would disguise problems with either or both monitors. It is
recommended that the auditor (1) perform the zero and span error determinations
for the combined system, and (2) perform additional zero and span error checks
for each transmissometer when the errors observed for the combined system
calibration exceed +_ 1% opacity.
8.2.2 Audit Procedures for Combiner Stack-Exit Opacity Values
After evaluating the performance of each of the individual transmissometers,
the auditor must evaluate the accuracy of the combiner stack-exit opacity
values. Two approaches are described below: the single-point check and the
multi-point check methods. For computerized data acquisition systems, the
single-point check is sufficient to detect programming errors. The single-
point check may also be used for "screening checks" of analog systems; if
problems are indicated, a multi-point check can be performed. The multi-point
check should be used to evaluate the performance of analog combiner systems
over the full range of operating conditions.
8-5
-------
(1) Single-Point Check - The single-point check is the simplest method of
checking the operations of the combiner device. The procedure requires
only that the auditor (1) determine the outputs of all of the
duct-mounted transmissometers for any convenient time period (e.g.,
simultaneous instantaneous measurements or six-minute averages); (2)
calculate the "expected" stack-exit opacity values using the
appropriate equations in Section 8.1; and (3) compare the expected
values to the opacity values indicated by the GEMS permanent data
recorder. The combiner responses and expected values should agree
within _+ 3 percent opacity. (If periods with varying opacity levels
are available, the single-point check procedure may be repeated to
provide a multi-point evaluation of the combiner operation.)
(2) Multi-Point Check - For an opacity CEMS with two duct-mounted
transmissometers, the multi-point check requires the use of two audit
devices and two sets of audit filters. Additional audit devices and
filter sets are needed if the opacity CEMS includes more than two
transmissometers; however, the multi-point check method becomes overly
cumbersome in such situations. In order to conduct the test in a
practical manner, the assistance of several people is necessary.
Typically, one person at each monitoring location and one person at the
combiner location are needed.
The multi-point check procedure involves: (1) installation of audit
devices on both transceivers, (2) adjustment of the audit device irises
to obtain the correct zero response for each monitor independently, (3)
placing various combinations of audit filters in the two monitors to
simulate varying opacity levels at the two monitoring locations, (4)
calculation of the "expected" stack exit opacity for each combination
of filters using the equations in Section 8.1 above, and (5) comparing
the calculated "expected" values to the actual combined stack exit
opacity values provided by the opacity CEMS. An example of the data
and results of such an audit is shown in Table 8-1. As shown in Table
8-1, a multi-point check of a combiner with two transmissometers
involves 16 sets of measurements since zero, low-, mid-, and high-range
filters are used at each monitoring location. Therefore, it is
important that instantaneous or 1-minute averages of the combiner
responses be obtained for the multi-point check. Again, the combiner
responses and the corresponding expected values should agree within +_ 3
percent opacity.
8-6
-------
SECTION 9
ZERO ALIGNMENT CHECKS
The zero alignment of an opacity CEMS is the relationship of the opacity
GEMS response to the clear path condition (i.e., zero opacity) relative to its
response to the simulated zero condition (or low range calibration check) used
for the daily zero/span checks of the CEMS calibration. The zero alignment is
important because the accuracy of the CEMS calibration is based directly on
this relationship. The zero alignment cannot normally be verified during a
performance audit. Therefore, the calibration error check included in the
audit assumes that the response to the simulated zero condition is accurate.
Generic procedures for conducting zero alignment checks are described in
this Section because of the importance of this factor. However, because of
practical constraints and the amount of time required to perform the zero
alignment, this check is not included as a performance audit procedure.
Several approaches for conducting zero alignment checks are presented in the
following subsections.
9,1 OFF-STACK ZERO ALIGNMENT
Performance Specification 1 of 40 CFR 60 requires that an off-stack zero
alignment be performed prior to installing the transmissometer at the
monitoring location. The procedures for conducting this check are described
briefly in "7.1.1, Equipment Preparation." In short, the procedures require
that the transmitter and receiver (single pass systems) or transceiver and
reflector (double pass systems) be set up in a laboratory or other opacity-free
environment at the same separation distance as when the same components are
installed at the monitoring location. It is emphasized that the separation
distance is the flange-to-flange distance or the actual distance between
optical components, rather than the duct or stack internal diameter at the
monitoring location. After establishing the proper separation distance, the
optical alignment is optimized, the pathlength correction factor is set, and
necessary zero and span adjustments are made to assure proper calibration of
the system. Following the successful completion of these steps, the zero
alignment is performed by balancing the response of the CEMS so that the
simulated zero check coincides with the actual clear path check performed
across the temporary monitor pathlength.
The off-stack zero alignment check can be repeated after the CEMS has been
installed and operating for some time; however, this approach is inherently
very cumbersome and time consuming. Typically, the transceiver must be
electrically disconnected 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, as well
as test stands, must be fabricated or obtained to allow the various components
to be electrically reconnected and set-up at the test location. Reasonable
precautions must be taken to ensure that ambient dust levels and other
potential interferents are minimized at the test location while the tests are
performed.
After the off-stack zero alignment is completed, each of the opacity CEMS
components must be electrically disconnected, transported to its normal
location, mechanically reinstalled, and electrically reconnected. The optical
9-1
-------
alignment of the transceiver and reflector components must also be
reestablished or at least verified to complete the procedure. All of the above
activities must be performed with extraordinary care in order 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
personnel believe that the likelihood of such problems are much greater than
the likelihood that the zero alignment has shifted, and are therefore extremely
hesitant to attempt off-stack zero alignment checks.
9.2 ON-STACK ZERO ALIGNMENT
Performance Specification 1 recognizes the difficulties and problems
associated with the off-stack zero alignment approach; "7.2.1, Optical and Zero
Alignment" requires that the optical 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 when the opacity GEMS is installed, Performance
Specification 1 requires that the zero alignment be verified the first time a
clear stack condition is obtained after the operational test period is
completed.
The on-stack zero alignment approach avoids virtually all of the problems
associated with the off-stack procedure. However, the on-stack procedure
requires that clear stack conditions be present in order to accomplish the zero
alignment procedure. Two major problems are commonly encountered. First, some
sources, such as major base-loaded electric utility steam generating units,
operate nearly continuously with very infrequent outages. These units may
operate continuously except for emergency outages and a one or two week annual
maintenance outage per year. For such units, the maintenance and repair
activities that must be performed for the boiler and control equipment during
the infrequent outages require substantial overtime work by the same personnel
who typically service and calibrate the monitoring equipment. Therefore, it is
unlikely that the zero alignment of the opacity GEMS can be performed at such
sources. The problem is further complicated where there are several generating
units served by a common exhaust stack with a single opacity monitor since it
is less likely that all units will be off-line simultaneously.
The second problem associated with the on-stack zero alignment procedure
relates to the presence of residual opacity when the source is not operating.
At many sources, clear stack conditions do not occur at the monitoring location
when the facility is not in operation. Residual opacity may exist because of
(1) boiler, air heater, ESP, or duct maintenance being conducted with the fans
running at a low rate to protect personnel, (2) fan operation or natural draft
conditions resulting in aspirated material remaining in the ducts, stack, or
control equipment for long periods after the facility is off-line, or (3) rain
or other precipitation entering the stack. For many sources, residual effluent
opacities are greater than the opacity observed during operation since the
control equipment is not operated during unit outages.
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 opacity GEMS's, this
9-2
-------
error will bias all subsequent opacity measurements low by the amount of the
residual opacity. 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 opacity GEMS be examined to determine whether fluctuations from zero
opacity are occurring before a clear path condition is assumed to exist.
Visible emission observations should 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. The on-
stack zero alignment procedures should not be performed during periods of
precipitation for stack-mounted transmissometers.
Finally, if an on-stack zero alignment 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.
9.3 ALTERNATE ZERO ALIGNMENT APPROACHES
Alternate approaches for conducting zero alignment checks are available for
some opacity CEMS. The applicability of these procedures depends on certain
monitor- and source-specific constraints.
For certain TECO monitors (DIGI 1400, formally manufactured by Environ-
mental Data Corporation) that combine the opacity CEMS with the S00, NO and
C02 monitoring channels and which also include a "zero-pipe," the zero x>
alxgnment 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 simple approach is often available for other opacity CEMS's which
allow access for cleaning of the transceiver and reflector windows through a
hinged support.system. Monitors which utilize this design include LSI Models
RM-4 and RM-41, TECO Model 400 (formally manufactured by Contraves Goerz) and
Enviroplan Model 280 AV (formally distributed by TECO). For many applications
of these types of opacity CEMS's, zero alignment checks can be performed at the
monitoring location without electrically disconnecting the transceiver. The
following basic procedures are followed where this approach is applicable.
(1) The transceiver is opened as if to clean 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.
9-3
-------
(4) The reflector is mounted on the test stand at the appropriate
separation distance from the transceiver, as shown in Figure 9-1 •
(This is most easily accomplished by use of a zero alignment jig which
maintains the correct separation distance and prevents interference
from ambient dust or precipitation. It is most 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 ins truetions.
(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 adjusted, if necessary.
Because of the design features which allow for cleaning of the transceiver
and reflector optics without requiring alignment adjustments, the above
procedures can usually be accomplished rather quickly. The procedure avoids
the problems associated with both the off-stack and on-stack zero alignment i
procedures. However, problems in maintaining the exact separation distance and
optical alignment during the zero alignment check can be encountered due to ;
spatial constraints, physical limitations, and the presence of extreme ;
vibration at the monitoring location. In some cases, spatial limitations can
be overcome by removing the transceiver from its hinges to allow greater
freedom in orienting the light path in a convenient direction. For example,
the alternate zero alignment approach can sometimes be used for opacity GEMS's
installed in the annular space between the stack liner and stack shell by
orienting the light path vertically, parallel to the access ladder, and
positioning the reflector at a different elevation. ;
Great care must be used to avoid contamination of the optical surfaces and
damage to the transmissometer components if the alternate approach is used. In
addition, adequate measures to establish the exact separation distance and
optical alignment must be used. Because of the risk of damaige to the opacity
GEMS and personal safety considerations, it is recommended that the alternate
zero alignment technique be performed only by experienced and qualified
personnel.
9-4
-------
TRANCEIVER MOUNTING
ADAPTER
INSTALLED
OPTICAL PATHLEN6TH
REFLECTOR
FIGURE 9.1 ZERO ALIGNMENT JIG.
9-5
4111-DR14
-------
-------
APPENDIX A.
LEAR SIEGLER, INC. MODEL RM-41 AUDIT DATA FORMS
A-l
-------
A-2
-------
AUDIT DATA SHEET
LSI RH-41 TRANSMISSOMETER AND MODEL 61! CONTROL UNIT
SOURCE IDENTIFICATION:
PROCESS UNIT/STACK IDENTIFICATION:
AUDITOR:
ATTENDEES:
DATE:
CORPORATION:
PLANT/SITE:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
PRELIMINARY DATA
1 Slack exit inside diameter (FT) = Lx =
2 [Stack (or duct) inside diameter (or width) at transmissometer location (FT)]* 2 = L $
3 Calculated OPLR - LY /Lt-
4 source-cited OPLR value
5 Source-cited zero automatic calibration values (R opacity)
6 Source-cited span automatic calibration value (S opacity)
[60 TO DATA RECORDER LOCATION]
[INSPECT DATA RECORDING SYSTEM AND MARK WITH 'OPACITY AUDIT/ AUDITORS NAME. DATE. SOURCE.
PROCESS UNIT/STACK IDENTIFICATION, AND THE TIME OF DAY.]
[GO TO CONTROL UNIT LOCATION]
FAULT LAMP INSPECTION
7 FILTER [status of purge air blowers]
8 SHUTTER [status of protective shutters]
9 REF [AGC fault and/or excessive reference signal error]
10 WINDOW (excessive zero compensation]
11 OVER RANGE [exceeding optical density range setting]
ON
OFF
CONTROL OMIT ADJUSTMENT CHECKS [TO BE DONE ONLY BY QUALIFIED PERSONNEL 1
[OPEN CONTROL UNIT AND PULL POWER FUSE]
[PULL CAL TIMER BOARD]
12 CAL timer board SI switch position
[Turn CAL timer board SI switch to sixth (6th) position, if necessary, and
reinstall board.]
[Pull OPTICAL DENSITY board]
13 OPTICAL DENSITY board SI switch position
[Turn OPTICAL DENSITY board SI switch to fifth (5th) position, if necessary,
and reinstall board.]
[Pull OPACITY board.]
1-4 OPACITY Board S1 switch position
[Turn OPACITY board S1 to fifth (5th) position, if necessary.]
(Optional OPLR check: Measure the resistance in OHMs of the "R* " potentiometer
on the OPACITY board, and divide by 400 to get the internally set OPLR value.]
.(OHMs)/400-
(Optional)
(If R graiue is not measured, then enter the value from (BLANK 4) in
(BLANK 14a).l
[Reinstall the OPACITY board.]
(Reinstall fuse and close control unit.]
15 Original position of "MEASUREMENT" switch
-------
AUDIT DATA SHEET
LSI RM-41 TRANSMISSOMETER AND MODEL 611 CONTROL UNIT
(Continued)
REFERENCE SIGNAL CHECK
1TURN "MEASUREMENT SWITCH TO -REFERENCE' POSITION AND TAP PANEL METER FACE]
IREAD REFERENCE SIGNAL CURRENT VALUE ON 0-30 mA SCALE]
16 Reference signal current value (mA)
ITum "MEASUREMENT switch to MOOS Op" position.]
JSRO CHECK
1PRESS THE -OPERATE/CAL- SWITCH]
ITAP THE PANEL METER AND READ THE ZERO CALIBRATION VALUE FROM THE
0-100J5 Op SCALE.]
17 Pawl Water zero calibration value (S Op)
1 8 Opacity data recorder zero calibration valua (S Op)
7ERO COMPENSATION CHECK (INITIAL)
[TURN THE "MEASUREMENT SWITCH TO THE 'COUP" POSITION.]
tTAP THE PANEL METER AND READ THE ZERO COMPENSATION VALUE ON THE
-0.02 TO 40.05 O'J). SCALE.l
19 Panel meter zero compensation value (OJ>.)
CHECK
tPRESS THE 'ZERO/SPAN' SWITCH AND TURN THE 'MEASUREMENT' SWITCH TO THE
•1008 Op" POSITION.]
ITAP THE PANEL METER FACE AND READ THE SPAN CALIBRATION VALUE FROM
THE 0-100X Op SCALE.l
20 Panel meter span calibration valua (S Op)
2 1 Opacity data recorder span calibration value (X Op)
(OPTIONAL CHECK: Turn tha 'MEASUREMENT" switch to the "INPUT position and
read the input current from the panel meter 0-30 mA scale.]
2I« Panel meter Input current value (mA) (Optional)
ITurn the -MEASUREMENT switch back to the '100S OPACITY' position.]
IPRESS THE 'OPERATE/CAL- SWITCH.]
IGO TO TRANSMISSOMETER LOCATION.]
RETRCKEFLECTPR DUST ACCUMULATION CHECK
IGET EFFLUENT OPACITY READIN6.FROM OPACITY DATA RECORDER.]
22 Pre-cleanlng effluent opacity (S op)
tOp«n r«tror«n»etor.Inspect and clean retroreflector optical surface, and
close retrorefiector.l
23 Posl-clsaning effluent opacity (X Op)
[Go to transceiver location.]
-------
AUDIT DATA SHEET
LSI RM-4I TRANSMISSOMETER AND MODEL 611 CONTROL UNIT
(Continued)
TRANSCEIVER BUST ACCUMULATION CHECK
[GET EFFLUENT OPACITY READING FROM OPACITY DATA RECORDER]
24 Pre-cleaning effluent opacity (X Op)
(Open transcatver.inspecl and clean primary Isns.fnspact end clean zero mirror,
end close transceiver.)
25 Post-cleaning effluent opacity (X Op)
{At control unit, press "OPERATE/CAT switch, turn -MEASUREMENT' switch to
"COW position, tap meter face, and read zero compensation value from the
-0.02 to +0.05 OH. scale.)
26 Post-cleaning zero compensation value (OD.)
lAt control unit, press "OPERATE/CAL" switch and turn "MEASUREMENT" switch
to -lOOX Op' position.]
A6C CHECK
27 A6C lamp status
OPTICAL AllSSfgMT CHECK
[REMOVE COVER FROM TRANSCEIVER MODE SWITCH AND TURN SWITCH ONE POSITION
COUNTER-CLOCKWISE TO 'ALIGN' POSITION.]
[LOOK INTO VIEWING PORT WITH ICON OF HUMAN EYE ABOVE AND OBSERVE POSITION
OF BEAM IMAGE WITH RESPECT TO BLACK CIRCLE.]
28 image centered?
{DRAW LOCATION Of BEAM IMAGE.]
[TURN THE TRANSCEIVER MODE SWITCH CLOCKWISE UNTIL OPERATE APPEARS IN
THE WINDOW. REPLACE THE MODE SWITCH PROTECTIVE COVER.]
SPAM F8LTER DATA CHECK
[READ SPAN FILTER OPTICAL DENSITY AND OUTPUT CURRENT FROM THE UNDERSIDE OF
THE TRANSCEIVER.]
29 Span niter optical density (OD.)
30 Span filter output currant OnA)
CALIBRATION ERROR CHECK
[OPEN THE TRANSCEIVER AND THE J-BOX.l
[INSTALL THE AUDIT JIG ON THE TRANSCEIVER PROJECTION LENS AND ADJUST THE JIG
ZERO UNTIL THE J-BOX METER READS BETWEEN 19 AND 20 mA, AND A VALUE BETWEEN
OS AND 2X OPACITY IS READ ON THE OPACITY DATA RECORDER.]
[RECORD AUDIT FILTER DATA.]
ON
OFF
YES
NO
FILTER
SJ LOW
32 MID
33 HIGH
SERIAL NO.
X OPACITY
-------
AUDIT DATA SHEET
LSI RM-41 TRANSMISSOMETER AND MODEL 611 CONTROL UNIT
(Continued)
(REMOVE AUDIT FILTERS FROM PROTECTIVE COVERS, INSPECT. AND CLEAN.]
IIHSERT EACH FILTER IN THE JIG, WAIT APPROXIMATELY 2 MINUTES PER FILTER FOR
A CLEAR RESPONSE. AND RECORD OPACTIY VALUE REPORTED FROM OPACITY DATA
RECORDER.!
IREPEAT ABOVE PROCESS FIVE TIMES.]
(IF JIS ZERO VALUES CHANGE BY MORE THAN 1 .OX OPACITY BETWEEN THREE (3)
FILTER RUNS. READJUST JIG ZERO TO ORIGINAL VALUE AND REPEAT RUN.]
ZERO LOW MID
HIGH
2B.Q
I IF SIX-MINUTE INTEGRATED DATA ARE AVAILABLE, THEN ALLOW 13 MINUTES EACH FOR
AN ADDITIONAL RUN OF THE ZERO. LOW. MID. HIGH. AND ZERO READINGS IN ORDER TO
CHECK SIX-MINUTE AVERAGED CALIBRATION ERROR.]
ZERO
LOW
MID
HIGH
(REMOVE AUDIT JIG AND CLOSE TRANSCEIVER.]
(RETURN TO CONTROL UNIT LOCATION.]
ZERO COMPENSATION CHECK (FINAL)
(PRESS 'OPERATE/CAL" SWITCH. TURN 'MEASUREMENT' SWITCH TO 'COMP" POSITION.
AND READ ZERO COMPENSATION VALUE FROM THE -0.02 TO +0.05 OD. SCALE.]
34 Ffnal zero compensation value (OS).}
(Press "OPERATE/CAP switch .1
CONTROL UNIT ADJUSTMENT RESET (TO BE DONE ONLY BY QUALIFIED PERSONNEL)
[OPEN CONTROL UNIT AND PULL POWER FUSE.]
(IF NECESSARY. PULL THE FOLLOWING CIRCUIT BOARDS AND RESET THE SI SWITCHES TO
THE POSITIONS INDICATED IN THE CORRESPONDING BLANKS.]
BOARD
CaJ Timer
Optical Density
Opacity
BLANK NO.
12
13
14
IREINSTALL THE POWER FUSE AND CLOSE THE CONTROL UNIT.l
(TURN THE "MEASUREMENT- SWITCH TO THE POSITION RECORDED IN (BLANK 15).l
{GET A COPY OF THE AUDIT DATA FROM THE OPACITY DATA RECORDER AND ENSURE
THAT THE DATA CAN BE CLEARLY READ AND INTERPRETED.]
-------
AUDIT DATA SHEET
LSI RM-41 TRANSMISSOMETER AND MODEL 61 I CONTROL UNIT
(Continued)
[READ AND TRANSCRIBE
ZERO
35
FINAL CALIBRATION ERROR DATA.]
LOtf
36
40
44
48
MID.
37
41
45
49
52 53
[SIX-MINUTE AVERAGE DATA, IF APPLICABLE.)
56
CALCULATIOM OF
57
AUDIT RESULTS
58
HIGH
38
42
46
SO
54
59
ZERO
39
43
47
51
""55"
60
STACK EXIT CORRELATION ERROR (X):
61 Source cited
(BLANK 4) (BLANKS)
(BLANK 3)
x 100
62 Measured
(BLANK Ha) (BLANK 3)
(Blank 3)
x 100
(OPTIONAL).
REFERENCE SIGNAL ERROR
-------
AUDIT DATA SHEET
LSI RM-4! TRANSMISSOMETER AND MODEL 611 CONTROL UNIT
(Continued)
ZERO COMPENSATION (OJU:
68 Initial
69 Post-cleaning
70 Final
(BLANK 19)
(BLANK 26)
(BLANK 34)
OPTICAL SURFACE DUST ACCUMULATION (X Op):
71 Rctroreflector:
(BLANK 22)
72 Transceiver:
73 Total:
(BLANK 24)
(BLANK 23)
(BLANK 25)
(BLANK 71) (BLANK 72)
OPLR AND ZERO OFFSET CORRECTION OF AUDIT FILTERS (5COP):
74 Low:
75 MJd:
1-
1-
2 x (BLA
j_ (BLANK 31) x
1 100 J
2 x (BL/
r ~i
1 (BLANK 32) y
±- 100 J
NK 14a)
1 (BLANK 55)
L 100 -L
WK 14a)
] (BLANK 55)
L 100 -i
—
x 100 -
K 100 =
76 High:
1-
2 x (BLANK 14a)
1—
(BLANK 33)
100
(BLANK 55)
100 -LI
x 100
-------
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-------
LEAR SIEGLER MODEL RM-411 TRANSniSSOtlETER AND
MODEL 611 CONTROL UNIT
OPACITY CEHS PERFOR11ANCE AUDIT REPORT
DATA SUMMARY
AimiTfiD
sniinrp
CFSIH TS PHFrrFn rtv
BATF
•IIMIT
DATF
PARAMETER
FAULT LAMPS
FILTER
SHUTTER
REFERENCE
WINDOW
OVER RANGE
A6C CIRCUIT STATUS
STACK EXIT CITED
CORRELATION ERROR MEASURED
REFERENCE SIGNAL ANALYSIS
INTERNAL ZERO ERROR PANEL METER
DATA RECORDER
INTERNAL SPAN ERROR PANEL METER
DATA RECORDER
INPUT ERROR (OPTIONAL)
MONITOR ALIGNMENT ANALYSIS
INITIAL ZERO COMPENSATION
POST-CLEANING ZERO COMPENSATION
FINAL ZERO COMPENSATION
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.
SSSSSSSS:
7
6
9
10
11
27
61
62
63
64
65
66
67
67
28
68
69
70
•\\;\NS^:^N>
71
72
73
v\^ssss\
>S^\\>SSs
77
86 a
76
87 a
79
8Ba
x^sS^vS
80
81
82
^S$8>^
83
84
85
AUDIT
RESULT
>^sSSSSSj
^ss^sss^
\j\SS^88^
S^SSS^
\-\>x\\S^
A\\\\\\\;
SPECIFICATION
SSSSSSSSIS^
OFF
OFF
OFF
OFF
OFF
ON
± 28
+ 28
± 108
± 480p
±480p
±48 Op
±480p
1.00 ±0.02
CENTERED
± 0.016 OD
± 0.018 OD
±0.01800
^^V^^-x-
i280p
4 28 Op
I 48 Op
>S$SS^SS^^
>SS^^^\\:\:\
$^SSSSS^^
^NX^-N^^
^\^<^^N
^\\S\\^>^\-\
^\::^SS>x\
^^^^
:v\^^S\:^
:^\^^<\>$x\:
^-^^^>\;\
\:^^\'\^\>
•x>>N^s\x^\>^
i380p
iZK Op
i380p
' ERROR BASED ON SIX-MINUTE AVERAGED DATA, FROM A SINGLE FILTER INSERTION.
-------
APPENDIX B.
LEAR SIEGLER, INC. MODEL RM-4 AUDIT DATA FORMS
B-l
-------
B-2
-------
AUDIT DATA SHEET
LSI RM-4 TRANSMISSOflETER
SOURCE IDENTIFICATION:
PROCESS UNIT/STACK IDENTIFICATION:
AUDITOR:
-CORPORATION:
-PLANT/SITE:-
ATTENDEES:
DATE:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
PRELIMINARY DATA
1 Stack exit inside diameter (FT) = L =x
2 [Stack (OP duct) inside diameter (or width) at transmissometer location (FT)] x2 - L
3 Calculated OPLR -i-x / Lt -
4 Source-cited OPLR value
5 Source-cited zero automatic calibration values (% opacity)
6 Source-cited span automatic calibration value (X opacity)
{GO TO CONVERTER CONTROL UNIT/DATA RECORDER LOCATION]
(INSPECT DATA RECORDING SYSTEM AND MARK WITH "OPACITY AUDIT."
AUDITORS NAME, DATE. SOURCE, PROCESS UNIT/STACK IDENTIFICATION.
AND THE TIME OF DAY.]
INSPECTION
7 FAULT [low A6C current]
8 OVER RANGE [exceeding optical density range setting]
ON
OFF
CONTROL UNIT ADJUSTMENT CHECK
9 Original position of "Measurement Switch"
ZERO CHECK
{TURN THE "MEASUREMENT" SWITCH TO THE "20* OPACITY" POSITION]
[TURN THE "MODE" SWITCH TO THE "ZERO" POSITION]
10 Panel Meter zero calibration value (0-20 mA scale)
11 Opacity data recorder zero calibration value (JSOp)
SPAN CHECK
[TURN THE "MEASUREMENT" SWITCH TO THE "100JS OPACITY" POSITION]
{TURN THE -MOM' SWITCH TO THE "CALIBRATE" POSITION!
12 Panel Meter span calibration value 0?0p)
13 Opacity data recorder span calibration value (ROp)
[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 "MODE" SWITCH TO THE "OPERATE" POSITION AND GO TO THE TRANSMISSOMETER LOCATION.]
-------
AUDIT DATA SHEET
LSI RM-4 TRANSMISSOMETER
(Continued)
RETROREFLECTOR DUST ACCUMULATION CHECK
IGCT EFFLUENT OPACITY LADINGS FROM THE OPACITY DATA RECORDER.]
15 Pra-clewiing effluent opacity (XOp)
[Open retroreflector. Inspect and clean relrorenector optical surface.
and close relroreflector.]
16 Post-cleaning effluent opacity (SOp)
160 TO TRANSCEIVER LOCATION]
TRANSCEIVER DUST ACCUMULATION CHECK
17 Pre-clatning effluent opacity (X Op)
tOpen transceiver, Inspect and clean primary lens, clean zero mirror,
and close transceiver.]
IB Post-cleaning effluent opacity (X Op)
(OPEN THE TRANSCEIVER CONTROL PANEL]
FAULT/TEST CHECK
IPRESS AND HOLD THE TAUT/TEST' BUTTON AND READ THE TRANSCEIVER METER
CURRENT VALUE ON THE 0-20 mA SCALE]
19 Fault/last current value (mA)
OPTICAL
[LOOK INTO VIEWING PORT ON THE RIGHT SIDE OF THE TRANSCEIVER AW) OBSERVE
POSITION OF BEAM IMAGE WITH RESPECT TO TARGET CIRCLE]
20 Image centered?
[DRAW LOCATION OF BEAM IMAGE.]
SPAN FILTER DATA CHECK
[READ SPAN FILTER OPTICAL DENSITY FROM THE BOTTOM OF THE TRANSCEIVER
CONTROL PANEL]
21 Span filter optical density (OH)
CALIBRATION ERROR CHECK
[INSTALL THE AUDIT JIG ON THE TRANSCEIVER PROJECTION LENS AND ADJUST THE JIG ZERO
UNTIL THE TRANSCEIVER METER READS APPROXIMATELY 2.0 mA AND A VALUE BETWEEN
OS AND 2* OPACITY IS READ ON THE OPACITY DATA RECORDER.]
[RECORD AUDIT FILTER DATA]
FILTER
22 LOW
23 MID
24 HIGH
SERIAL NO.
X OPACITY
-------
AUDIT DATA SHEET
LSI RM-4 TRANSMISSOMETER
(Continued)
IREMOVE AUDIT FILTERS FROM PROTECTIVE COVERS. INSPECT, AND CLEAN.]
[INSERT EACH FILTER IN THE JIG, WAIT APPROXIMATELY TWO MINUTES,
AND RECORD OPACITY VALUES REPORTED FROM OPACITY DATA RECORDER.]
IIP JIG ZERO VALUES CHANGE BY MORE THAN I .OS OPACITY BETWEEN ANY
FILTER RUN. READJUST THE JIG ZERO TO ORIGINAL VALUE AND REPEAT THE RUN.]
ZERO
LOW
MID
UF SIX-MINUTE INTEGRATED DATA ARE ALSO AVAILABLE. THEN ALLOW 13 MINUTES
EACH FOR AN ADDITIONAL RUN OF THE ZERO. LOW. MID. HIGH. AND ZERO READINGS.]
LOW
MID
IREMOVE AUDIT JIG AND CLOSE TRANSCEIVER.]
(RETURN TO CONVERTER CONTROL UNIT LOCATION.]
HIGH
. HIGH
ZERO
ZERO HiLLIAHP CHECK
(OPTIONAL)
[TURN THE MODE SWITCH TO ZERO AND THE -MEASUREMENT' SWITCH TO -20* OPACITY-
AMD RECORD THE ZERO MILLIAMP VALUE.]
25 Fins! zero currant value, ma (OPTIONAL)
[TURN THE "MODE" SWITCH TO 'OPERATE' AND THE 'MEASUREMENT' SWITCH TO THE
POSITION RECORDED ON BLANK 9.]
(GET A COPY OF THE AUDIT DATA FROM THE OPACITY DATA RECORDER AND ENSURE
THAT THE DATA CAN BE READ AND INTERPRETED.]
[READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA.]
ZIBO LOW MID.
~26~~ "~27~"
28
35
~39~
"43
HIGH
~~29~
~"33'
""37"
"~4l"
~~45~
ZERO
~~30~
~ 34"
~ 38"
"42"
"46~
[SIX-MINUTE AVERAGE DATA, IF APPLICABLE.]
47
48
49
50
51
-------
AUDIT DATA SHEET
LSI RM-4 TRANSMISSOMETER
(Continued)
CALCUIATION OF AUDIT RESULTS
STACK EXIT CORRELATION ERROR (X):
52 Source cited
ZERO ERROR (X Op):
53 Panel meter
54 Opacity data recorder
SPAN ERROR (X Op):
55 Panel Meter
56 Opacity data recorder
57 Final zero mA (optional)
(BLANK 4) (BLANKS)
(BLANK 3)
x 100-
(BLANK10) - (BLANKS)
(BLANK 11) - (BLANKS) =
(BLANK 12)
(BLANK 13)
,-K
r K Tl
[(BLANK 4) (BLANK 21) J
^ ™"^^
(BLANK 4) K (BLANK 21)
X 100
x100
m
(BLANK 25) (BLANKS)
OPTICAL SURFACE DUST ACCUMULATION (X Op):
58 Retrorenector:
59 Transceiver:
60 Total:
(BLANK 15)
(BLANK 17)
(BLANK 58)
(BLANK 16)
(BLANK 18)
(BLANK 59)
OPLR AND ZERO OFFSET CORRECTION OF AUDIT FILTERS:
61 Low:
62 Mid:
1-
1-
L (BLANK 22)
L" 100 J
2 (BLANK 4)
(BLANK 46)
100
E-j2(BLANK4) i- _ ~j
(BLANK 25) x ,_ (BLANK 46)
100 J L 10° -L
x 100 =
x 100 -
63 High:
1-
(BLANK 24)
100 _J
2 (BLANK 4)
X
(BLANK 46)
100 J
x 100
-------
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x
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-------
LEAR SIE6LER MODEL RM-4 TWANSMISSOMETER
OPACITY CEMS PERFORMANCE AUDIT REPORT
DATA SUMMARY
AUDITOR.
SOURCE-
RESULTS CHECKED BY:.
BATE.
UNIT.
DATE-
PARAMETER
FAULT LAMPS
FAULT
OVER RANGE
STACK EXIT CORELATION ERROR
INTERNAL ZERO ERROR PANEL METER
DATA RECORDER
INTERNAL SPAN EROR PANEL METER
DATA RECORDER
2ERO MILLIAMP ERROR (OPTIONAL)
POST-CLEANING ZERO
MONITOR ALIGNMENT
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
<^\;N>
7
8
52
53
54
55
56
57
25
20
^^:
58
59
60
•^8^
^•^
64
73 a
65
74a
66
75 a
\W^
67
68 ,
69
^^
70
71
72
AUDIT
DF«5II[T
C^SSSSS^
s^^
;^^m
^S^-N
:^W^S
^^^>
SPECIFICATION
SSS^S^;^
OFF
OFF
± 2X
±4XOp
±48 Op
±4SOp
±4SOp
±2mA
±2mA
CENTERED
^^\-^
i2SOp
i2J50p
44%OD
:>^^;^
^>"S^^\^
^SSSS^^
^^^^
^SSS::^^
m>^^
^^^^
^^^^
^^^
vSSS^S^N^
^^ss^S:
s^s^ssss;
^^vS^^
i3ROp
i3J50p
i380p
aERROR BASED ON SIX-MINUTE AVERAGED DATA FROM A SINaE FILTER INSERTION.
-------
APPENDIX C.
DYNATRON MODEL 1100 AUDIT DATA FORMS
C-l
-------
C-2
-------
AUDIT DATA SHEET
DYNATRON MODEL 1 100 TRANSMISSOMETER
SOURCE IDENTIFICATION:
PROCESS UNIT/STACK IDENTIFICATION:
AUDITOR:
ATTENDEES:
DATE:
-CORPORATION
-PLANT/SITE
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
PRELIMINARY DATA
I
Stack exit inside diameter (FT) = L
2 [stack (or duct) inside diameter (or width) at transmissometer location (FT)]*2 - L
3 Calculated "M" Factor = L x / L t
4 Source-cited "M" Factor value
5 Source-cited zero automatic calibration values (K opacity)
6 Source-cited span automatic calibration value (X opacity)
IGO TO CONTROL UNIT DATA RECORDER LOCATION]
[INSPECT DATA RECORDING SYSTEM AND MARK WITH -OPACITY AUDIT,' AUDITORS NAME. DATE. SOURCE.
PROCESS UNIT/STACK IDENTIFICATION, AND THE TIME OF DAY.]
FAULT LAHP CHECKS
7 LAMP [insufficient measurement lamp output]
8 WINDOW [excessive dust on transceiver optics]
9 AIR FLOW [insufficient purge air flow]
ON
OFF
CONTROL UMIT CHECKS
i 0 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" postion. if necessary.]
ZERO CHECK
(PRESS ZERO/SPAN SWITCH)
12 Panel Meter zero calibration value (X Op)
13 Opacity data recorder zero calibration value CK Op)
-------
AUDIT DATA SHEET
DYNATRON MODEL 1100 TRANSMISSOMETER
(Continued)
SPAM CHECK
M Panel meter span calibration value (JS Op)
15 Opacity data recorder span calibration value (X Op)
[GO TO TRANSMISSOMETER LOCATION.]
RETROREFLfCTOR DOST ACCUMULATION CHECK
[GET EFFLUENT OPACITY READINGS FROM THE OPACITY DATA RECORDER.]
16 Pro-cleaning effluent opacity (X Op)
(Remove, inspect, clean, and replace protective window.]
17 Post-cleaning effluent opacity (X Op)
(Go to transceiver location.]
TRANSCEIVER DUST ACCUMULATION CHECK
18 Pre-cleaning effluent opacity (55 Op)
[Remove, Inspect, clean, and replace protective window.]
19 Post-cleaning effluent opacity (% Op)
OPTICAL ALIGNMENT CHECK (OPTIONAL)
[IF ALIGNMENT TUBE IS PRESENT ON TRANSCEIVER SIDE OF STACK OR DUCT, LOOK
THROUGH TUBE AND OBSERVE WHETHER BEAM IMAGE IS CENTERED AROUND
RETROREFLECTORPORT.l
20 Image centered?
IDRAW ORIENTIAT1ON OF RETROREFLECTOR PORT IN ALIGNMENT CIRCLE.]
CALIBRATION ERROR CHECK [JI6 PROCEDURE!
[REMOVE THE DIRTY WINDOW DETECTOR PHOTOCELL. IF THE TRANSCEIVER DOES NOT HAVE A
DIRTY WINDOW PHOTOCELL OR A REMOVABLE ACCESS PANEL COVER AT THAT POSITION,
THEN THE INCREMENTAL CALIBRATION ERROR PROCEDURE MUST BE USED.]
[REMOVE THETRANSCEIVER PROTECTIVE WINDOW.]
[INSTALL THE AUDIT JIG IN THE DIRTY WINDOW DETECTOR LOCATION AND ADJUST
THE JIG ZERO UNTIL A VALUE BETWEEN 0* AND 28 OPACITY IS READ ON THE
OPACITY DATA RECORDER.]
[INSTALL THE TRANSCEIVER PROTECTIVE WINDOW AND RECORD THE PROTECTIVE
WINDOW OPACITY.]
21 Window opacity (Including jig zero offset)
[REMOVE THE TRANSCEIVER PROTECTIVE WINDOW.]
[RECORD AUDIT FILTER DATA,]
YES
NO
FIITER
22 LOW
23 MID
24 HIGH
SERIAL NO.
S.OPACLTY
-------
AUDIT DATA SHEET
DYNATRON MODEL 1100 TRANSMISSOMETER
(Continued)
{REMOVE AUDIT FILTERS FROM PROTECTIVE COVERS. INSPECT. AND CLEAN J
IINSERT EACH FILTER. WAIT APPROXIMATELY TWO MINUTES.AND RECORD OPACITY VALUES
REPORTED FROM OPACITY DATA RECORDER.]
IIP JI6 ZERO VALUES CHANGE BY MORE THAN 1 .OX OPACITY BETWEEN THREE (3)
FILTER RUNS. READJUST JIG ZERO TO ORIGINAL VALUE AND REPEAT RUN ]
ZERO
LOW
MID
HI6H
ZERO
f IF SIX-MINUTE INTEGRATED DATA AR£ ALSO AVAILABLE, THEN ALLOW 13 MINUTES
EACH FOR AN ADDITIONAL RUN OF THE ZERO, LOW, MID, HIGH, AND ZERO READINGS.)
ZERO
LOW
IREMOVE AUDIT JIG. REPLACE THE DIRTY WINDOW INDICATOR AND THE PROTECTIVE
WINDOW. AND CLOSE THE TRANSCEIVER HOUSING.]
IRETURN TO CONTROL UNIT LOCATION.]
COHTHOt UNIT ADJUSTMENT RESET
HF NECESSARY. RESET THE CONTROL UNIT CALIBRATION TIMER AND METER DISPLAY
KNOBS TO THE POSITIONS INDICATED IN THE
CORRESPONDING BLANKS.]
KNOB
Automatic Calibration Timer
Meter Display
BLANK NO.
10
II
IMARK THE DATA RECORD FOR THE END OF THE AUDIT. GET A COPY OF THE AUDIT DATA
FROM THE OPACITY DATA RECORDER. AND ENSURE THAT THE DATA CAN BE CLEARLY
READ AND INTERPRETED.]
HIGH
ZERO
[READ AND TRANSCRIBE FINAL CALIBRATION ERROR DATA.]
2BQ LOW MJfi.
25
26
"30
34"
Sff
"42"
27
31"
HI6H
2ff
~32 ~
46
fSIX-MJNUTE AVERAGE DATA. IF APPLICABLE.]
~~~47~ 48-
49
ZERO
"29"
-33"'
"37"
'45~
~50~
-------
AUDIT DATA SHEET
DYNATRON MODEL 1100 TRANSMISSOMETER
(Continued)
CAJCMJATION OF AUDIT RESULTS
STACK EXIT CORRELATION ERROR (X):
51
ZERO ERROR (X Op):
52 Panel mrter
53 Opacity data recorder
(BLANK 4) (BLANK 3)
(BLANK 3)
(BLANK 12)
(BLANKS)
(BLANK 13) (BLANK 5)
x 100
SPAN ERROR (X Op):
54 Penal
Malar
(BLANK 14)
(BLANK 6)
55 Opacity
Data
Recorder
(BLANK 15)
(BLANK 6)
OPTICAL SURFACE DUST ACCUMULATION (X Op):
SB Retroreflector:
(BLANK 16)
57 Transceiver:
58 Total:
(BLANK 18)
(BLANK 56)
(BLANK 17)
(BLANK 19)
(BLANKS?)
tl" FACTOR AMD ZERO OFFSET CORRECTION OF AUDIT FILTERS:
59 Low:
1 «"
-"I
_ (BIANK22)
^ 100 J
(BLANK 4)
x
1. (BLANK 45)
L '°0 4
x 100 =
60 Mid:
61 High:
t_
—
1_
[— I
_ (CLANK 23)
_ 100 J
2
r- — |
, . (BLANK 24)
_L 100 J
(BLANK4) r- ~~j
K 1_ (BLANK •«)
[_ 100 _
J(
fFU Afli; A\ T~~
x L - (BLANK 45)
L 100 _
—
_l
X 100
x 100
-------
-------
DYNATRON MODEL 1100 TRANSM1SSOMETER
OPACITY CEI1S PERFORMANCE AUDIT REPORT
DATA SUMMARY
(JIG PROCEDURE)
AUDITOR.
SOURCE _
RESULTS CHECKED BY
DATE.
UNIT .
DATE.
PARAMETER
FAULT LAMPS
LAMP
WINDOW
AIR PURGE
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
HI6H
CONFIDENCE INTERVAL
LOW
MID
Htm
CALIBRATION ERROR
LOW
MID
HIGH
BLANK
NO.
(SS5SSS
7
6
9
51
52
53
54
55
20
^^
56
57
58
S^S
^^
62
71 a
63
72 a
64
73 a
m>^
65
66
67
sW^
68
69
70
AUDIT
RESULT
^S^
^^^
^^5^
i^sss
m^ss
^ms
SPECIFICATION
^m^
OFF
OFF
OFF
±2%
± 480p
±4JSOp
+ 4r. OP
+ 4550p
CENTERED
;<^^^
i2J50p
i 255 Op
i480p
Si^^^^S:
^•m^
^^NN^^S
^^^^
^^^^
^^^S^
^m^
^C^S^N^
^^^^S
^^
-------
AUDIT DATA SHEET
DYNATRON MODEL 1100 TRANSMISSOMETER
(Continued)
INCREMENTAL CAL ERROR
CAUBKATION EBBOP CHECIT HMCPEMEMTAL PROCEMIPn
ITHE INCREMREMENTAL CALIBRATION ERROR PROCEDURE SHOULD BE USED ONLY WHEN THE
JIG PROCEDURE CANNOT BE USED. SUCH AS DURING AUDITS OF OLDER MODEL 1100 MONITORS
WHICH DO NOT HAVE DIRTY WINDOW INDICATORS.]
[IF THE EFFLUENT OPACITY IS FLUCTUATING BY 2* OPACITY OR MORE, THE INCREMENTAL
PROCEDURE CANNOT BE USED.]
[THE RATED OPACITY VALUES OF THE AUDIT FILTERS MUST INCLUDE AN ASSUMED NOMINAL
OPACITY VALUE FOR THE TRANSCEIVER PROTECTIVE WINDOW.]
tRECORD AUDIT FILTER DATA.]
FILTER
SERJAUfiL
It OPACITY
1-21 LOW
1-22 MID
1-23 HIGH
[REMOVE AUDIT FILTERS FROM PROTECTIVE COVERS. INSPECT. AND CLEAN.]
[RECORD THE EFFLUENT OPACITY VALUE FROM THE OPACITY DATA RECORDER ]
[REMOVE THE TRANSCEIVER PROTECTIVE WINDOW. INSERT A FILTER.WAIT APPROXIMATELY TWO MINUTES AND RECORD
THE OPACITY VALUE REPORTED FROM THE OPACITY DATA RECORDER.]
[REMOVE THE FILTER. REPLACE THE TRANSCEIVER PROTECTIVE WINDOW AND RECORD THE EFFLUENT OPACITY.)
[REPEAT THIS PROCESS FOR FIVE RUNS OF THREE FILTERS EACH.]
EFFLUENT
LOW
EFFLUENT
EFFLUENT
HIGH
[IF SIX-MINUTE INTEGRATED DATA ARE ALSO AVAILABLE. THEN ALLOW 13 MINUTES EACH FOR AN
ADDITIONAL RUN OF THE EFRUENT LOW. MID. AND HIGH READINGS.]
EFFLUENT
LOW
EFFLUENT
MID
EFFLUENT
HIGH
EFFLUENT
[CLOSE THE TRANSCEIVER HOUSING.]
[RETURN TO CONTROL UNIT LOCATION.]
-------
AUDIT DATA SHEET
DVNATRON MODEL 1100 TRANSMISSOMETER
(Continued)
INCREMENTAL CAL ERROR
CONTROL UNIT ADJUSTMENT RESET
IF NECESSARY, RESET THE CONTROL UNIT CALBRATION TIMER AND METER DISPLAY
KNOBS TO THE POSITIONS WDICATED IN THE CORRESPONDING BLANKS.]
ms.
Automatic Cilibr*tion Timer
M«tw Display
BLANK NO.
10
11
[MARK THE DATA RECORD FOR THE END OF THE AUDIT, GET 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.]
EFFLUENT
LOW
EFFLUENT MID
EFFLUENT
1-24
1-25
1-26
1-27
1-28
1-29
1-30
1-31
1-32
1-33
1-34
1-35
1-36
1-37
1-38
1-39
1-40
1-41
1-42
1-43
1-44
1-45
1-46
1-47
1-48
1-54
1-49 1-50 1-51 1-52 1-53
SIX-MINUTE AVERAGE DATA (IF APPLICABLE)
1-55
1-56
1-57
1-58
1-59
1-60
1-61
" FACTOR CORRECTION OF AUDIT FILTER (TRAHSMITTAKCE):
2x
t-62
t-63
1-64
Low:
Mk):
High:
E-
(BLANK 1-21)
100 _J
2x
. (BLANK H22)
100 _J
2x
(BLANK 4)
(BLANK 4)
(BLANK 4)
. (BLANK 1-23)
100
-------
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e
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-------
DYMATRON MODEL 1100 TRANSniSSOMETER
OPACITY OEMS PERFORMANCE AUDIT REPORT
DATA SUMMARY
(INCREMENTAL CAL ERROR PROCEDURE)
AUDITOR.
DATE.
UNIT.
RESULTS CHECKED BY.
HATT
PARAMETER
FAULT LAMPS
LAMP
WINDOW
AIR PURGE
STACK EXIT CORRELATION ERROR
INTERNAL ZERO ERROR PANEL METER
)ATA RECORDER
INTERNAL SPAN ERROR PANEL METER
)ATA RECORDER
MONITOR ALIGNMENT ANALYSIS
OPTICAL SURFACE DUST ACCUMULATION
RETROREFLECTOR
TRANSCEIVER
TOTAL
CALIBRATION ERROR ANALYSIS
MEAN ERROR
LOW
MID
HIGH
CONFIDENCE INTERVAL
LOW
MID
UICLJ
niwi
CALIBRATION ERROR
LOW
MID
HIGH
BLANK
NO.
C^s^sS
7
6
9
51
52
53
54
55
20
^v'v^x
56
57
58
SSSS^s:
^SSSS^S^
1-63
1-92 *
1-64
1-93 a
1-65
1-94 8
N^S$$$
1-66
1-87
1-66
^SSSS^S
1-89
1-90
1-91
AUDIT
RESULT
^s^>s^
^SSSSS^xN
<^\SSSS^
SSS^SSSSJ
^$SS^^
^S$^SSS^
SPECIFICATION
^SSSSSSSS>v
OFF
OFF
OFF
±29!
±4XOp
± 4% Op
+ 4X Op
+ 45SOp
CENTERED
^S^SSS^S^
i2XOp
£2JSOp
£4SOp
^SS^^SS^
S^sN^s^^
^S^SSS^SSS
;\\^>^^
S^^^
^^^v^S^S
J^§N§§^
^^^^s
^S$$$S$S^SS$
^s^^^^
^S^^^s;
^^^\>^s
^§§§§S
i3SOp
53XOp
i3XOp
ERROR BASED ON SIX-MINUTE AVERAGED DATA FROM A SINGLE FILTER INSERTION.
-------
-------
APPENDIX D.
THERMO ELECTRON (CONTRAVES GOERZ) MODEL 400 AUDIT DATA FORMS
D-l
-------
D-2
-------
AUDIT DATA SHEET
THERMO ELECTRON (CONTRAVES GOERZ) MODEL 400 TRANSMISSOMETER
AND MODEL 500 CONTROL UNIT
SOURCE IDENTIFICATION: '.
PROCESS UNIT/STACK IDENTIFICATION:
AUDITOR:
-CORPORATION:
-PLANT/SITE:
ATTENDEES:
DATE:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
PRELIH1NARY DATA
1 Stack exit inside diameter (FT) «=LX
Slack (or duct) inside diameter (or width) at transmissometer location (FT)
Calculated STR - Lx / Lt
Source-cited STR value
Soiree-cited zero automatic calibration values (% opacity)
Source-cited span automatic calibration value (X opacity)
160 TO DATA RECORDER LOCATION]
{INSPECT DATA RECORDING SYSTEM AND HARK WITH 'OPACITY AUDIT.' AUDITORS NAME. DATE SOURCE
PROCESS UNIT/STACK IDENTIFICATION. AND THE TIME OF DAY.]
160 TO CONTROL UNIT LOCATION]
FAULT LATIP IMSPFCTMH
7 CAL FAULT {excessive zero and/or span error]
8 DIRTY WINDOW [excessive dirt on transceiver optics]
9 PURGE AIR [insufficient purge air flow]
10 STACK POWER [no power to transmissometer]
11 LAMP FAILURE (insufficient measurement lamp intensity]
12 ALARM [effluent opacity exceeds source-selected limil]
ON
OFF
2ERO CHECK
IPRESS THE -ZERO/CAL- SWITCH]
[READ THE ZERO CALIBRATION VALUE FROM
THE PANEL METER AND THE DATA RECORDER]
13 Panel Meter zero calibration value (XOp)
M Opacity data recorder zero calibration value (XOp)
SPAM CHECK
IPRESS THE -SPAN/CAL- SWITCH]
[READ THE SPAN CALIBRATION VALUE FROM THE
PANEL METER AND THE DATA RECORDER]
15 Panel Meter span calibration value (XOp)
16 Opacity data recorder span calibration value (XOp)
160 TO TRANSMISSOMETER LOCATION]
-------
AUDIT DATA SHEET
THERMO ELECTRON (COHTRAVES 6QERZ) MODEL 400 TRANSMISSOMETER
AND MODEL 500 CONTROL UNIT
(Continued)
PETROPEFLECTOP DUST ACCUMULATION CHECK
16ET EFFLUENT OPACITY READING FROM THE OPACITY DATA RECORDER.]
17 Pre-cleaning effluent opacity (XOp)
lOpen retroreflector. Inspect and clean retroreflector opUcal surface.
and close ratroreftecbr.]
IB Post-cltanirag affluentopacity (XOp)
[GO TO TRANSCEIVER LOCATION]
MIST ACOnmiLATlOM CHECK
16£T EFFIUENT OPACITY READINGS]
ITURH OFF CHOPPER MOTOR SWITCH ON TRANSCEIVER CONTROL PANEL]
1 9 Pro-cleaning effluent opacity (X Op)
[Open transceiver, clean primary lens, close transceiver.
and turn chopper motor switch on.)
20 Post-cleaning effluent opacity (8 Op)
OPTICAL ALI6HMEKT CHECK
[LOOK INTO VIEWING PORT ON BACK OF TRANSCEIVER AND OBSERVE POSITION
OF BEAM IMAGE WITH RESPECT TO CROSS HAIRS]
21 linage centered?
[DRAW LOCATION OF BEAM IMAGE.]
CALIBRAT10H ERROR CHECK
I TURN OFF THE CHOPPER MOTOR SWITCH AND OPEN THE TRANSCEIVER]
[GET THE SOURCES CALIBRATION JIG AND INSTALL ON THE TRANSCEIVER]
[NOTE: MOST SOURCES HAVE A CALIBRATION DEVICE SUPPLIED BY THE MONITOR
MANUFACTURER THAT IS ADJUSTED FOR THE MONITORS OPTICAL PATH-
LENGTH. IF THIS DEVICE IS NOT AVAILABLE. THE AUDITOR MUST SUPPLY A
SIMILAR DEVICE THAT CAN BE ADJUSTED TO COMPENSATE FOR THE MONITORS
OPTICAL PATH LENGTH.]
[INSTALL THE AUDIT JIG ON THE TRANSCEIVER FACE IN FRONT OF THE PROJECTION LENS]
[RESTART THE CHOPPER MOTOR]
[RECORD AUDIT FILTER DATA.]
SfBIALJNa
OPACITY
22 LOW
23 MID
24 HIGH
-------
AUDIT DATA SHEET
THERMO ELECTRON (CONTRAVES GOERZ) MODEL 400 TRANSMISSOMETER
AND MODEL 500 CONTROL UNIT
(Continued)
[REMOVE AUDIT FILTERS FROM PROTECTIVE COVERS. INSPECT. AND CLEAN.)
[INSERT EACH FILTER IN JI6.THEN WAIT APPROXIMATELY TWO MINUTES AND RECORD
OPACITY VALUES REPORTED FROM OPACITY DATA RECORDER.]
ZERO
LOW
MID
HIGH
ZERO
[IF SIX-MINUTE INTEGRATED DATA ARE ALSO AVAILABLE, THEN ALLOW 13 MINUTES
EACH FOR AN ADDITIONAL RUN OF THE ZERO, LOW, MID, HIGH, AND ZERO READINGS.]
LOW
MID
HIGH
ZERO
[TURN CHOPPER OFF. REMOVE AUDIT JIG. RESTART CHOPPER. AND
CLOSt TRANSCEIVER.]
[RETURN TO CONTROL UNIT LOCATION.]
[GET 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.]
LOW 0JP_
HIGH
ZERO
25
26
~3~o~
27
34
"38~
~42~
35
~39~
~43~
28
32
29
33
36
44
37
4?
45
ISIX-MINUTE AVERAGE DATA. IF APPLICABLE.]
46
47
48
49
SO
-------
AUDIT DATA SHEET
THERMO ELECTRON (CONTRAVES GOERZ) MODEL 400 TRANSMISSOMETER
AND MODEL 500 CONTROL UNIT
(Continued)
CALCULATION OF AUDIT RESULTS
STACK EXIT CORRELATION ERROR (X):
51
ZERO ERROR IX Op):
52 Panel meter
53 Opacity data recorder
SPAN ERROR (X Op):
54 Pane) Meier
55 Opacity data recorder
(BLANK 4)
(BLANKS)
(BLANK 3)
x 100'
(BLANK 13) - (BLANKS)
(BLANK 14) - (BLANK 5)
(BLANK 15) - (BLANK 6)
(BLANK 16) - (BLANKS)
OPTICAL SURFACE DUST ACCUMULATION (X Op):
56 Retroreflector:
57 Transceiver:
58 Total:
(BLANK 17)
(BLANK 19)
(BLANK 56)
(BLANK 18)
(BLANK 20)
(BLANKS?)
PATH LENGTH AND ZERO OFFSET CORRECTION OF AUDIT FILTERS:
59 Low:
60 Mid:
1-
, _ (BLANK 22)
100
] (BLANK 4) r- "I
x 1 - (BLANK 45)
L 10° -!_
1-
-j(BLANK4) p -j
_ (BLANK 25) x i . (BLANK 45)
100 J L '«> -L
x 100
x 100
61 High:
1-
-i (BLANK 4) r-
_ (BLANK 24) x ,-
100 J L
(BLANK 45)
100 J
X 100 "
-------
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-------
THERMO ELECTRON (CONTRAVES 80ERZ) MODEL 400 TRANSMISSOMETER
AND MODEL 500 CONTROL UNIT
OPACITY CEMS PERFORMANCE AUDIT REPORT
DATA SUMMARY
AUDITOR.
SOURCE_
DATE.
UNIT.
RESULTS CHECKED BY
DATE
PARAMETER
FAULT LAMPS
CAL FAULT
DIRTY WINDOW
PURGE AIR
STACK POWER
LAMP FAILURE
ALARM
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.
sS^SSS^
7
8
9
10
11
12
51
52
53
54
55
21
\^s\^;>\
55
57
58
\^\\;x\^s
^^\N>
62
71 a
63
72 a
64
73 a
C^\>^
65
66
67
^N^SV
68
69
70
AUDIT
RFSIII T
N^S^^\>S
\^\\>^:\\^
;^\^\^\
^^^sSS
^m^
SSSm
SPECIFICATION
^\;>;;^\\^;>
OFF
OFF
OFF
OFF
OFF
OFF
±2%
±4*0p
±4% Op
+ 4KOp
t 4SOp
CENTERED
s^^\\S\>^
i2ROo
i2!50p
< 4K Op
\^;^\\^N:N>^>
\^\;^\\sS:>^
^>^v^:\\:\\:
^^SsX^^vN
;\^\\^c^
^X^x^^XS
^$^J^?$$$$
N'^^^V^
<^\\^>^^
\^\^^x^
^^s^i^
^\SS^Sx\\\S
i^§^^
s3J50p
i3JSOp
i3ROp
ERROR BASED ON SIX-MINUTE AVERAGED DATA FROM A SINGLE FILTER INSERTION.
-------
APPENDIX E.
THERMO ELECTRON (EDC) MODEL 1000A AUDIT DATA FORMS
E-l
-------
E-2
-------
AUDIT DATA SHEET
THERMO ELECTRON (ENVIRONMENTAL DATA CORPORATION)
MODEL 1000ATRANSMISSOMETER
SOURCE IDENTIFICATION:
PROCESS UNIT/STACK IDENTIFICATION:
AUDITOR:
ATTENDEES:
-CORPORATION
-PLANT/SITE
DATE:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
PRELIMINARY DATA
' Stack exit inside diameter (FT)« L*
2 • [Stack (or duct) Inside diameter (or width) at transmlssometer location (FT) x 2] - L-t
3 Calculated optical pathlength correction factor = L x / it
4 Source-cited optical pathlength correction factor
5 Source-cited zero automatic calibration values (8 opacity)
6 Source-cited span automatic calibration value (% opacity)
{GO TO DATA RECORDER LOCATION]
[INSPECT DATA RECORDING SYSTEM AND MARK WITH "OPACITY AUDIT.' AUDITORS NAME. DATE. SOURCE.
PROCESS UNIT/STACK IDENTIFICATION, AND THE TIME OF DAY.]
ZERO CHECK
[IF THE SOURCE HAS INSTALLED A "CAL-INITIATE" BUTTON NEAR THE
DATA RECORDER. PRESS THIS BUTTON TO INITIATE THE ZERO/SPAN
CHECK AND RECORD THE VALUES BELOW.]
[IF THE SOURCE HAS NOT INSTALLED A "CAL-INITIATF BUTTON,
TURN THE TRANSCEIVER "MODE SWITCH" TO THE "ZERO" POSITION
AND WAIT THREE MINUTES.]
7 Opacity data recorder zero calibration value (%0p)
[FROM "GAL-INITIATE" CHECK]
7a Opacity data recorder zero calibration value (SOp)
[FROM TRANSCEIVER MODE SWITCH CHECK]
-------
AUDIT DATA SHEET
THERMO ELECTON (ENVIROMENTAL DATA CORPORATION)
MODEL 1000ATRANSMISSOMETER
(Continued)
SPAM CHECK
[IF THERE IS HO 'CAL-INITIATE' BUTTON, TURN THE TRANSCEIVER "MODE SWITCH-
TO THE -SPAN' POSITION. WAIT THREE MINUTES. OBTAIN A SPAN VALUE. AND
RETURN THE TWOE SWITCH' TO THE NORMAL OPERATING POSITION.
0 Opacity data recorder span calibration value (XOp)
[FROM -CAL-INiTIATE" CHECK]
9 Opacity data recorder span calibration value (X Op)
[FROM TRANSCEIVER TK30E SWITCH" CHECK]
[60 TO TRANSMISSOMETER LOCATION.]
RETROREFIECTOR DUST ACCUMULATION CHECK
[6£T EFFLUENT OPACITY READINGS FROM THE OPACITY DATA RECORDER.]
10 Pro-cleaning effluent opacity (X Op)
[Inspect and clean optical window.]
11 Post-cleaning effluent opacity (8 Op)
[60 to transceiver location.]
YPAMSCEIVER DUST JtCCUMULATlOU CHECK
12 Pre-clesilng effluent opacity (X Op)
(Inspect and clean optical window.]
13 Post-cleaning effluent opacity (X Op)
CALIBRATION EWROR CHECK
[INSTALL THE FILTER HOLDER ASSEMBLY ON THE RETROREFLECTOR.]
[RECORD AUDIT FILTER DATA.]
FILTER
14 LOW
is mo
16 HJ6H
SERIAL HO.
OPACITY
-------
AUDIT DATA SHEET
THERMO ELECTRON (EDO MODEL 1000A TRANSMISSOMETER
(Continued)
{REMOVE AUDIT FILTERS FROM PROTECTIVE COVERS, INSPECT, AND CLEAN J
{RECORD THE EFFLUENT OPACITY VALUE FROM THE OPACITY DATA RECORDER.]
{INSERT A FILTER.WAIT APPROXIMATELY TWO MINUTES, AND RECORD THE
OPACITY VALUE REPORTED FROM THE OPACITY DATA RECORDER.]
[REMOVE THE FILTER AND RECORD THE EFFLUENT OPACITY.]
[REPEAT THIS PROCESS FOR FIVE RUNS OF THREE FILTERS EACH.]
EFFLUENT
LOW
EFFLUENT
MID
EFFLUENT
HI6H
{IF SIX-MINUTE INTE6RATED DATA ARE ALSO AVAILABLE, THEN ALLOW 13 MINUTES EACH FOR AN
ADDITIONAL RUN OF THE EFFLUENT LOW. MID. AND HI6H READINGS.]
EFFLUENT
LOW
EFFLUENT
MID
EFFLUENT HI6H
[CLOSE THE RETROREFLECTOR HOUSING.]
[RETURN TO CONTROL UNIT LOCATION.]
-------
AUDIT DATA SHEET
THERMO ELECTRON (EDO MODEL 1000A TRANSMISSOMETER
(Continued)
fREAD AND TRANSCRIBE FINAL CALIBRATION ERROR DATA.)
35
36
MID
37
38
EFFLUENT HIGH
17
23
29
18 19 20 21 22
24 25 26 27 28
30 31 32 33 34
39
40
41
42
43
44
45
46
47
48
54
SIX-MIHUTE AVERA6E DATA (IF APPLICABLE)
49
50
52
53
CORRECTION OF AUDIT FILTER (TRANSMITTANCE):
2x
55
56
57
Low:
Mid:
High:
E_ (BLANK 14)
100 J
_ (BLANK 15)
100
2x
-1
E-
2x
(BLANK 16)
100 -J
(BLANK)
(BLANK)
(BLANK)
-------
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-------
AUDIT DATA SHEET
THERMO ELECTRON (EDO MODEL 1000A TRANSMISSOMETER
(Continued)
STACK EXIT CORRELATION ERROR (S):
88 (BLANK*) " (BLANK 3)" x
(BLANKS)
ZERO ERROR (3 Op):
89 Opacity data recorder -
(BLANK 7 or 7a) (BLANK 5)
SPAN ERROR (S Op):
90 Opacity -
Data (BLANK 8 or 9) (BLANKS)
Recorder
OPTICAL SURFACE DUST ACCUMULATION (8 Op):
91 Retroreflector: -
(BLANK 10) (BLANK 11)
92 Transceiver: -
(BLANK 12) (BLANK 13)
93 Total: • + •
(BLANK 91) (BLANK 92)
-------
THERMO ELECTRON (EDO MODEL 1000A TRANSMISSOMETER
OPACITY GEMS PERFORMANCE AUDIT REPORT
DATA SUMMARY
AltniTOD HATF
smipcF "»"T
RESULTS C
HFflfFn RV I>ATF
PARAMETER
STACK EXIT CORRELATION ERROR
INTERNAL ZERO ERROR
INTERNAL SPAN ERROR
OPTICAL SURFACE DUST ACCUMULATION
RETROREFLECTOR
TRANSCEIVER
TOTAL
CALIBRATION ERROR ANALYSIS
MEAN ERROR
LOW
MID
H16H
CONFIDENCE INTERVAL
LOW
MID
HIGH
CALIBRATION ERROR
LOW
MID
HIGH
BLANK
NO.
sx>^\^\N>
88
89
90
v^ss^vs
91
92
93
sjsjs^s^s
^N^S
76
85 a
77
86 a
78
87 8
>SSSv^!Sv
79
80
81
^JsS^sJs
82
83
84
AUDIT
RESULT
\^SSl\^^
^^^\\N
^JSS^SSS
^>S^\^
S^SSJsSSSSj
:$^s?^\$
SPECIFICATION
•^^SSSSS^:
i m
±4»0p
±47, Op
X^V^^SS^
i2XOp
i25SOp
i2JSOp
v^^NSS^v^
\$^>^x:x^
SSisi^SS^x
^^^$\^NN
x^^SSSSSS
VCVO^\N>s\''
\"^^\NS^^
^x^^^$^\\
S^S^l^vW
;N^V^^^
\\^C$^\^\$
^$^\\N>S?^\
^N^N^V^
i 3S Op
i 3% Op
13F. Op
a
ERROR BASED ON SIX-MINUTE AVERAGED DATA FROM A SINGLE FILTER INSERTION.
-------
APPENDIX F.
ENVIROPLAN MODEL D-R280 AV "DURAG" AUDIT DATA FORMS
F-l
-------
F-2
-------
AUDIT DATA SHEET
ENVIROPLAN (THERMO ELECTRON) MODEL D-R280AV
(DURAG) TRANSMISSOMETER
SOURCE IDENTIFICATION:
PROCESS UNIT/STACK IDENTIFICATION:
AUDITOR: '
-CORPORATION
-PLANT/SITE
ATTENDEES:
DATE:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
REPRESENTING:
PRELIMINARY DATA
1
2
3
4
5
6
Stack exit inside diameter (FT) = Lx
Stack (or duct) inside diameter (or width) at transmissometer location (FT) = L t
Calculated optical pathiength correction factor = L x / Lt
Source-cited optical pathiength correction factor
Source-cited zero automatic calibration values (% opacity/milliamps)
Source-cited span automatic calibration value (R opacity/milliamps)
160 TO CONTROL UNIT DATA RECORDER LOCATION]
[INSPECT DATA RECORDING SYSTEM AND MARK WITH 'OPACITY AUDIT.' AUDITOR'S NAME. DATE. SOURCE
PROCESS UNIT/STACK IDENTIFICATION, AND THE TIME OF DAY.]
FAULT LAMP CHECKS
7 BLOWER FAILURE {loss of purge air blower power]
8 FILTER BLOCK [inadequate purge air now]
9 WINDOW [excessive dirt on transceiver window]
ON
OFF
CONTROL UNIT CHECKS
10 Opacity range switch position
[ Turn RANGE SWITCH to "4' position,]
ZERO CHECK
(PRESS CALIBRATION BUTTON ON CONTROL PANEL)
11 Internal zero value (milliamps)
(WAIT TWO MINUTES FOR AUTOMATIC CHANGE TO EXTERNAL ZERO MODE.)
I2» Panel meter zero calibration value (milliamps)
-------
AUDIT DATA SHEET
ENVIROPLAN (THERMO ELECTRON) D-R280AV TRANSMISSOMETER
(Continued)
SPAN CHECK
13 Internal span calibration value (mflliamps)
M Opacity data recorder span calibration value (X Op)
[GO TO TRANSMISSOMETER LOCATION.]
PFTRORFFI FCTOft DUST ACCUMULATION CHECK
IGET EFFLUENT OPACITY READINGS FROM THE OPACITY DATA RECORDER.]
IS Pre-cleaning effluent opacity (J5 Op)
[Inspect and clean optical surface.]
16 Post-cleaning effluent opacity (X Op)
[Go to transceiver location.]
TRANSCEIVER DMST ACCtBHHATIQH CHECK
17 Pre-cloanlng effluent opacity (X Op)
[Inspect and clean optical surface.]
IB Post-cleaning effluent opacity (X Op)
AllfiHMFHT CHECK fOPTlOHAL)
[LOOK THROUGH ALIGNMENT SIGHT AND DETERMINE IF BEAM IMAGES ARE CENTERED.]
19 linages centered?
[DRAW LOCATION Or IMAGES IN SIGHT.]
20 Span filler value (milliamps)
21 Span filter value (XOp)
YES
NO
CALIBRATtOH ERROR CHECK tJIS PROCEDURE]
[INSTALL THE AUDIT JIG OK THE PRIMARY LENS AND ADJUST THE JIG 2ERO UNTIL
A VALUE OF 4 mA IS READ ON THE REMOTE PANEL METER.]
[MAKE FINAL JIG ZERO ADJUSTMENTS BASED ON OPACITY DATA FROM DATA RECORDER.]
21* Jig zero value from data recorder (ROp)
[RECORD AUDIT FILTER DATA.]
FILTER
22 LOW
23 MID
24 HIGH
SERIAL NO.
OPACITY
-------
AUDIT DATA SHEET
ENVIROPLAN (THERMO ELECTRON) D-R280AV TRANSMISSOMETER
(Continued)
IREMOVE AUDIT FILTERS FROM PROTECTIVE COVERS. INSPECT. AND CLEAN.]
(INSERT EACH FILTER. WAIT APPROXIMATELY TWO MINUTES.AND RECORD OPACITY VALUES
REPORTED FROM OPACITY DATA RECORDER.]
[IF JIG ZERO VALUES CHANGE BY MORE THAN 1 .OX OPACITY BETWEEN THREE (3)
FILTER RUNS. READJUST JIG ZERO TO ORIGINAL VALUE AND REPEAT RUN.]
ZERO
LOW
MID
HI6H
ZERO
[IF SIX-MINUTE INTEGRATED DATA ARE ALSO AVAILABLE, THEN ALLOW 13 MINUTES
EACH FOR AN ADDITIONAL RUN OF THE ZERO, LOW, MID, HI6H. AND ZERO READINGS.]
LOW
MID
HIGH
IREMOVE AUDIT JIG. CLOSE THE TRANSCEIVER HEAD AND THE WEATHER COVER.]
[RETURN TO CONTROL UNIT LOCATION.]
CONTROL UNIT ADJUSTMENT RESET
[IF NECESSARY. RESET THE OPACITY RANGE SWITCH TO THE POSITION INDICATED IN BLANK 10.]
[MARK THE DATA RECORD FOR THE END OF THE AUDIT. GET 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
38
27
3T"
US'
"35
42 43
ISIX-fllNUTE AVERAGE DATA, IF APPLICABLE.]
HIGH
28
"32"
ZERO
29
~33~
~37"
~4f"~
46
47
48
49
50
-------
AUDIT DATA SHEET
ENVIROPLAN (THERMO ELECTRON) D-R280AV TRANSMISSQMETER
(Continued)
CAJCJUIATION OF AUDIT RESULTS
STACK EXIT CORRELATION ERROR (X):
51
ZERO ERROR (X Op):
52 Panel mrier
53 Opacity data recorder
(BLANK 4)
(BLANK 3)
(BLANK 3)
(BLANK 12a) (BLANKS)
(BLANK 12b) (BLANK 5)
x 100
SPAN ERROR (X Op):
54 Panel
Mater
(BLANK 13)
(BLANK 6)
55 Opacity
Data
Recorder
(BLANK 14)
(BLANK 6)
OPTICAL SURFACE DUST ACCUMULATION (X Op):
56 Retroreflector:
57 Transceiver:
58 Total:
(BLANK 15)
(BLANK 17)
(BLANK 56)
(BLANK 16)
(BLANK 18)
(BLANK 57)
OPTICAL PATHLEN6TH CORRECTION FACTOR AND Z1ERO OFFSET
CORRECTION OF AUDIT FILTERS:
59 Low
60 Kid*
61 High*
1
\ _
i _
E1" -j (BLANK 4) r- ~
_ (BLANK 22) x i- (BLANK 45)
_ 100 J L 10°
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_ (BLANK 23) x i- (BLANK 45)
100 J L 10° -1
r- -i (BLANK 4) r~ ~
, . (BLANK24) x t - (BLANK 45)
L 100 J L 10°
_
_
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y 1QO - ,. . , .
-------
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-------
ENVIROPLAN (THERMO ELECTRON) D-R280AV TRANSMISSOHETER
OPACITY CEMS PERFORMANCE AUDIT REPORT
AUDIT SUMMARY
AUDITOR.
SOURCE _
RESULTS CHECKED BY.
DATE.
UNIT.
DATE.
PARAMETER
BLANK
NO.
AUDIT
RFSIJLT
SPECIFICATION
FAULT LAMPS
BLOWER FAILURE
FILTER BLOCK
WINDOW-
CfF
OFF
OFF
STACK EXIT CORRELATION ERROR
51
INTERNAL ZERO ERROR
PANEL METER
52
DATA RECORDER
53
INTERNAL SPAN ERROR
PANEL METER
54
DATA RECORDER
55
Op
OPTICAL ALIGNMENT ANALYSIS
19
CENTERED
OPTICAL SURFACE DUST ACCUMULATION
RETROREFLECTOR
56
TRANSCEIVER
57
TOTAL
58
CALIBRATION ERROR ANALYSIS
MEAN ERROR
LOW
MID
HIGH
62
71a
63
72a
64
73a
CONFIDENCE INTERVAL
LOW
MID
HIGH
65
66
67
CALIBRATION ERROR
LOW
MID
HIGH
68
69
70
i 38 Op
i 3JS Op
a
ERROR BASED ON SIX-MINUTC AVERAGED DATA FROM A SINGLE FILTER INSERTION.
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
2.
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
PERFORMANCE AUDIT PROCEDURES FOR OPACITY MONITORS
5. REPORT DATE
6. PERFORMING ORGANIZATION CODE
7. AUTHOR
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