EPA-340/1 -86-010
Recommended Quality Assurance
Procedures for Opacity
Continuous Emission
Monitoring Systems
Prepared by
James W. Peeler
CEM/Engineering Division
Entropy Environmentalists, Inc.
Research Triangle Park, North Carolina 27709
Under Contract No. 68-02-3962
Work Assignments 2-52 and 3-101
With JACA Corp.
Fort Washington, PA 19039
Prepared for
EPA Project Officer: John Busik
EPA Work Assignment Managers: Anthony Wayne
and Mary Cunningham
U.S. ENVIRONMENTAL PROTECTION AGENCY
Stationary Source Compliance Division
Office of Air Quality Planning and Standards
Washington, D.C. 20460
February 1986
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DISCLAIMER
This material has been funded wholly or in part by the United states
Environmental Protection Agency under Contract 68-02-3962 to Entropy
Environmentalists, Inc. It has been subject to the Agency's peer and
administrative review, and it has been approved for publication as an EPA
document. Mention of trade names or commercial products does not constitute
endorsement or recommendation for use."
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TABLE OF CONTENTS
Page
1.0 Introduction « » .... 1
2.0 Elements of An Opacity GEMS QA Program. 2
2.1 Daily QA Checks , 2
2.2 Periodic QA Checks/Preventive Maintenance .' 4
2.3 Corrective Action Procedures 8
2.4 Accuracy Checks 9
3.0 Organization of QA Activities 11
4.0 QA Plan Implementation and Revision 13
4.1 Establish Initial QA Objectives 13
4.2 Develop Draft QA Plan. 15
4.3 Initial Trial Implementation and Debugging. 15
4.4 Finalize Initial QA Plan. 16
4.5 Implement Current QA Plan. 16
4.6 Review of QA Records and Information. 16
4.7 Revision of the QA Plan 16
4.8 Notify/Train Involved Personnel 17
5.0 Organization of QA Responsibilities 18
Appendix A. Example Quality Assurance Plans
Appendix B. Example Quality Assurance Data Summaries
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1 . 0; INTRODUCTION
This report presents recommended quality assurance (QA) procedures for
opacity continuous emission monitoring systems (CEMS's) installed at electric
utility steam generating stations. The recommended procedures are based on
experience and information gained from the Opacity GEMS Pilot Project that was
conducted in Missouri. As part of this project, QA procedures for opacity
CEMS's were developed, implemented, and evaluated during approximately one-year
of field study.
The field study included opacity CEMS's installed on six coal-fired
electric utility generating units located at four generating stations, each of
which is owned by a different utility company. The sources included in this
study were selected to be representative of a wide range of monitoring
applications and conditions, and were equipped with contemporary opacity
monitoring instrumentation provided by the three major CEMS manufacturers.
Detailed descriptions of the sources, opacity CEMS's, and QA procedures that
were evaluated during the project are included in "Evaluation of Opacity CEMS
Reliability and QA Procedures, " CEMS Pilot Project Report, March 1986.
The recommended QA procedures contained in this report are intended to
provide a simple, cost-effective approach to the development and implementation
of opacity CEMS QA plans. The recommended approach allows for much flexibility
in the selection of monitor- and spurce-specific procedures, the establishment
of QA control limits, and the organization of the quality assurance elements.
Because of the flexibility retained in the recommended procedures, source
personnel may use them to develop a QA plan that most effectively meets their
specific needs. Thus, no attempt has been made to determine or define the
minimally acceptable QA procedures or requirements.
Section 2.0 of this report outlines the major elements of a QA plan:
(1) daily QA checks, (2) periodic QA checks and preventive maintenance,
(3) corrective action procedures, and (4) accuracy checks. Procedures that may
be included are identified and described for each of the four elements.
Recommendations regarding the appropriate procedures for an initial QA plan are
also provided. Section 3.0 describes briefly the organization and interaction
of the elements of the QA plan. Section 4.0 presents an approach that may be
used for the implementation and revision of the QA plan to optimize its
usefulness and cost-effectiveness. Section 5.0 provides comments regarding
considerations affecting the assignment of the various QA responsibilities at a
particular plant. Example QA procedures developed during the opacity CEMS
Pilot Project are included in Appendix A and example QA data summaries are
included in Appendix B.
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2.0 ELEMENTS OF AN OPACITY GEMS QA PLAN
This section describes each of the major elements of an opacity CEMS QA
Plan. These elements include: (1) daily QA checks; (2) periodic QA checks and
preventive maintenance; (3) corrective action procedures; and (4) accuracy
checks. The following discussions describe the nature and types of activities
that may be included in each of these elements. The interaction and
organization of the above elements are described in Section 3.0 of this report.
2.1 DAILY QA CHECKS
Daily QA check procedures for opacity CEMS's should be developed and
implemented to allow for the identification of monitoring problems and, thus,
for the timely initiation of corrective action. Adequate daily QA check
procedures can be performed from the monitor control unit/data recording
location in virtually all cases. The daily check procedures should require
only a few minutes per day to complete for each monitoring system, and can be
performed by personnel who are not thoroughly familiar with the technical
details of the opacity monitoring instrumentation.
The daily QA checks may include the following:
1' Zero and Span Checks - Opacity monitoring regulations require that
checks of the zero (or low level) and span drift be performed at least
once daily. (Adjustments to the monitoring system are required when
the zero or span drift exceed specified limits.) Daily zero and span
checks should be included in all opacity CEMS QA plans, since these
checks are required by the applicable regulations, and because they
provide an overall indication of the performance (i.e., accuracy and
precision) of virtually the entire monitoring system.
The daily check procedures should contain a written procedure for
performing the zero and span checks. This procedure should indicate
that the determination of zero and span drift be based on the
measurements displayed by the permanent data recording system that is
used as the basis for preparation of quarterly reports. The zero and
span drift check procedure should also specify the criteria that are
used to determine when adjustments to the CEMS will be performed.
2. Fault Indicators - Virtually all contemporary opacity CEMS's
incorporate fault indicators in the monitor control unit. When
activated, the fault indicators warn of monitor malfunctions and/or
operating conditions that may affect the quality of the monitoring
data. The number and type of fault indicators are monitor-specific and
vary both between monitor manufacturers and, in some cases, among the
different models provided by the same manufacturer.
For opacity CEMS's equipped with computerized data recording systems,
the software may be designed to provide flags and/or error messages in
the computer printout to warn of problems with the monitoring system.
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These messages should be considered equivalent to the fault indicators
incorporated in the monitor control unit.
It is strongly recommended that a check of all available fault
indicators and/or error messages in computer printouts be included in
the daily QA check procedures.
3. Auxiliary Monitor Performance Parameters - Some opacity CEMS's provide
easy access to important monitor performance parameters, such as
reference current values or zero compensation levels, at the monitor
control unit. Inclusion of checks of these parameters in the daily QA
check procedures allows data to be compiled that can be used to assess
both (a) the stability of these parameters and (b) whether the fault
indicators for the same parameters are operating reliably. It is
recommended that checks of these monitor performance parameters be
included in the initial daily check procedures and that the frequency
of checking these parameters be subsequently adjusted based on the
observed monitor performance.
4. Auxiliary Data Recording/Data Display Devices - Many opacity CEMS's use
a computerized data recording system or data logger as the primary data
recording system. Most of these CEMS's are also equipped with strip
chart recorders that serve either as back-up data recorders or as
analog data display devices for use by the boiler operators. In
addition, the opacity GEMS control unit usually includes either an
analog or a digital panel meter. At some sources, measurements that
are used to assess monitor performance are obtained from the panel
meter. Therefore, at these sources the accuracy of the panel meter can
affect the accuracy of the opacity GEMS data.
Checks of auxiliary recorders and/or data display devices are important
in those cases where (1) back-up recording devices are used during
malfunctions of the primary data recording system, or (2) the accuracy
of panel meter readings can affect either the determination of the need
for adjustment of the GEMS calibration or the accuracy of the GEMS
data. Checks of the auxiliary data recording/data display devices can
be accomplished by either (1) expanding the daily zero and span check
procedures to include evaluation of the responses of the auxiliary
devices in addition to the responses of the primary data recorder, or
(2) comparison of simultaneous measurements provided by the permanent
data recorder and the auxiliary device. It is recommended that such
checks be included in the daily QA check procedures until sufficient
data are obtained to justify less frequent checks. Alternatively,
these checks could be performed only on those occasions when data from
auxiliary data recording/data display devices are actually used.
Decisions regarding which of the above parameters should be included in
daily QA checks depend on many monitor- and source-specific factors. Among the
most important factors to consider are: (1) the design and operational features
of the specific opacity monitor, (2) the data recording/data display devices
used in the opacity CEMS's, (3) historical monitor performance and previously
encountered problems, and (4) zero and span drift adjustment procedures.
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Although an attempt should be made to choose the best parameters for the daily
checks at the outset, periodic review and revisions of the QA plan (see Section
4.0) will allow for the inclusion of additional parameters and/or for the
deletion of unnecessary checks relative to the initially established daily QA
check procedures.
At most electric utility generating stations, a number of people will be
involved in the performance of the daily QA checks. Therefore, it is extremely
important that clear, concise written procedures be developed for the daily QA
checks to ensure that all involved personnel will perform them in a consistent
manner. It is recommended that a one-page daily log be developed for recording
of the necessary data. The daily log can be formatted in a manner that (1)
minimizes the recording burden, (2 ) encourages the consistent recording of
data, and (3) clearly delineates the acceptance criteria for the daily checks
and whether corrective action is necessary. It is strongly recommended that
the daily log require the person performing the daily check to sign or initial
the log sheet. Examples of detailed instructions for daily checks and daily
log sheets for several opacity monitoring systems are included in Appendix A of
this report.
If only a small number of people (i.e., one or two) perform all of the
daily QA checks, or after all personnel involved in the daily QA checks nave
become completely familiar with the data recording procedures and criteria for
initiating corrective action, it may be possible to eliminate the daily log and
instead substitute a control chart or condensed log. Such a record keeping
procedure would allow for summarizing all data from the daily checks during a
one-month period on a single log sheet. (Examples of such summaries are
included in Appendix B of this report.) It is emphasized that the use of a
summary log or control chart will reduce the volume of paper records and will
facilitate periodic review of the data; however, in most cases such a log is
not as effective as a daily log sheet in requiring consistent recording of data
or ensuring the initiation of corrective action when applicable control limits
are exceeded.
2.2 PERIODIC QA CHECKS/PREVENTIVE MAINTENANCE
The periodic QA procedures provide for checks of monitoring system
components and operational status that are unfeasible, impractical, or
unnecessary on a daily basis. These procedures include activities that are
only necessary on a semi-frequent basis (e.g., weekly, monthly, or quarterly,
etc.), and include checks of the instrumentation at both the actual monitoring
location and the control unit/data recording location. The periodic QA checks
should be designed to identify developing or existing problems with the opacity
GEMS that cannot be detected in the daily checks. The periodic QA procedures
should also incorporate preventive or routine maintenance procedures for the
opacity GEMS. The nature of the periodic QA procedures requires that personnel
who are familiar with the operation, maintenance, and calibration of the
opacity CEMS perform these activities. The time required to perform a periodic
QA check typically ranges from 2 to 8 hours. The time required may be
significantly affected by the difficulty of the access to the monitoring
location, the availability of communications between the monitoring location
and the control unit location, and the complexity of the monitoring system.
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The periodic QA procedures may include the following:
1. Transmissometer Optical Alignment - The optical alignment of the
transceiver and reflector components is a critical factor in
obtaining accurate effluent opacity measurements. Virtually all
contemporary opacity CEMS's provide an optical alignment sight for
determining whether the transmissometer components are properly
aligned.
It is recommended that a check of the optical alignment and the
recording of the alignment status be included in the periodic QA
check procedures.
2. Dust Accumulation on Optical Surfaces - The periodic QA procedures
should include some means for estimating the amount of particulate
(in terms of apparent opacity) that has accumulated on the exposed
optical surfaces of the transmissometer, and should also provide for
cleaning of the optical surfaces. A simple method of accomplishing
both of these objectives is to record the effluent opacity
measurements, clean the transceiver window, and again record the
effluent opacity measurements. The procedure is then repeated for
the reflector window. The difference between the effluent opacity
measurements before and after cleaning of each window provides a
rough estimate of the quantity of dust deposited on each window.
However, the validity of such determinations may be affected by
fluctuations in the actual effluent opacity while the "before" and
"after" measurements are being made. Experience has shown that the
suggested procedure provides adequate results at sources where
significant levels of dust accumulation are encountered (i.e.,
> 4% opacity) and where the effluent opacity is relatively constant
for at least short periods of time. At sources where the levels of
dust accumulation are small (i.e., < 2% opacity) and where effluent
opacity fluctuations are relatively large, use of the suggested
procedure often produces erroneous results. In these cases, the
optical surfaces should be cleaned; however, the quantification of
dust accumulation can either be omitted or attempted using an
alternate approach. For example, reference to the changes in the
zero compensation level or the zero check response before and after
cleaning will provide a rough estimate of the quantity of dust
deposited on the transceiver optics for some opacity CEMS's.
3. Auxiliary Monitor Performance Parameters - For most opacity CEMS's,
periodic checks of a few critical operating parameters can be very
helpful ±n the identification of developing or existing monitor
problems. The nature and type of such checks is inherently dependent
on the design and operational features of the specific opacity
monitor. Examples of critical monitor performance parameters include
(a) operational status of the automatic gain control circuit for LSI
RM41 monitors, (b) lamp reference voltage for Dynatron Model 1100
opacity monitors, and (c) response to the simulated zero opacity
condition provided by the calibration test kit (i.e., audit device)
for Contraves Model 400 opacity monitors.
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It is recommended that checks of critical monitor operating param-
eters such as those mentioned above and those identified by the
monitor manufacturer be included in the periodic QA check proce-
dures. It is also recommended that checks of important monitor
performance parameters such as those described in Section 2.1, Item 3
above (i.e., reference current values and zero compensation levels)
be included in the periodic QA checks if they are not included in the
daily QA checks.
Auxiliary Data Recording/Data Display Devices - In addition to the
auxiliary data recording devices and control unit panel meters
described in Section 2.1, Item 4 above, many opacity monitors are
equipped with electronic test meters at the transceiver location
which may be used to assess the need for adjustments or as a
reference when adjustments are made. It is recognized that at many
power plants, instrument technicians ignore these test meters, and
instead use digital voltmeters to obtain more accurate and precise
electronic measurements than are provided by the installed meters.
Checks of installed test meters may be performed by either (a) com-
paring the meter responses for zero and span checks of the opacity
GEMS to the permanent data recorder responses, 6r (b) comparing the
meter response to the responses of an external measurement device
(i.e., calibrated digital voltmeter).
It is recommended that the periodic QA procedures include checks of
all electronic data display devices (i.e., control unit panel meters
and/or test meters at the transceiver location) which are used by
station personnel to assess monitor performance. It is also
recommended that checks of all auxiliary data recording devices
(e.g., strip chart recorders for opacity CEMS's equipped with
computerized data acquisition systems or data loggers)'be included in
the periodic QA procedures.
Purge Air System/Shutters - All opacity CEMS's are equipped with
purge air systems that are designed to provide a flow of highly
filtered ambient air across the exposed optical surfaces of the
transmissometer to minimize contamination of these optical surfaces
by particulate in the effluent stream. Some opacity CEMS's are also
equipped with shutter systems which close in the event of failure of
the purge air system. When operating properly, the shutters do not
obstruct the transmissometer light beam while the purge air system is
operating, and they close when the purge air system provides
insufficient air flow to protect the optical surfaces. Typical
failures of the purge air system and shutter devices include: (a)
plugging of air filters, (b) leaks in the purge air system supply
.hoses, (c) failure of the air flow sensor to detect insufficient
purge air flow, (d) partial or complete closure of the shutters when
the purge air system is working properly, and (e) failure of the
shutters to close when the purge air system is inoperative. Failure
of the purge air system or shutter devices may result in costly
damage to the transmissometer components, loss of data, or a high
bias in all effluent opacity measurements due to dust accumulation on
the exposed optical surfaces.
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It is recommended that the periodic QA check procedures include a
visual inspection of the purge air system filters and supply hoses,
and checks that the shutters do not obstruct the transmissometer
light beam during normal operation and that they close when the purge
air flow rate is inadequate.
6. Preventive Maintenance - Preventive or routine maintenance procedures
are typically specified by the monitor manufacturer in the operator's
manual for the monitor. These procedures usually include replacement
of measurement lamps, fault lamp bulbs, purge-air filters, and
desiccant cartridges. Monitor manufacturers typically specify either
a frequency for replacing expendable materials or criteria for
determining when such components must be replaced. Operational
experience with the opacity monitor may indicate other maintenance
activities that should be performed periodically, such as the removal
of accumulated material from the transmissometer flanges or sampling
ports. Other preventive or routine maintenance activities are .
necessary to maintain data recording equipment in proper working ; .
order. In addition to the maintenance practices specified by the ,,
data recorder vendor, common sense requires (a) reasonable cleaning, 7;
of data recording devices, (b) checks and/or replacement of chart
recorder inking supplies or printer ribbons, and (c) replacement of
paper supplies as necessary.
It is recommended that preventive or routine maintenance activities
for the opacity monitor either specified by the monitor manufacturer
or developed based on operational experience be incorporated into the
periodic QA procedures. This approach will ensure that these
activities are performed at the same time other checks of monitor
operational status are performed, and will therefore minimize
additional trips to the monitoring location. To the extent that
routine maintenance activities of the data recording equipment are
not included in the daily QA checks, it is recommended that these
activities also be included in the periodic QA procedures in order to
avoid unnecessary GEMS downtime.
Decisions regarding the exact procedures that should be included in the
periodic QA procedures depend on monitor- and source-specific factors. In
addition, the appropriate frequency for performing the periodic QA procedures
is source-specific. Choosing an appropriate frequency requires balancing
concerns regarding data quality against the amount of time and effort required
to perform the checks. Important factors to consider in this decision are
(1) the reliability of previous monitor operation and (2) the difficulty
associated with access to the monitoring location. For example, at sources
where chronic monitor operational problems have been encountered and where
access to the monitoring location is easy, it may be appropriate to conduct
periodic QA checks every two weeks, at least initially. In contrast, at
sources where the opacity GEMS has operated reliably and where access to the
monitoring location is difficult, it may be sufficient to conduct periodic QA
checks only once every three or four months.
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If no previous monitor operational experience is available upon which to
base a decision, it is recommended that the periodic QA checks be performed 'on
a monthly basis during the initial period of the QA plan implementation.
Periodic review of the QA data and corresponding revisions to the QA plan (as
described in Section 4.0) will allow for appropriate revision of the frequency
of QA checks, as well as for the inclusion of additional checks and deletion of
unnecessary procedures based on actual monitor performance.
As with the daily QA checks, it is recommended that concise, clearly
written procedures should be developed for performing the periodic QA checks to
ensure that all involved personnel perform the checks in the same manner, and
to ensure that corrective action is initiated when control limits are
exceeded. In addition, it is strongly recommended that a periodic QA log be
developed and completed for each periodic QA check to provide a record for
assessing monitor performance. Periodic QA check logs can be developed that
(a) minimize the data recording burden, (b) encourage consistent data recording
practices, and (c) clearly indicate when control limits are exceeded, and thus
when corrective action is necessary. Example periodic QA check procedures and
log sheets for several opacity CEMS's are included in Appendix A of this
report.
2.3 CORRECTIVE ACTION PROCEDURES
Control limits must be established for virtually all of the parameters
included in either the daily QA check procedures or periodic QA check
procedures. (Control limits are not necessary for parameters or measurements
recorded for informational purposes only.) Whenever the control limits are
exceeded, corrective action activities should be initiated in order to resolve
the problem with the opacity GEMS. Corrective action may also be initiated as
a result of accuracy checks performed by source personnel or performance audits
conducted by the control agency. In general, corrective action procedures and
corresponding records should provide documentation of what was wrong with the
CEMS, what was done to correct the problem, and performance check results that
demonstrate that the problem was actually resolved.
Clearly, corrective action procedures are even more monitor- and source-
specific than are the daily and/or periodic QA check procedures. To a large
extent, the corrective action procedures are contained in the monitor
operator's manual within applicable sections that describe procedures for
instrument (a) start-up, (b) calibration, (c) trouble-shooting, and (d)
repairs/maintenance. (These procedures can be incorporated into the QA plan
simply by reference to the operator's manual.) The corrective action
procedures should stress "before" and "after" measurements of appropriate
parameters in order to provide a basis for assessment of the impact of repairs
and/or adjustments on fault indicators, zero and span check responses, and
'. monitor calibration. In addition, the corrective action procedures should
indicate the need for only the measurements, adjustments, and repairs for those
components or subsystems of the opacity CEMS necessary to return the entire
opacity CEMS to operation within the applicable control limits. For example,
if a zero offset develops between the control unit and strip chart recorder (as
indicated by the daily QA check), all that would be necessary is (a) recording
of the pre-adjustment zero and span reponses, (b) adjustment of the chart
recorder calibration, (c) a final zero and span drift check that showed the
proper responses for the chart recorder and agreement between the control
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unit and chart recorder responses. In contrast, failure of an important
electronic component in the transceiver might require a complete recalibration
of the opacity monitor, including an off-stack,"clear path check (i.e., zero
alignment).
It is recommended that a corrective action log be developed and that it be
appropriately completed on each occasion that repairs or adjustments are made.
A corrective action log satisfies the regulatory requirement for maintaining
records of all GEMS adjustments and/or repairs, and also provides a very useful
basis for evaluating the effectiveness of repairs and adjustments and for
identifying chronic monitor problems. Notes recorded by the person performing
the repairs are perhaps most useful, provided that they can be understood by
the other personnel who make repairs and adjustments to the monitoring system.
At a minimum, it is recommended* that the corrective action log provide for
recording of the same parameters that are included in the daily and periodic QA
checks both before and after adjustments are completed. Examples of corrective
action logs for several opacity CEMS's are included in Appendix A of this
report.
2.4 ACCURACY. CHECKS
As used here, accuracy checks refer to either (a) an on-stack performance
audit, or (b) an off-stack (or clear path) zero alignment and calibration
check. These accuracy checks are briefly described below.
2.4.1 Performance Audits
Performance audits of an installed opacity CEMS may be conducted by either
source personnel or the control agency to assess the operational status of the
opacity CEMS and the accuracy and precision of the opacity measurements
relative to the simulated zero condition provided by the zero check device.
Performance audits do not quantify the absolute accuracy of the opacity
measurements.
Performance audit procedures for many contemporary opacity CEMS's are
contained in "Performance Audit Procedures for Opacity Monitors" (EPA No.
340/1-83/010). Additional information and suggestions for modifications to the
above referenced procedures are contained in "Opacity CEMS Audit Procedure
Guidelines," Opacity CEMS Pilot Project Draft Report, March 1985.
In essence, virtually all of the checks included in the referenced audit
procedure documents should be included in either the daily or periodic QA
checks described in Sections 2.1 and 2.2 of this report, except for the
calibration error check. In general, the calibration error check procedure
uses an audit device and a set of three calibrated neutral density filters to
assess the precision, linearity, and accuracy of the opacity CEMS (relative to
the zero check response) at three test points over the measurement range of the
monitor. Each of the three test filters is inserted into the light path five
times, and the calibration error check result for each filter is calculated in
the same manner as the calibration error test results described in Performance
Specification 1, Appendix B, 40 CFR 60. (Alternate procedures are used for
some monitors.)
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Audit devices are commercially available for most opacity CEMS's. Neutral
density filters can be obtained from a number of suppliers and calibrated
neutral density filters (traceable to the National Bureau of Standards) can
also be obtained.
It is recommended that the calibration error check portion of the
performance audit procedures be conducted at least once per year for each
installed opacity GEMS. The calibration error check should also be performed
when there are questions regarding the accuracy or linearity of the opacity
data.
2.4.2 Clear Path Calibration - Zero Alignment
For the daily and periodic QA checks and for the performance audit checks,
the accuracy of the opacity measurements is determined relative to the
monitor's response to the simulated zero check devices. The procedure for
establishing the equivalency of the simulated zero check device and the actual
clear-path (zero opacity) condition is referred to as "zero alignment."
Performance Specification 1 (Appendix B, 40 CFR 60) requires that this
procedure be performed either under clear stack conditions or prior to
installing the opacity monitor at the measurement location. Since some amount
of residual opacity is usually present at the monitoring location even when the
source is not operating, the zero alignment procedure is almost always
performed prior to the initial installation of the monitor.
Prior to the March 30, 1983 revisions to Performance Specification 1, the
regulations required that the clear-path calibration/zero alignment be
performed .at least once per year. The requirement for the annual check was
deleted, since the purpose of the Performance Specification is to ensure the
initial capability of the opacity GEMS to provide valid data, rather than to
provide QA guidelines.
The frequency for performing a clear-path calibration or zero alignment
should be based on the typical rate of change between the simulated zero check
response and the true zero check response. However, there is almost no avail-
able public information regarding this factor. (One plant that participated in
the Opacity GEMS Pilot Project indicated that the zero alignment procedure was
performed once per year for each of the four transmissometers installed at that
plant.)
It is recommended that a clear-path calibration check be performed once per
year or at some other frequency for which there are data supporting the choice
of the interval between clear-path calibration/zero alignment checks.
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3.0 ORGANIZATION OF QA ACTIVITIES
The four elements of the QA plan for opacity GEMS's are (1) daily QA check
procedures, (2) periodic QA check procedures and preventive maintenance, (3)
corrective action procedures, and (4) accuracy checks. These four elements
include all of the activities necessary for the acquisition of quality assured
opacity monitoring data after the monitor has been properly installed and after
it has been successfully demonstrated to comply with the requirements of
Performance Specification 1 (Appendix B, 40 CFR 60).
. One possible arrangement of the four elements of the QA Plan is shown in
Figure 1. Other organizational schemes are possible and may be advantageous in
certain circumstances. The organization shown in Figure 1 is recommended
because it is extremely simple and flexible. The four elements are
interconnected only by (1) the schedules for the daily QA checks, periodic QA
checks, and accuracy checks, and (2) the criteria for initiating (and
completing) corrective action. Changes in the schedules for the periodic QA
checks and/or accuracy checks, and changes in the acceptance criteria (control
limits) for the three quality assessment activities would not require
reorganization of the QA plan.
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12
CONDUCT DAILY
CHECKS
WAIT FOR NEXT
DAILY CHECK
TIME
FOR
ACCURACY
CHECK
DAILY
CHECKS
O.K.
ACCURACY CHECKS
PERIODIC OA CHECKS
AND PREVENTIVE
MAINTENANCE
1
CORRECTIVE ACTION
RECTIV
ACTION
PLETE
YES
FIGURE I. ORGANIZATION OF QA ACTIVITIES
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4.0 QA PLAN IMPLEMENTATION AND REVISION
The development and implementation of a QA plan for an opacity GEMS is to
some extent a trial and error procedure. In most cases, the QA plan that is
initially developed, should be'reviewed from time to time to determine if
additional or more frequent activities are necessary to ensure data quality
and/or -to determine if some of the QA procedures can be relaxed in order to
reduce resource expenditures in'those cases where the quality of the data is
more than adequate. A majdr QA management goal should be to achieve the
desired level of data quality at-the lowest real cost. Since opacity GEMS QA
plans are inherently monitor- and source-specific, achievement of this goal
requires that the QA plan be considered a dynamic rather than a static
document.
The major steps in the implementation and revision of a QA plan are shown
in Figure 2. These steps are briefly described below.
4.1 ESTABLISH INITIAL QA OBJECTIVES /„..-•
. >v ' v • •* "?*v.. ••- "'* •• •
Management of tne QA.plan implementation to achieve the necessary level of
data quality at the lowest cost requires that the QA objectives be clearly
defined. In the most general sense., ,the quality of the data must be compatible
with the intended use of the data... .. Two potential,'uses of opacity GEMS data at
electric utility plants are: (1) the plant personnel may use the data to
identify process and control system1 problems in order to initiate actions that
will maximize efficiency and minimize equipment deteriorization, and (2) the
control agency will rely on the data to .identify periods of excess emissions in
order to prioritize source inspections and/or other follow-up activities. The
data quality required by the source will be subject to the conditions imposed
by particular generating units and other internal considerations of the utility
company. The data quality requirements imposed by a plant's own internal use
of the data are considered to be.no less rigorous, than those imposed by the
agency's use of the data.
The use of the opacity GEMS data to identify periods of excess emissions is
somewhat dependent on the proximity of the effluent opacity for the particular
generating unit under normal operating conditions to the opacity level used to
identify periods of excess emissions. Coal-fired electric utility generating
units are typically subject to opacity limits in the range of 20% to 40%
opacity. For most generating units, the opacity under normal operating
conditions is generally well below 20% opacity (regardless of the applicable
standard); however, when process or control system problems are encountered,
the effluent opacity is often much greater than the standard (e.g., greater
than 150 percent of the standard). In these situations, if the overall
accuracy of the opacity monitoring data is within +_ 5% opacity, there is little
chance that periods of actual excess emission will be overlooked or that
periods of operation below the opacity standard will be inadvertently reported
as periods of excess emissions due ^to monitor inaccuracy.
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14
ESTABLISH INITIAL QA OBJECTIVES.
I
DEVELOP DRAFT OA PLAN
I
INITIAL TRIAL IMPLEMENTATION AND DEBUGGING
I
FINALIZE INITIAL QA PLAN
I
IMPLEMENT CURRENT OA PLAN
I
REVIEW QA RECORDS AND
INFORMATION
I.
2. PwMIc QA checks. |«f«. «rf
3. C«rr«cUv»
4. Acoracy chMk
5. CMMMMU ft-ma
REVISE QA PROCEDURES
NOTIFY/TRAIN INVOLVED PERSONNEL
FIGURE 2. QA PLAN IMPLEMENTATION AND REVISION
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Using an accuracy of +_ 5% opacity as the overall objective, appropriate
individual QA objectives (i.e., control limits) can be developed. For example,
a particular generating unit might choose the following control limits:
Parameter Control Limit
Zero Alignment +_ 2% opacity
Calibration Error +_ 3% opacity
Dust Accumulation +_ 2% opacity
Calibration Drift (zero _+ 2% opacity
or span drift)
Assuming that an opacity CEMS is operating at the maximum for each of the
control limits simultaneously (which is grossly pessimistic from the source's
perspective), and assuming that the associated biases are randomly distributed
(which is optimistic from the source's perspective, since dust, accumulation
results only in a positive bias), the overall probable error can be calcu-
lated. For the above control limits and assumptions, the probable error would
be on the order of +^4.6% opacity. If the calibration drift control limit were
increased from +^ 2%~~opacity to +_ 4% opacity, then the probable error would be
increased from +_ 4.6% opacity to approximately 4^ 5.7% opacity.
The above example analysis is somewhat simplistic from a statistical point of
view. Nevertheless, the example shows (1) that overall QA objectives can be es-
tablished based on considerations of how "good" the data needs to be and (2) how
control limits that allow attainment of the overall objectives can be selected.
4.2 DEVELOP DRAFT QA PLAN
The draft QA plan may be developed in accordance with the recommendations
provided in Section 2.0. Again, monitor- and source-specific factors and
previous operational experience with the opacity CEMS are among the most
important factors to consider. The example QA procedures evaluated at four
generating stations for Lear Siegler, Dynatron, and Contraves Goerz opacity
CEMS's equipped with a variety of data recording systems provide much back-
ground information for the development of a draft QA plan. Extensive dis-
cussions of these QA plans are contained in "Evaluation of Opacity CEMS
Reliability and QA Procedures," Opacity CEMS Pilot Project, Draft Report, April
1985.
4.3 INITIAL TRIAL IMPLEMENTATION AND DEBUGGING
It is recommended that the draft QA procedures be implemented for a short
time period in order to identify ambiguous instructions, problems with data logs,
and procedures that are simply overly cumbersome. Some of these problems are
bound to occur in even the most carefully prepared QA plan. The trial
implementation/debugging period should last for several weeks or at least until
most of the personnel who will perform the daily QA checks have worked through
the instructions and completed the daily log, and at least until one periodic QA
check has been performed.
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16
4.4 FINALIZE INITIAL QA PLAN
The problems identified in the initial trial implementation/debugging
period must be resolved. The comments of the personnel performing the checks
are probably the most useful source of information for revising the
instructions and log sheets for each element of the QA plan. It may also be
necessary to revise the QA objectives and/or individual control limits at this
point in the development of the QA Plan.
4.5 IMPLEMENT CURRENT QA PLAN
After all initial revisions to the QA plan have been completed, the plan
should be implemented for at least several months. Implementation of the QA
plan for six months will provide sufficient data to allow appropriate
adjustments to each of the elements of the QA plan to be made within the same
time frame.
4.6 REVIEW OF QA RECORDS AND INFORMATION
At the end of the first implementation period of the initial QA plan, the
available QA documentation should be reviewed. This review should include
daily QA check logs, periodic QA check results, corrective action records,
accuracy check results, and comments from the personnel who have carried out
each of these procedures. It is recommended that data from the daily QA checks
be consolidated into monthly summaries or control charts to facilitate analysis
of data for trends. The objectives of the review and analysis of data are (1)
to identify problem areas and/or recurring monitor problems that require
additional attention and (2) to identify those parameters that are documented
to be very stable and thus, no longer warrant checking at the initially
scheduled frequency. Examples of this type of analysis are provided in
"Evaluation of Opacity GEMS Reliability and QA Procedures," Opacity GEMS Pilot
Project Draft Report, April 1985.
If no changes to the QA plan appear to be necessary, either the review and
analysis are too superficial or the QA plan has already reached a maximum cost-
effectiveness level. In the latter case, the QA plan should continue to be
implemented without changes.
4.7 REVISION OF THE QA PLAN
The QA plan should be revised in accordance with the results of the review
and analysis of the QA data from the implementation period. It is important
that changes in both the instructions and the QA data logs be made, even though
most of the personnel involved with the implementation of the QA procedures
will no longer refer to the instructions. (The use of out-dated instructions
with revised data sheets can create many problems when personnel changes
occur.)
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17
4.8 NOTIFY/TRAIN INVOLVED PERSONNEL
Personnel responsible for the implementation of specific elements of the QA
plan must be properly notified of changes in the specific QA procedures. One
result of the initial period of QA implementation may be the identification of
the need for additional training of specific individuals. If this situation
occurs, either the necessary training should be provided or the division of QA
responsibilities should be altered to relieve the need for training.
After all involved personnel have been notified of changes in the specific
QA procedures and after all training issues have been resolved, implementation
of the revised QA plan should begin again at Step 5, "Implement Current QA
Plan."
The entire process should be repeated indefinitely; however, the periods
between review of the QA documentation may be extended during subsequent
implementation periods. Eventually, the most cost-effective QA plan will be
developed through iteration.
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18
5.0 ORGANIZATION OP QA RESPONSIBILITIES
The implementation of opacity CEMS QA plans usually involves multiple
personnel from several different departments or groups at electric utility
generating stations. Therefore, the clear delineation and assignment of the
responsibilities for various aspects of the QA plan to different groups and/or
individuals, as well as coordination among the different groups and/or
individuals, is usually necessary. '.
The management and organizational structure used for power plant personnel
vary among electric utility companies, and may also vary among different
generating stations operated by the same company. Union labor agreements
differ greatly for different companies. The number of people who may be
involved with an opacity monitoring program can vary dramatically among
companies and generating stations. Finally, different approaches are often
taken by different companies regarding the interaction of corporate environ-
mental representatives and station personnel. All of these factors must be
considered in the development and implementation of an opacity CEMS QA plan.
To be successful, an opacity CEMS QA plan must be compatible with the
existing management and organizational structure at the generating station.
The QA plan should be designed to rely on the established lines of communi-
cation and decision making authority among the various groups and/or
individuals involved with the opacity monitoring program.
The opacity CEMS QA plan delineated in the preceding sections involves
various activities included in the four elements of the QA plan: (1) daily QA
checks, (2) periodic QA checks and preventive maintenance, (3) corrective
action, and (4) accuracy checks. Decisions regarding the assignment of QA
responsibilities should take into account the differences in the technical
skills and knowledge required by the specific activities associated with each
of the QA plan elements. In essence, the daily QA checks do not require a
detailed under-standing of how the opacity CEMS works; however, the other three
elements do. Another major difference between these two groups of elements is
the frequency with which activities are performed. The daily QA checks are
obviously performed on a daily basis; the other activities are performed
relatively infrequently. Because of these differences, some power plants may
assign responsibilities for performing daily QA checks to one group of people
and assign the responsibilities for the other activities to a second group.
Three of the four generating stations participating in the Opacity CEMS Pilot
Project chose this option. (The fourth station assigned responsibility for all
of the QA activities to the instrument department personnel.) Of the three
stations that divided the QA responsibilities, two stations chose to have the
boiler operators perform the daily QA checks; the third station had an
individual from the "Results Department" perform the daily QA checks. In all
cases, instrument technicians performed the other activities included in the QA
plan. f,
In some cases, a large number of people (10-15 individuals) may be involved
in performing the daily QA checks. In this situation, the importance of clear,
step-by-step instructions, completion of the daily QA logs, and keeping track
of who performed the checks is increased, since verbal communication among all
the different individuals is not likely to provide much continuity of operation.
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19
The periodic QA procedures, corrective action activities, and accuracy
checks all require that the personnel performing these activities have a
working knowledge of how the opacity GEMS works. Usually, these activities
will be performed by a relatively small group of individuals whose jobs
routinely require effective exchange of information. Thus, the instructions
associated with these activities may be less detailed; however, the acceptance
criteria should be very clear. In addition, since these elements of the QA
plan are performed relatively infrequently and/ or in response to the
unpredictable development of problems, communications with other departments or
individuals and keeping track of schedules are important.
In addition to the responsibilities associated with the four elements of
the QA plan, someone must be assigned the responsibility for overseeing the
on-going QA program. The responsibilities associated with this task include
making sure that: (1) required activities are performed, (2) data logs are
properly completed, and (3) proper decisions are made when exceedances of the
established QA control limits occur. This person or group of people may also
be responsible for the periodic review of QA data to determine whether an
increase or reduction in the frequency for specific QA procedures is
appropriate. Ideally, the person responsible for making these decisions would
not be involved in performing the specific activities required by the QA plan;
however, this is not absolutely necessary.
The person or group responsible for overseeing the implementation of the QA
plan should be in contact with those persons responsible for the preparation of
the quarterly reports that are submitted to the control agency. This is
necessary: (1) to ensure that the correct information regarding GEM performance
is included in the report, and (2) to close the feedback loop regarding any
response of the control agency to reported GEMS performance data. Finally, the
person overseeing the implementation of the QA plan should be in contact with
other station personnel and/or corporate personnel who use the GEMS data to
ensure that the level of data quality is sufficient for the internal use of the
monitoring information.
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APPENDIX A.
EXAMPLE QUALITY ASSURANCE PROCEDURES
This Appendix contains quality assurance procedures that were used by the
four sources participating in the CEMS Pilot Project. Four separate sets of
quality assurance procedures are included which address the monitoring
instrumentation provided by three major CEMS manufacturers and the source-
specific constraints encountered at each of the four participating sources.
(All company and plant names and other identifiers have been deleted.)
Additional information regarding these QA procedures may be found in
"Evaluation of Opacity CEMS Reliability and QA Procedures," CEMS Pilot Project
Report, March 1986.
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EXAMPLE A
STATION
OPACITY MONITOR QUALITY ASSURANCE .PROCEDURES.
•""''••' ? "STATION
DYNATRON MODEL 1100 OPACITY MONITORING SYSTEMS -.
OVERVIEW OF QA PROCEDURES
A proposed quality assurance program has been developed for the
Station opacity monitoring systems. The specific QA
procedures have been developed to be compatible with the Station
(1) opacity monitoring instrumentation and monitoring system configuration,
(2) data recording devices, (3) effluent handling system, and (4) management
and organizational structure. The proposed QA program will be field-tested
during implementation, reviewed and evaluated periodically, and revised as
necessary over a one-year period. Through this process, it is expected that
QA procedures will be developed and demonstrated which are both adequate for
maintaining high levels of data quality and cost effective in terms of
necessary time and material resource expenditures.
The following elements are included in the proposed Station
opacity monitor quality assurance program.
(1) Daily Log, Daily Check Instructions - The Daily Log is to be
completed by the personnel responsible for checking the monitoring
system on a daily basis. Step-by-step Daily Check Instructions are
provided for completing the Daily Log. The Daily Check and Daily
Log do not require extensive time to complete, nor do they require
that the person performing the procedure be intimately familiar
with the opacity monitoring instrumentation. The Daily Check and
Daily Log provide for identification of monitoring problems and
initiation of corrective action.
(2) Corrective Action Log and Instructions - The Corrective Action
Instructions and Log are used when adjustment, repairs, and/or
other non-routine corrective action is necessary as indicated by
the Daily Checks. The Corrective Action procedures are to be
utilized by technical personnel experienced in resolving problems
with the monitoring systems. The specific corrective action
procedures are relatively extensive, but will provide adequate
documentation for future refinement of QA procedures and
demonstration of their effectiveness. The corrective action
procedures are utilized only on an "as necessary" basis.
(3) Periodic QA Check and Instructions - The Periodic QA check is
intended to be performed in conjunction with the opacity monitor
routine maintenance program performed monthly at the
Station. The Periodic QA Check procedures provide for checks of
monitoring system components and operating status which are
unfeasible, impractical, and unnecessary on a daily basis.
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(4) The documentation of the QA program will be reviewed periodically to
determine if modification to the proposed procedures are
appropriate. Such modifications may be made as additional experience
and data are obtained.
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STATION
DAILY CHECK INSTRUCTIONS
DYNATRON MODEL 1100 OPACITY MONITORING SYSTEMS
The following are step-by-step instructions for conducting the Daily
Check of the Station Unit # and Unit # opacity monitoring
systems. Criteria are provided for determining when corrective action should
be initiated. The person conducting the Daily Check of each monitoring system
should complete all blanks on the Daily Log as indicated below. (Separate
forms are used for the Unit #4 and #5 monitoring systems.)
I. GENERAL INFORMATION
o Enter name of person performing check, the date (month, day, year), and
the time of day (24-hour clock) that the check is begun.
o Hours Boiler Down - Enter the number of hours the boiler was not in
operation (i.e., not combusting fuel) during the preceding 24-hour
period.
0 Hours Monitor Down - Enter the number of hours the monitor did not
provide a record of effluent opacity during the preceding 24-hour
period. Describe monitor downtime in "Comments" section (i.e., cause of
outage, time began, time ended, and any corrective action taken to return
monitor to service).
II. FAULT LAMPS
o Examine the fault lamps on the Control Unit. Check the appropriate box
on the Daily Log to indicate the status of each fault lamp (check "YES"
if lamp is illuminated).
o If any fault lamps are illuminated, corrective action should be initiated
as soon as possible.
III. ZERO/SPAN CHECK DATA
o Examine the strip chart to determine the zero and span responses of the
most recent monitor calibration. Record the zero and span calibration
values on the Daily Log in units of % opacity.
o Examine the data logger tape to determine the zero and span response of
the most recent monitor calibration, and record these values on the Daily
Log.
o Check the appropriate boxes on the Daily Log to indicate whether the zero
and span values are outside acceptable limits.
o Check the data logger tape to determine if the proper time of day is
displayed. Reset the timer of the data logger if necessary.
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Note: IF YES ANSWERS ARE INDICATED FOR ANY OF THE QUESTIONS ON THE
DAILY LOG, CORRECTIVE ACTION SHOULD BE INITIATED AS SOON AS
POSSIBLE.
IV. COMMENTS
o Describe any problems observed during the performance of the Daily Check
and/or any other apparent problems which may affect monitor performance.
O ENTER THE TIME OF DAY THAT THE DAILY CHECK IS COMPLETER (PART I).
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Opacity Monitoring System
DAILY LOG
STATION
UNIT:
I. GENERAL INFORMATION
Name:
Date:
Time Start:
Time Complete:
Hours Boiler Down:
II. FAULT LAMPS
Hours Monitor Down:
FAULT LAMPS ON?
Lamp
Window
Air Flow
NO
YES
III. ZERO/SPAN CHECK DATA
Chart Recorder, Zero Value:
Data Logger, Zero Value:
Span Value:_
Span Value:
Does Zero Value exceed acceptable limits of H
Does Span Value exceed acceptable limits of -i
- 2% opacity?
- 27, opacity?
NO
YES
| Data Logger
Timer
Correct
Incorrect
IF YES ANSWERS ARE INDICATED FOR ANY OF THE ABOVE QUESTIONS, CORRECTIVE
ACTION SHOULD BE INITIATED AS SOON AS POSSIBLE.
IV. COMMENTS:
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., , STATION
PERIODIC QUALITY ASSURANCE CHECK INSTRUCTIONS
DYNATRON OPACITY MONITORING SYSTEM
The following are step-by-step instructions for performing the Periodic
QA Checks of the Station opacity monitoring systems. Initially,
the Periodic QA Checks are to be performed Once per month. The person
performing the monthly checks should complete all blanks on the Periodic QA
Check Log. (A separate data form should be used for each monitor.) The
manufacturer's instructions for cleaning optical surfaces, performing
electronic adjustments, and inspecting/servicing the purge-air system should
be followed throughout the Periodic QA Check.
I. GENERAL INFORMATION
o Enter the Unit number for the monitor on the QA Log.
o Enter the name of the person performing the check, the date (month
day, year), and the time of day (24-hour clock) that the check is
begun.
II. CALIBRATION CHECK DATA
(1) Place the "CYCLE TIME HOURS" knob on the "MANUAL POSITION." Rotate
the "METER DISPLAY" knob to the "OPACITY" position. Depress
"ZERO/SPAN" switch and record the low range calibration check
responses of the panel meter chart recorder, and data logger
(% opacity).
(2) Record the high range calibration check responses of the panel meter,
chart recorder, and data logger (% opacity).
(3) Corrective action should be initiated if all "zero" and "span"
responses are not within +_ 2% opacity of the proper values. A
Corrective Action Log should be completed if such action is
necessary.
(4) Using an accurate volt meter, measure the Lamp Reference Voltage from
available test points on the back of the control unit. Record the
.voltage on the QA log. If the Lamp Reference voltage is outside the
range of 6.5 + 1.0 volts, adjust the monitor according to the
manufacturer's instructions and record the post-adjustment Lamp
Voltage on the data sheet.
(5) Record the minimum 6-minute average opacity indicated by the chart
recorder for the hour preceding the QA check.
III. TRANSMISSOMETER CHECK/SERVICE
This segment of the Periodic QA Check requires that effluent opacity
measurements "before and after" both alignment adjustments and cleaning of
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optical windows be obtained in order to assess the impact of these
activities. These measurements may be obtained by two methods: (1) have an
assistant record real-time data if two-way communication between the control
unit and monitoring location is available, or (2) sychronize watch and chart
recorder, and note the exact time each action is performed to facilitate
recovery of opacity measurements from the chart recorder after the various
activities are completed.
(1) Alignment Check - Determine the optical alignment status of the
transceiver and reflector components by looking through the alignment
sight on the transceiver and observing whether the image is within
the circular target (acceptable), or outside the circular target
(unacceptable). Indicate the position of the light beam on the
diagram, and check the appropriate box for alignment status on the QA
Log.
If the optical alignment is unacceptable, note the effluent opacity,
and then realign the opacity monitoring system in accordance with the
manufacturer's instructions. Record the effluent opacity after
realignment is completed. If a shift in the baseline opacity occurs
after realignment, note the magnitude of the change which was
observed in "Part V COMMENTS."
(2) Reflector Window Check - Record the exact time (or effluent opacity)
prior to cleaning the reflector optics. Remove the protective window
(slide) from the reflector and clean the glass according to the
manufacturer's instructions. Replace the reflector protective
window. Record the exact time, and wait at least two full
integration periods before performing the next step, (or record
directly the effluent opacity).
(3) Transceiver Window Cleaning/Check - Record the exact time (or
effluent opacity) prior to cleaning the transceiver optics. Remove
the protective window (slide) from the transceiver and clean the
glass according to the manufacturer's instructions. Replace the
transceiver protective window and record the exact time, (or record
the effluent opacity).
(4) Purge Air Service - Inspect and service, as necessary, the purge-air
blowers, air filters, and shutter mechanism as per the manufacturer's
instructions. Note any corrective action taken on the QA Log.
IV. FINAL MEASUREMENTS
(1) If necessary, examine the data record to obtain the average opacity
values corresponding to the times recorded on the data sheet (i.e.,
before and after alignment adjustments, before and after cleaning of
the reflector window, and before and after cleaning of the
transceiver window). Record all data on the QA Log.
(2) Record the minimum 6-minute average effluent opacity value during the
hour period following completion of all adjustments, repairs, and
service for the monitor.
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(3) Note periods of alignment adjustment and window cleaning on the
permanent data record to ensure that these periods will not be later
mistaken for excess emissions. Reset alarms if activated during QA
checks. Note that the periodic QA check was performed in the "Part V
COMMENTS" section of the Daily Log.
V. COMMENTS
All observations regarding monitor performance should be detailed and
explained.
ENTER TIME OF DAY PERIODIC QA CHECK IS COMPLETED (PART 1).
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Opacity Monitoring System
PERIODIC QA CHECK
STATION
UNIT:
I. GENERAL INFORMATION
Name:
Date:
Time Start:
Time Complete:_
II. CALIBRATION CHECK DATA
m
r?>
m
(4)
Low Range Response
High Range Response
Adjusted Low Range Response
Adjusted High Range Response
% Opacity
Panel Meter
Chart Recorder
Data Logger
Lamp Reference Voltage:_
Adjusted Lamp Reference Voltage:
Minimum 6-min. opacity value (hour preceding QA check):
III. TRANSMISSOMETER CHECK/SERVICE
1. Alignment Status (Note position of light beam on diagram)
[Alignment Acceptable?
YES
NO
See instructions if
alignment is not acceptable
2. Before reflector cleaning
3.
After reflector cleaning
Before transceiver cleaning
After tranceiver cleaning
TIME
EFFLUENT OPACITY
IV. FINAL MEASUREMENTS
Minimum 6-min. opacity value (hour following QA Check):
V. COMMENTS:
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, STATION
CORRECTIVE ACTION INSTRUCTIONS
DYNATRON OPACITY MONITORING SYSTEM
The following are step-by-step instructions for completing the Corrective
Action Log when adjustments and/or repairs of either the Unit # or Unit //
opacity monitoring systems are necessary. The person performing the corrective
action should complete all blanks on the Corrective Action Log as indicated
below.
I. GENERAL INFORMATION
o Enter the Unit number corresponding to the monitor for which repairs or
adjustments are performed.
o Enter the name of person performing repairs or adjustments, the date
(month, day, year), and the time of day (24-hour clock) that the corrective
action is initiated.
II. FAULT LAMPS
o Enter "ON" or "OFF" for each fault lamp on the Log.
o Monitor calibration and completion of Part III of the Log are not required
if an Air Flow problem initiates the Corrective Action. However, if the
"WINDOW," or "LAMP" fault lamps are illuminated, data listed below must be
obtained prior to adjusting the monitor.
o If "LAMP" is illuminated, (1) measure and record the lamp reference
voltage, (2) adjust reference voltage to manufacturer's specifications, and
(3) record the post-adjustment reference voltage.
o If "WINDOW" is illuminated, (1) record the effluent opacity indicated by
the data recorder, (2) clean transceiver and reflector windows, and (3)
record the effluent opacity indicated by the data recorder.
o Record the time when the fault is corrected. Describe all corrective
action taken in the "Part IV COMMENTS."
III. CALIBRATION DATA/ADJUSTMENTS
(1) Place the "CYCLE TIME HOURS" knob on the "MANUAL POSITION." Rotate the
"METER DISPLAY" knob to the "OPACITY" position. Depress "ZERO/SPAN"
switch and record the low range calibration check responses of the
panel meter, chart recorder, and data logger (% opacity).
(2) Record the high range calibration check responses of the panel meter,
chart recorder, and data logger (% opacity).
(3) Adjustment of the monitoring system is necessary when the low range
check responses of the panel meter, chart recorder or data logger
exceed +_ 2% opacity from the correct low range check value. (Correct
value of the low range check should be labeled on the front cover of
the control unit.)
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If no adjustment is made, enter "NA" on line 3 of the Corrective
Action Log, and proceed to step (4).
Describe all adjustments and/or corrective action in "Part IV
COMMENTS." After all adjustments are completed, repeat step (1)
above, and record the post-adjustment low range responses on line 3
of Log.
(4) Adjustment of the monitor is necessary if the high range responses of
either the panel meter, chart recorder, or data logger exceed +_ 2%
opacity from the correct value. (Correct value of the high range
check should be labeled on front of control unit.)
If no adjustment is made, enter "NA" on line 4 of the Log. Describe
all adjustments and/or corrective action in "Part IV COMMENTS."
After all adjustments are completed, repeat steps (1) and (2) above,
and record post-adjustment span response on line 4 of Log.
IV. COMMENTS
All repairs and/or adjustments performed as a result of the above
procedures should be described. Sufficient explanation should be
provided to determine what was done and what effect it had on monitor
performance.
In addition, any preventive or non-routine maintenance performed on
the monitor should be detailed in this section.
ENTER TIME OF DAY ALL CORRECTIVE ACTION IS COMPLETED. (Part I)
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Opacity Monitoring System
CORRECTIVE ACTION LOG
STATION UNIT:
I. GENERAL INFORMATION
Name:
Date:
Time Start:
Time Complete:
II. SYSTEM/MONITOR FAULTS
FAULT LAMPS
LAMP
WINDOW
AIR FLOW
ON/OFF
DATE/ TIME CORRECTED
"LAMP" ON Lamp Voltage - before adjustment:
"WINDOW" ON Recorded Opacity - before cleaning:
III. CALIBRATION DATA/ADJUSTMENT
after adjustment:
after cleaning:
(1)
(2)
(3)
(4)
Low Range Response
High Range Response
Adjusted Low Range Response
Adjusted High Range Response
% Opacity
Panel Meter
Chart Recorder
Data Logger
IV. COMMENTS
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EXAMPLE B
STATION
STATION
DAILY CHECK INSTRUCTIONS
LSI OPACITY MONITORING SYSTEM
* RM41 Transmissometers •
* 622 Emission Monitor Combiner and Chart Recorder
* DP-30 Data Logger and Printer
The following are step-by-step instructions for conducting the .
Daily Check of the Station Unit #1 and Unit #2 opacity monitor-
ing systems. Criteria are provided for determining when corrective
action should be initiated. The person conducting the Daily Check of
each monitoring system should complete all blanks on the Daily Log as
indicated below. (Separate forms are used for the Unit #1 and #2
monitoring systems.)
I. GENERAL INFORMATION
* Enter name of person performing check, the date (month, day,
year), the time of day (24-hour clock) that the check is begun,
and the total boiler 0.0.S time for the previous 24 hours.
II. COMBINER DATA
* Examine the fault lamps on the Combiner. Check the appropriate
box on the Daily Log to indicate the status of each fault lamp
(check "YES" if lamp is illuminated).
* Rotate the Measurement switch to the "COMP" position. Rotate
the Analyzer switch to position (1) and record the 2ero compen-
sation level for Monitor A. The panel meter readout is in units
of optical density (OD). Rotate the Analyzer switch to position
(2) and record the zero compensation level for monitor B.
Return the ANALYZER switch to the "EXIT" position and return the
Measurement switch to the "30% OPACITY" position.
* Examine the strip chart to determine the zero and span responses
of the most recent monitor calibration. Record the zero and
span calibration values on the Daily Log in units of % opacity.
The zero and span calibration comes in every 4 hours.
III. DP-30 HOURLY REPORT DATA
* Record on the Daily Log the zero and span values displayed on
the most recent Hourly Report.
* Check the appropriate box on the Daily Log to indicate whether
the zero and span values are outside acceptable limits.
* Circle on the Daily Log the Reason Code and/or Flags which ap-
pear on the most recent Hourly Report.
-------
- 2 -
* Check the appropriate box on the Daily Log to indicate whether
the "M" or "R" Flags are present.
* Check the appropriate box on the Daily Log to indicate whether
the listed error messages are shown on the Hourly Report.
NOTE: IF YES ANSWERS ARE INDICATED FOR ANY OF THE QUESTIONS ON
THE DAILY LOG, A JOB REQUISITION MUST BE INITIATED.
IV. COMMENTS
* If a J.R. is required, enter J.R. number in space provided.*
* Describe any problems observed during the performance of the
Daily Check and/or any other apparent problems which may affect
monitor performance.
* Enter the TIME OF DAY that the Daily Check is completed.
(*JR means "job requisition")
-------
CO.
Opacity Monitoring System
DAILY LOG
STATION
I. GENERAL INFORMATION
Name:
Date:
83
UNIT:
Time Start:
TOTAL BOILER O.O.S. TIME (PREVIOUS 24 HOURS):
II. COMBINER DATA
NO i
FAULT LAMPS ON?
Filter
Shutter
: _Ref
Windows
Over Range
YES
Zero Compensation Level: Monitor A COMP (OD):
Chart Recorder, Zero Value:
III. DP-30 HOURLY REPORT DATA
Zero Calibration: Span Calibration:
Monitor B COMP (OD):_
Span Value:
NO
Does zero value exceed acceptable limits of + 2.5% opacity?
Does span value exceed acceptable limits (67.5% to 72.5% opacity)?
Reason Code/Flags (Circle those present on hourly report)
##
M
NO
A
YES I
Is the "M" or "R" Flag present?
Error Messages on Hourly Report? NO YES
1. A/D REFERENCE FAULT
2. DIGITAL/ANALOG DIFFERENTIAL ALARM
3. A/D TIME OUT
IF YES ANSWERS ARE INDICATED FOR ANY OF THE ABOVE QUESTIONS, A JOB
REQUISITION SHOULD BE INITIATED
IV. COMMENTS: J.R. No.
was initiated
YES
TIME COMPLETED:
Route: Operating Engineer
File A/13/26(d)
SP-192
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Page 1 of 8
JOB INSTRUCTION BREAK-DOWN (J.I.B.)
Job
Periodic QA Check
J.I.B. No. 1-13-5.1
Prepared by
Date
6-15-83
1-10-79
Job Class. Tech.
The following are step-by-step instructions for performing the
Periodic QA checks of the Station opacity monitoring systems. .
The Periodic QA checks are to be performed at least once per month.
The person performing the monthly checks should complete the Periodic
QA Check Log. (A separate data form should be used for each monitor.)
I. General Information
* Enter the Unit number (1 or 2) and the monitor indentifier (A
or B).
* Enter the name of the person performing the check, the date
(month, day, year), and the time of day (24-hour clock) that
the check is begun.
II. Calibration Check Data
(1) Enter PA/PD commands at the DP-30 printer to initiate display
of instantaneous analog and digital computer values at one-
minute intervals for the monitor being evaluated.
Example: Control is gained by pressing the CTL and I keys
simultaneously. The DP-30 system response and the operator
response should be as follows:
System Response
DP-30 I/O REQ
STACK ID?
(or 2)
(or 2)
(or 2)
Enter
1 (or 2)
P A
P D
Return
System Response Enter
1 (or 2) Return
PA ' Return
PD Return
(2) Rotate the Analyzer switch on the combiner to the ^position
corresponding to the monitor being evaluated. Position 1
corresponds to the A monitor and position 2 corresponds to
the B monitor. Rotate the measurement switch to the "REF"
position and record the reference current value (ma) on the
Log. Return the Analyzer switch to the "EXIT" position and
the Measurement switch to the "30% Opacity" position.
-------
.B. 1-13-5.1 page 2 Qf 8
(3) Switch the monitor (duct) not being evaluted out-of-service
at the Combiner and initiate a manual zero calibration.
Record the zero calibration responses of the panel meter and
strip chart recorder. Record the analog system zero calibra-
tion response from the DP-30 printout (see sample DP-30 prin-
tout sheet attached).
(4) Rotate the Analyzer switch to the position corresponding to
the monitor being evaluated. Rotate the Measurement switch
to the "COMP" position and record the zero compensation value
indicated^by the panel meter. Return the Analyzer switch to
the "EXIT" position and the Measurement switch to the "100%
Opacity" position.
(5) Initiate a span calibration check and record the panel meter
and strip chart responses on the Log. Record the analog sys-
tem span response from the DP-30 printout.
(6) Record the minimum 6-minute average opacity indicated by the
chart recorder and DP-30 printout for the hour preceding this
check. ~~ SL
(7) Switch the out-of-service monitor (duct) back to operate.
(8) Repeat steps 2 through 7 for the monitor (duct) which was
previously taken 0.0.S. Be sure to use a separate form.
(9) Return the combiner unit back to normal operation, that is...
* "Operate" light illuminated
* Measurement switch in the "30% Opacity" position
* Analyzer switch in the "Exit" position.
(10) Reissue the PA/PD command to stop the DP-30 printout.
Example: Control is gained by pressing CTL and I keys
simultaneously. The DP-30 system response and the operator
response should be as follows:
System Response Enter System Response Enter
DP-30 REQ
STACK ID? 1 (or 2) 1 (or 2) Return
?/l (or 2) P A PA Return
?/1 *1> TO Return
?./l (or 2) . P D PD Return
?/l (or 2) Return
-------
J.l.B. 1-13-5.1 - • Page 3 of 8
III. Transmissometer Check/Service
All the time spent performing this procedure on each instrument
is counted as out-of-service hours. It is very important that
this job be done as quickly and as thoroughly as possible so the
system remains as continuous and trouble free as possible.
(1) In the Control Room:
Before starting to work on any monitor, transceiver, and/or re-
flector, log that particular monitor out-of-service with the "OS"
commands. It is suggested that both monitors be taken 0.0.S.
before preceeding out to the field in order to save time.
Example: Control is gained by pressing the CTL and I keys
simultaneously. The DP-30 system response and the operator
response should be as follows:
System Response Enter System Response Enter
DP-30 REQ
STACK ID?
1/1 (or 2)
INSTRUMENT?
?/l (or 2)
INSTRUMENT?
(or 2)
1 (or 2)
0 S
MONA
0 S
M 0 N B
Return
1 (or 2)
OS
MONA
OS
M 0 N B
Return
Return
Return
Return
Return
NOTE: Both field monitors cannot be taken O.O.S. on the same in-
struction line, that is, "MONA and MONB" is not a valid entry and
will result in the computer issuing the instruction "BAD ENTRY".
(2) At the Reflector:
A. Remove, empty, and wipe clean with a rag, the pre-cleaner
collector .
B. Remove, empty, and wipe clean with a rag, the pre-filter
collector.
C. Remove and inspect the filter element and replace it with
a new or clean one.
NOTE: These filter elements can be cleaned and several
times before a new one is needed by following the in-
structions on the blower housing.
-------
J.I.B. 1-13-5.1 . • Page 4 of 8
D. After cleaning, inspect the filter by dropping a light
down inside the element. If any ruptures or pin holes
are observed, discard and use a new element.
E. Replace the filter element and the pre-filter collector
only.
F. Before replacing the pre-cleaner collector, place your
hand over the intake to completely obstruct air flow.
* Check to see that the shutter falls.
* Check that the "shutter" and "filter" alarms occur,
on the combiner panel in the Control Room, for that
particular duct by positioning the analyzer switch.
G. Replace the pre-cleaning collector.
H. Restore the shutter to the open position by de-energizing
the blower motor and then re-energizing it again.
NOTE: If shutter fails to open after the above proce-
dure, the shutter solenoid or T.D. relay may be faulty.
Replace the defective part and try the above procedure
again.
I. Inspect all air hoses for mechanical integrity. Test all
hose clamps for tightness.
J. Clean the reflector lens completely by removing the iris
plate and wiping with the clean, dry, lint free cloth
stored inside the cylinder located in the reflector
mounting flange.
K. If any moisture, small beads, are present within the re-
flector (between glass cover and reflector) then the des-
sicant cartridge should be changed.
NOTE: Be sure the reflector module is replaced in the
exact 3-hole position found, when changing dessicant.
L. Inspect the duct mounting flange for any accumulation of
dust. Rod out any accumulation with'wire brush rods.
M. Close up the reflector unit.
N. Perform an alignment check at the reflector by determin-
ing if the light beam is within the circular target of
the viewing port. Indicate the position of the image
within the circular target on the diagram and check the
appropriate box for alignment status on the QA Log.
(3) At the Transceiver:
A. Repeat Steps 2-A through 2-1.
-------
J.I.B. 1-13-5.1 Page 5 of 8
B. Clean the projection lens and the zero mirror face with
the clean, dry, lint free lens cloth by positioning the
mode switch from "Operate" to "Zero".
C. Return the mode switch back to "Operate" position. Be
sure the zero mirror returns to the rest (down) position.
Do not change mode switch from "Operate" again until zero
mirror cam comes to rest.
D. If any moisture, small bead , are present on the inside of
the projection lens, the dessicant cartridge should be
changed.
£. Inspect the duct mounting flange for any dust
accumulation. Rod out any dust with wire brush rods.
F. Close up the transceiver unit.
G. Check the AGC LED (Automatic Gain Control light emitting
diode) on the right hand side of the transceiver, and
record whether it is "ON" or "OFF".
If the AGC is not on, repairs to the monitoring system
must be completed before continuing.
H. Perform an alignment check by removing the plastic cover
from the mode switch on the transceiver and turn the
switch to the "ALIGN" position. Determine the optical
alignment status of the transceiver and retroreflector by
looking through the "bull's eye" and observing whether
the image is within the circular target (acceptable), or
outside the circular target (unacceptable). Indicate the
position of the light beam on the diagram, and check the
appropriate box for alignment status on the QA Log.
Return the transceiver to the "OPER" position.
* If the optical alignment is unacceptable, realign the
opacity monitoring system in accordance with the
manufacturer's instructions.' If a shift in the base-
line opacity occurs after realignment, note the mag-
nitude of the chance which was observed in "Part V
Comments".
I. Repeat the above instructions for the other field monitor
starting at step number 2.
(4) In the Control Room:
A. At the combiner unit make a manual "zero" calibration
(1 minute) and a manual "span" calibration (1 minute).
B. Issue the "IS" command to stop the DP-30 printout.
-------
1 (or 2)
I S
M 0 N A
I S
M 0 N B
See step
1 (or 2)
IS
M 0 N A
IS
M 0 N B
C
Return
Return
Return
Return
Return
J.l.B. 1-13-5.1 Page 6 of S
Example: Control is gained by pressing CTL and I keys
simultaneously. The DP-30 system response and the opera-
tor response should be as follows:
System Response Enter System Response Enter
DP-30 I/O REQ
STACK ID?.
1/1 (or 2)
INSTRUMENT?
1/1 (or 2)
INSTRUMENT?
1/1 (or 2)
C. Using the "AC" command type in the following comment for
the particular stack:
"QA" MAINTENANCE FOLLOW-UP"
Example:
System Response Enter System Response Enter
AC AC Return
"COMMENT IS" Type in System will Return
the above print out
comment comment
entered
?/l (or 2) Return
IV. Final Measurements
(1) Upon completion of all the above steps , record the minimum 6-
minute average effluent opacity value during the hour period
following completion of all adjustments, repairs, and service
for the monitor.
(2) Record the final zero compensation value for such monitor us-
ing the procedure detailed in Part II Step (4) above.
(3) Write a J.R. for any problems that cannot be immediately
corrected. Write comments on the QA Log about the nature of
the problems.
(4) Write down the time on the QA Log when this procedure is
completed.
-------
J.I.B. 1-13-5.1
Page 7 of 8
I.
UNIT
Name
Opacity Monitoring System
PERIODIC QA CHECK
, * STATION
MONITOR
Date: - - 83
Time Start:
II. CALIBRATION CHECK DATA
Reference Current (ma)
Zero Value (% opacity)
Zero compensation (OP)
Span value (% opacity)
Minimum 6-min. average opacity
value for preceding hour
Panel Meter
Chart
Recorder
7777/7777""
DP-30
(Analog)
Ill/Hill
III. TRANSMISSOMETER. CHECK/SERVICE
1.
AGC
ON?
YES
NO
(See Instructions if AGC is not on.
2. Alignment Status (Note position of Light Beam on Diagram)
Transceiver -4- 4- 4- Retroreflector -f •»-
Alignment Acceptable?
Transceiver
Retroreflector
YES
NO
(See Instructions if alignment
is not acceptable.)
IV. FINAL MEASUREMENTS
1. Minimum 6-min. average effluent opacity during hour:
2. Final Zero Compensation value (panel meter, OD):
V. COMMENTS:
Time Completed:
Route: Operating Engineer •
-------
J.I.B. 1-13-5.1
Page 8 of 8
SAMPLE DP-30 PRINTOUT - PA/PD
COMMAND - QA PERIODIC CHECK
STACK # 1
ADRS.
ADRS.
ADRS.
ADRS.
ADRS.
ADRS.
STACK
ADRS.
02/0
02/1
02/2
02/3
02/4
02/7
# 1
Analog System Response Zero or
Span (% Opacity)
3.88
3.80
1.02 VOLTS
0.95 VOLTS
1.01 VOLTS
1.00 VOLTS
0.36 VOLTS
0.97 VOLTS
-------
i I Page 1 of 3
I '»
; «
•5' , JOB INSTRUCTION BREAK-DOWN
I
j Job CORRECTIVE ACTION LOG INSTRUCTIONS J.I.B. No. 1-13-5.3
1 {
Lear-Siegler RM41 Opacity Monitoring System
*
i
Prepared by . ., Date Job Class.
The following are step-by-step instructions for completing the
CORRECTIVE ACTION LOG when adjustments and/or repairs of either the
Unit #1 or Unit #2 opacity monitoring system are necessary. The per-
sons performing the corrective action should complete all blanks on
the CORRECTIVE ACTION LOG as indicated below.
I. GENERAL INFORMATION
*Enter the date, plant and unit number corresponding to the moni-
toring system for which repairs or adjustments are performed, and
the number of the job requisition that initiated the corrective
action.
*Enter the name of the technician performing the repair or ad-
justment and the time started.
II. DESCRIBE SYSTEM PROBLEM >;
Describe the system problem in as much detail as necessary to
clearly state the as found condition, to include meter readings,
fault lamps, calibration data, etc. Use the reverse side of the
CORRECTIVE ACTION if necessary. Refer to the DAILY LOG which in-
itiated corrective action.
III. DESCRIBE ALL CORRECTIVE ACTION TAKEN
Describe all the corrective action taken, in as much detail as
necessary to clearly state the repairs or adjustments or other
actions taken. Reference and attach all data sheets, DP-30 hand-
copy, calculations, etc. which resulted from this corrective
action.
IV. RECORD TIME AND DATE CORRECTIVE ACTION WAS COMPLETED
Record the time and date when the corrective action was com-
pleted, i.e. when the system is again considered operational.
V. THE NEXT DP-30 HOURLY REPORT DATA
Hand carry the CORRECTIVE ACTION LOG to the UCO responsible for
the affected generating unit. Notify the UCO that the opacity
monitoring system is again operational and that it will be neces-
sary for the UCO to obtain certain information from that unit's
NEXT hourly opacity report generated by the DP-30 terminal. Per-
form the following:
-------
J.I.B. 1-13-5.3 Page 2 of 3
*0n the CORRECTIVE ACTION LOG, record the zero and span cali-
bration values printed on the next Hourly Report.
*Check the appropriate box on the CORRECTIVE ACTION LOG to
indicate whether the zero and span values are outside accept-,
• able limits.
*0n the CORRECTIVE ACTION LOG, circle the Reason Code and/or
Flags which appear on the next Hourly Report.
*Check the appropriate box on the CORRECTIVE ACTION LOG to
indicate whether the "M" or "R" Flags are present.
*Check the appropriate box on the CORRECTIVE ACTION LOG to
indicate whether the listed error messages are shown on the
Hourly Report. ,
NOTE: IF YES ANSWERS ARE INCIATED FOR ANY OF THE QUESTIONS,
A JOB REQUISITION MUST BE INITIATED.
VI. COMMENTS
*If a J.R. is required, enter the J.R. number in space provided.
*UCO to route completed CORRECTIVE ACTION LOG as indicated at the
bottom of the LOG. '...-.-
-------
U.JL.O.
. — J.O— _/._>
Opacity Monitoring System
CORRECTIVE ACTION LOG
I. GENERAL INFORMATION
Date
Plant
Unit No.
J.R. No.
Technician
Time Corrective Action Started
II. DESCRIBE SYSTEM PROBLEM
III. DESCRIBE ALL CORRECTIVE ACTION TAKEN
Hrs,
IV.
RECORD TIME AND DATE CORRECTIVE ACTION WAS COMPLETED
Time HRS.
Date
V.
THE NEXT DP-30 HOURLY REPORT DATA
Zero Calibration:
Span Calibration:
NO YES
Does zero value exceed acceptable limits of +2.5% opacity?
Does span value exceed acceptable limits (67.5% to 72.5% opacity)
Reason Code/Flags (Circle those present on hourly report)
i
## * D M R A
Fls the
"M"
or
"R"
Flag
present?
NO
YES
Error Messages on Hourly Report?
1. A/D REFERENCE FAULT
2. DIGITAL /ANALOG DIFFERENTIAL ALARM
3. A/D TIME OUT
NO
YES
IF YES ANSWERS ARE INDICATED FOR ANY OF THE ABOVE QUESTIONS, A JOB
REQUISITION SHOULD BE INITIATED
VI. COMMENTS: J.R. No.
was initiated
ROUTE: Original to Operating Engr.
-------
EXAMPLE C
STATION
OPACITY MONITOR QUALITY ASSURANCE PROCEDURES
COMPANY, STATION
LSI RM41 OPACITY MONITORING SYSTEM
OVERVIEW OF QA PROCEDURES
A proposed quality assurance program has been developed for the
- Co. Station opacity monitoring system. The
specific QA procedures have been developed to be compatible with the
Station (1) opacity monitoring instrumentation and monitoring system
configuration, (2) data recording device, (3) effluent handling system, and (4)
management and organizational structure. The proposed QA program will be
field-tested during implementation, reviewed and evaluated periodically, and
revised as necessary over a one-year period. Through this process, it is
expected that QA procedures will be developed and demonstrated which are both
adequate for maintaining high levels of data quality and cost effective in
term's of necessary time and material resource expenditures.
The following elements are included in the proposed Station opacity
monitor quality assurance program.
(1) Daily Log. Daily Check Instructions - The Daily Log is to be completed
by Operations personnel in the boiler control room. Step-by-step
Daily Check Instructions are provided for completing the Daily Log.
The Daily Check and Daily Log do not require extensive time to
complete, nor do they require that the person performing the procedure
be intimately familiar with the opacity monitoring instrumentation.
The Daily Check and Daily Log provide for identification of monitoring
problems and initiation of corrective action.
(2) Corrective Action Log and Instructions - The Corrective Action
Instructions and Log are used when adjustment, repairs, and/or other
non-routine corrective action is necessary as indicated by the Daily
Checks. The Corrective Action procedures are to be utilized by
technical personnel experienced in resolving problems with the
monitoring systems. The specific corrective action procedures are
relatively extensive, but will provide adequate documentation for
future refinement of QA procedures and demonstration of their
effectiveness. The corrective action procedures are utilized only on
an "as necessary" basis.
(3) Periodic QA Check and Instructions - The Periodic QA check is intended
to be performed in conjunction with the opacity monitor routine
preventive maintenance program performed three times per year at the
Station. The Periodic QA Check procedures provide for checks of
monitoring system components and operating status which are
unfeasible, impractical, and unnecessary on a daily basis.
-------
(4) The documentation of the QA program will be reviewed periodically to
determine if modification to the proposed procedures are
appropriate. Such modifications may be made as additional experience
and data are obtained.
(5) An attempt will be made to develop a practical method for conducting
an annual clear-path check of the Station opacity monitoring
system. If successful, this method will be utilized in conjunction
with a performance audit of each monitor to be conducted by station
personnel during the project and a performance audit to be conducted
at the end of the one-year study by the Pilot Project Staff.
-------
. COMPANY
STATION
DAILY CHECK INSTRUCTIONS
OPACITY MONITORING SYSTEM
(Lear Siegler, Inc. RM41)
The following are step-by-step instructions for conducting the Daily
Check of the Station opacity monitoring systems. Criteria are provided
for determining when corrective action should be initiated. The person
conducting the Daily Check of each monitoring system should complete all
blanks on the Daily Log as indicated below.
I. GENERAL INFORMATION
o Enter name of person performing check, the date (month, day, year), and
the time of day (24-hour clock) that the check is begun.
o Hours Boiler Down - Enter the number of hours the boiler was not in
operation (i.e., not combusting fuel) during the preceding 24-hour
period.
o Hours Monitor Down - Enter the number of hours the monitor did not
provide a record of effluent opacity during the preceding 24-hour
period. Describe monitor downtime in "Part IV Comments" (i.e. , cause of
outage, time began, time ended, and any corrective action taken to
return monitor to service.)
II. FAULT LAMPS
o Examine the fault lamps on the Control Unit. Check the appropriate box
on the Daily Log to indicate the status of each fault lamp (check "YES"
if lamp is illuminated).
III. PANEL METER DATA
o Rotate the Measurement switch to the "REF" position and record the
reference current value (ma) indicated on the 0 to 30 scale.
o Rotate the Measurement switch to the "COMP" position and record the zero
compensation level. (The panel meter readout is in units of optical
density, OD.) Return the Measurement switch to the "100% OPACITY"
postion.
o Check the appropriate boxes on the Daily Log to indicate whether the
reference and zero compensation values are outside of acceptable limits.
IV. STRIP CHART DATA
o Examine the strip chart to determine the zero and span responses of the
most recent monitor calibration. Record the zero and span calibration
values on the Daily Log in units of % opacity.
-------
o Check the appropriate boxes on the Daily Log to indicate whether the
zero and span values are outside acceptable limits.
Note: IF YES ANSWERS ARE INDICATED FOR ANY OF THE QUESTIONS ON THE DAILY
LOG, CORRECTIVE ACTION SHOULD BE INITIATED AS SOON AS POSSIBLE.
V. COMMENTS
o Describe any problems observed during the performance of the Daily Check
and/or any other apparent problems which may affect monitor performance.
O ENTER THE TIME OF DAY THAT THE DAILY CHECK IS COMPLETED. (Part I)
-------
Opacity Monitoring System
DAILY LOG
I. GENERAL INFORMATION
Name:
Date:
STATION
Time Start:
Time Complete:
Hours Boiler Down:
II. FAULT LAMPS
Hours Monitor Down:
FAULT LAMPS ON?
Filter
Shutter
Ref
Windows
Over Range
NO
YES
III. PANEL METER DATA
"REF" value (ma):
Does
Does
"REF"
"ZERO
value
COMP"
exceed
exceed
acceptable
acceptable
range
range
(17
(+
.9-22
.018
.2
OD)
ma)? .
7 ;
NO
YES
IV. STRIP CHART DATA
Zero Calibration (% opacity):
Span Calibration (% opacity):
Does zero value exceed acceptable limits of j
Does span value exceed acceptable limits (.32
h 2.0% opacity?
.5 +_ 2.0% opacity?.
NO
YES
IF YES ANSWERS ARE INDICATED FOR ANY OF THE ABOVE QUESTIONS, CORRECTIVE
ACTION SHOULD BE INITIATED AS SOON AS POSSIBLE.
V. COMMENTS:
-------
. COMPANY, STATION
PERIODIC QUALITY ASSURANCE CHECK INSTRUCTIONS
LSI OPACITY MONITORING SYSTEM
The folLowing are step-by-step instructions for performing the Periodic
QA Checks of the . opacity monitoring system. Initially, the Periodic QA
Checks are to be performed in conjunction with the routine opacity monitoring
system maintenance program performed at least once every four months. The
person performing the QA Checks should complete all blanks on the Periodic QA
Check Log.
I. GENERAL INFORMATION
o Enter the. name of the person performing the check, the date (month,
day, year) , and the time of day (24-hour clock) that the check is
begun. -W,
II. CONTROL UNIT CALIBRATION CHECK DATA
(1) Rotate the Measurement switch to the "REF" position and record the
reference current value (ma) on the Log. Return the Measurement
switch to the "100% Opacity" position.
(2) Initiate a manual calibration by depressing the "OPERATE/GAL"
switch. Record the zero calibration responses (% opacity) of the
panel meter and strip chart recorder.
(3) Rotate the Measurement switch to the "COMP" position and record the
zero compensation value indicated by the panel meter (OD). Return
the Measurement switch to the "100% Opacity" position.
(4) Initiate a span calibration check by depressing the "ZERO/SPAN"
switch, and record the panel meter and strip chart span check
responses (% opacity) on the Log.
(5) Record the minimum 6-minute average opacity indicated by the chart
recorder for the hour period preceding the QA check.
III. TRANSMISSOMETER CHECK/SERVICE
(1) At the monitoring location, check the AGC LED (Automatic Gain Control
light emitting diode) on the right hand side of the transceiver, and
record whether it is "ON" or "OFF." If the AGC is not illuminated,
repairs to the monitoring system must be completed before continuing.
(A Corrective Action Log Sheet should be filled out.)
(2) Alignment Check - Remove the plastic cover from the mode switch on
the transceiver and turn the switch to the "ALIGN" position.
Determine the optical alignment status of the transceiver and
retroreflector by looking through the "bull's eye" and observing
-------
whether the image is within the circular target (acceptable), or
outside the circular target (unacceptable). Indicate the position of
the light beam on the diagram, and check the appropriate box for
alignment status on the QA Log.
Open the retoreflector, and determine if the light beam appears to be
centered within the port. Indicate the apparent position of the
light beam on the diagram and check the appropriate box for
retroreflector alignment status on the QA Log.
If the optical alignment is unacceptable, realign the opacity
monitoring system in accordance with the manufacturer's
instructions. If a shift in the baseline opacity occurs after
realignment, note the magnitude of the change which was observed in
"Part V COMMENTS."
(3) Inspect and service, as necessary, the purge-air blowers, air
filters, and shutter mechanism as per the manufacturer's ,
instructions. Note whether the blower system status is acceptable,
and describe any corrective action taken on the QA Log.
(4) Retroreflector Cleaning/Check - Record the average current value (ma)
corresponding to the double-pass transmittance indicated by the J-Box
meter. Also, record the exact time to allow subsequent determination
of the "before cleaning" effluent opacity from the chart record (or
have an assistant note the panel meter opacity value if two-way
communications are available). Release the retroreflector latches,
swing the retroreflector open, and remove all accumulated particulate
within the optical path of the monitor. Clean the retroreflector
surfaces according to the manufacturer's instructions. Close and
secure the retroreflector.
Record the average transmittance indicated by the J-Box meter and the
"post cleaning" exact time (or effluent opacity level). Wait at
least two full integration periods (12 minutes) before performing
step (5) unless an assistant records real time data.
(5) Transceiver Cleaning/Check - Record the average effluent
transmittance indicated by the J-Box meter and the exact time (or
average effluent opacity). Release the transceiver latches, swing
the transceiver open, and remove all accumulated particulate matter
from the optical path of the monitor. Clean both the transceiver
window and the zero reflector according to the manufacturer's
instructions. Close and secure the transceiver.
Record the average effluent transmittance indicated by the J-Box
meter and the exact time (or the "post-cleaning" effluent opacity).
(6) Return to the control unit/data recorder station and obtain the
average opacity values indicated by the 6-minute chart recorder
corresponding to the times recorded on the data sheet (i.e. before
and after alignment adjustments, before and after cleaning of the
retroreflector, and before and after cleaning of the transceiver).
-------
Record all data on the QA Log. (This step is not necessary if an
assistant records real-time opacity values during the QA Check
activities.)
(7) Note periods of cleaning on the strip chart record to ensure that
these periods will not be later mistaken for excess emissions. Reset
alarms if activated during QA Checks. Initiate zero calibration to
reset zero compensation and record the post-QA Check zero
compensation level (OD) on the QA Log.
(8) Note that the periodic QA Check was performed in the "Part V
COMMENTS" section of the Daily Log.
IV. FINAL MEASUREMENTS
(1) Upon completion of all the above steps, record the minimum 6-minute
average effluent opacity value displayed on the strip chart for the
hour period following completion of all adjustments, repairs, and
service for the monitor.
(2) Initiate a manual calibration by depressing the "OPERATE/CAL" switch.
Record the final zero compensation value using the procedure detailed
in II (3) above.
V. COMMENTS
All observations regarding monitor performance should be explained.
ENTER TIME OF DAY PERIODIC QA CHECK IS COMPLETED (PART I).
-------
I. Name:
Opacity Monitoring System
PERIODIC QA CHECK
COMPANY
Date:
STATIONS
Time Start:
Time Complete:
II. CALIBRATION CHECK DATA
Reference Current (ma)
Zero value (% opacity)
Zero compensation (OD)
Span value (% opacity)
Panel Meter
Chart Recorder
///////
/ / / / / / /
Minimum 6-min. opacity value (hour preceding QA Check):_
III. TRANSMISSOMETER CHECK/SERVICE
i AGC ON?
YES
NO
See instructions
if AGC is not on.
2. Alignment Status (Note position of Light Beam on Diagram)
Transceiver -v--4--?— Retroref lector
Alignment Acceptable?
Transceiver
Retroref lector
YES
NO
See instructions if
alignment is not acceptable.
3.
Blower Status OK?
Transceiver
Retroref lector
YES
NO
4.
5.
Before retroref lector cleaning
After retroref lector cleaning
Before transceiver cleaning
After transceiver cleaning
TIME
STRIP CHART
(% opacity)
J-BOX
(% transmittance)
IV. FINAL MEASUREMENTS
1. Minimum 6-min. opacity value (hour following QA Check)
2. Final Zero Compensation value (panel meter, OD):
V. COMMENTS:
-------
CO.
STATION
CORRECTIVE ACTION INSTRUCTIONS
LSI OPACITY MONITORING SYSTEM
The following are step-by-step instructions for completing the Corrective
Action Log when adjustments and/or repairs of the opacity monitoring system
are necessary. The person performing the corrective action should complete
all blanks on the Corrective Action Log as indicated below.
I. GENERAL INFORMATION
o Enter the name of person performing repairs or adjustments, the date
(month, day, year), and the time of day (24-hour clock) that the
corrective action is initiated.
II. SYSTEM/MONITOR FAULTS
o Enter "ON" or "OFF" for each fault lamp on the Log.
o Monitor calibration and completion of Part III of the Log is not required
if "FILTER" or "SHUTTER" problems initiate the corrective action.
However, if the "REF," "WINDOW," or "OVER RANGE" fault lamps are
illuminated, the Control Unit data listed in Part III must be obtained
prior to adjustment of the monitor.
o Record the time when the fault is corrected.
action taken in the "Part IV COMMENTS".
Describe all corrective
III. CONTROL UNIT
(1) Rotate the Measurement switch to "REF" position and record the panel
meter ma reading (0 - 30 scale).
If the "REF" is not within acceptable range (green band of panel meter:
17.9 - 22.2 ma), make necessary adjustments, and enter post-adjustment
"REF" ma reading on the Log. (If no adjustment is required, enter
"NA.")
(2) Rotate the Measurement switch to the "100% OPACITY" position. Depress
the "OPERATE/CAL" switch and record the monitoring system zero check
responses indicated by both the panel meter and the data recorder
(% opacity).
(3) Rotate the Measurement switch to the "COMP" position, and record the
zero compensation level displayed by the panel meter in units of optical
density (OD).
-------
(4) Cleaning of the transceiver and retroreflector optics and/or other
adjustments are necessary when:
(a) zero check response exceeds +_ 2% opacity, or
(b) zero compensation exceeds +_ .018 optical density.
If no adjustment is necessary, enter "NA" on "Adjusted Zero Value" and
"Adjusted Zero Comp" lines of the Log.
Describe all adjustments and/or corrective action in "Part IV
COMMENTS." After all adjustments are completed, repeat steps (2) and
(3) above and record the post-adjustment zero responses and zero
compensation values on the Log.
(5) With Measurement switch on "100% OPACITY" and the monitor in zero check
mode, depress "ZERO/SPAN" switch. Record the monitoring system span
check response displayed on both the panel meter and the chart recorder
(% opacity).
(6) Adjustment of the monitor is necessary if either of the span responses
of the monitor exceeds -h 2% opacity from the correct value.
If no adjustment is necessary, enter "NA" on the "Adjusted Span Value"
line of the Log. Describe all adjustments and/or corrective action in
"Part IV COMMENTS." After all adjustments are completed, repeat step
(5) above and record the post-adjustment span response on the Log.
IV. COMMENTS
The reason for initiating corrective action should be stated, and all
repairs and/or adjustments performed as a result of the above procedures or
as a result of other monitor malfunctions should be described. Sufficient
explanation should be provided to determine what was done and what effect it
had on monitor performance.
ENTER TIME OF DAY ALL CORRECTIVE ACTION IS COMPLETED. (Part I)
-------
Opacity Monitoring System
CORRECTIVE ACTION LOG
COMPANY
I. GENERAL INFORMATION
Name:
Date:
STATION:
Time Start:
Time Complete:
II. SYSTEM/MONITOR FAULTS
FAULT LAMPS ON?
FILTER
SHUTTER
REF
WINDOWS
OVER RANGE
NO
YES
CORR1
Date
5CTED
Time
Note: Monitor calibration and completion of Part III below is not required if
"FILTER" or "SHUTTER" problems initiate Correction Action.
"REF" value (ma)
Adjusted "REF" value (ma)
ZERO value (% opacity)
ZERO comp (OD)
Adjusted ZERO value (% opacity)
Adjusted ZERO comp (OD)
SPAN value (% opacity)
Adjusted SPAN value (% opacity)
PANEL METER
CHART RECORD
/ / / / / s
/ / / / /
/ / / / /
/////,
Note: (ma) and (OD) values from panel meter; all other data from strip chart
recorder.
IV. COMMENTS: (Describe adjustments to monitor and/or all other corrective action)
-------
- COMPANY
STATION
DAILY CHECK INSTRUCTIONS
OPACITY MONITORING SYSTEM
(Contraves Goerz Model 400)
The following are step-by-step instructions for conducting the Daily
Check of the Station opacity monitoring systems. Criteria are
provided for determining when corrective action should be initiated. The
person conducting the Daily Check of each monitoring system should complete
all blanks on the Daily Log as indicated below.
I. GENERAL INFORMATION
o Enter name of person performing check, the date (month, day, year), and
the time of day (24-hour clock) that the check is begun.
0 Hours Boiler Down - Enter the number of hours the boiler was not in
operation (i.e., not combusting fuel) during the preceding 24-hour
period.
0 Hours Monitor Down - Enter the number of hours the monitor did not
provide a record of effluent opacity during the preceding 24-hour
period. Describe monitor downtime in "Part IV COMMENTS" (i.e. , cause of
outage, time began, time ended, and any corrective action taken to
return monitor to service.)
II. FAULT LAMPS
o Examine the fault lamps on the Control Unit. Check the appropriate box
on the Daily Log to indicate the status of each fault lamp (check "YES"
if lamp is illuminated).
III. STRIP CHART DATA
o Examine the strip chart to determine the zero and span responses of the
most recent automatic monitor calibration. Record the zero and span
calibration values on the Daily Log in units of % opacity.
o Check the appropriate boxes on the Daily Log to indicate whether the
zero and span values are outside acceptable limits.
Note; IF YES ANSWERS ARE INDICATED FOR ANY OF THE QUESTIONS ON THE
DAILY LOG, CORRECTIVE ACTION SHOULD BE INITIATED AS SOON AS
POSSIBLE.
IV. COMMENTS
o Describe any problems observed during the performance of the Daily Check
and/or any other apparent problems which may affect monitor performance.
o ENTER THE TIME OF DAY THAT THE DAILY CHECK IS COMPLETED. (Part I)
-------
EXAMPLE D
STATION
OPACITY MONITOR QUALITY ASSURANCE PROCEDURES
COMPANY, STATION
CONTRAVES GOERZ MODEL 400 OPACITY MONITORING SYSTEM
OVERVIEW OF OA PROCEDURES
A proposed quality assurance program has been developed for the
Co., Lake Road Station opacity monitoring system. The specific
OA procedures have been developed to be compatible with the Station
(1) opacity monitoring instrumentation and monitoring system configuration, (2)
data recording device, (3) effluent handling system, and (4) management and
organizational structure. The proposed QA program will be field-tested during
implementation, reviewed and evaluated periodically, and revised as necessary
over a one-year period. Through this process, it is expected that QA
procedures will be developed and demonstrated which are both adequate for
maintaining high levels of data quality and cost effective in terms of
necessary time and material resource expenditures.
The following elements are included in the proposed Station
opacity monitor quality assurance program.
(1) Daily Log, Daily Check Instructions - The Daily Log is to be completed
by Operations personnel in the boiler control room. Step-by-step
Daily Check Instructions are provided for completing the Daily Log.
The Daily Check and Daily Log do not require extensive time to
complete, nor do they require that the person performing the procedure
be intimately familiar with the opacity monitoring instrumentation.
The Daily Check and Daily Log provide for identification of monitoring
problems and initiation of corrective action.
(2) Corrective Action Log and Instructions - The Corrective Action
Instructions and Log are used when adjustment, repairs, and/or other
non-routine corrective action is necessary as indicated by the Daily
Checks. The Corrective Action procedures are to be utilized by
technical personnel experienced in resolving problems with the
monitoring systems. The specific corrective action procedures are
relatively extensive, but will provide adequate documentation for
future refinement of QA procedures and demonstration of their
effectiveness. The corrective action procedures are utilized only on
an "as necessary" basis.
(3) periodic QA Check and Instructions - The Periodic QA check is intended
to be performed in conjunction with the opacity monitor routine
preventive maintenance program and should be performed once per month
at the Station. The Periodic QA Check procedures provide
for checks of monitoring system components and operating status which
are unfeasible, impractical, and unnecessary on a daily basis.
-------
(4) The documentation of the QA program will be reviewed periodically to
determine if modification to the proposed procedures are
appropriate. Such modifications may be made as additional experience
and data are obtained.
(5) An attempt will be made to develop a practical method for conducting
a clear-path check of the Station opacity monitoring
system. If successful, this method will be utilized in conjunction
with a performance audit of each monitor to be conducted by station
personnel during the project and a performance audit to be conducted
at the end of the one-year study by the Pilot Project Staff.
-------
Opacity Monitoring System
DAILY LOG
CO.
I. GENERAL INFORMATION
Name:
Hours Boiler Down:
II. FAULT LAMPS
Date:
III. STRIP CHART DATA
Zero Calibration (% opacity):
Span Calibration (% opacity):
, STATION, UNIT
Time Start:
Time Complete:
Hours Monitor Down:
FAULT LAMPS ON?
Stack Power
Dirty Window
NO
YES
Does
Does
zero
span
value
value
exceed
exceed
acceptable
acceptable
limits
limits
of
of
+ 2
+ 2
.0%
.M
opacity?
opacity?
NO
YES
IF YES ANSWERS ARE INDICATED FOR ANY OF THE ABOVE QUESTIONS, CORRECTIVE
ACTION SHOULD BE INITIATED AS SOON AS POSSIBLE.
IV. COMMENTS:
-------
COMPANY, STATION
PERIODIC QUALITY ASSURANCE CHECK INSTRUCTIONS
CONTRAVES GOERZ MODEL 400 OPACITY MONITORING SYSTEM
QA Chicks " of 15£ng ^ Ste7rbnSrP lnSJrUCtl°nS f°r Perf°™ing the Periodic
QA Checks of the ... Unit # opacity monitoring system. Initiallv th*>
Periodic QA Checks are to be performed in conjunction with the routine opacity
monitoring system maintenance program performed at least once a month. ?he
?heck\og! g QA ChGCkS Sh°Uld C°mplete aU blanks °n the Periodic QA
I. GENERAL INFORMATION
o Enter the name of the person performing the check, the date (month,
day, year), and the time of day (24-hour clock) that the check is
begun.
II. CONTROL UNIT CALIBRATION CHECK DATA
(1) Rotate the "MODE" switch on the control panel to the "ZERO" position
responses of the panel meter and
(2) Rotate "MODE" switch on the control panel to the "SPAN" position, and
record the span check responses of the, panel meter and chart recorder
{.* opacity).
(3) Record the minimum 6-minute average opacity indicated by the chart
recorder for the hour period preceding the QA check.
III. TRANSMISSOMETER CHECK/SERVICE
(1) Alignment Check - Determine the optical alignment status of the
transceiver and reflector by looking through the alignment sight and
observing whether the image is within the circular target
(acceptable), or outside the circular target (unacceptable).
*™-Cat? ^ P08*'1™ of the «*l* be*"> °« the diagram, and check the
appropriate box for alignment status on the QA Log.
Open the reflector, and determine if the light beam appears to be
centered within the port. Indicate the apparent position of the
light beam on the diagram and check the appropriate box for reflector
alignment status on the QA Log.
If the optical alignment is unacceptable, realign the opacity
monitoring system in accordance with the manufacturer's
instructions. If a shift in the baseline opacity occurs after
realignment, note^the magnitude of the change which was observed in
Part V COMMENTS . "
-------
(2) Inspect and service, as necessary, the purge-air blowers, air
filters, and shutter mechanism as per the manufacturer's
instructions. Note whether the blower system status is acceptable,
and describe any corrective action taken on the QA Log.
(3) Reflector Cleaning/Check - Record the average effluent opacity value
indicated by the transceiver meter. Also, record the exact time to
allow subsequent determination of the "before cleaning" effluent
opacity from the chart record (or have an assistant note the panel
meter opacity value if two-way communications are available).
Release the reflector latches, swing the reflector open, and remove
all accumulated particulate matter within the optical path of the
monitor. Clean the reflector surfaces according to the
manufacturer's instructions. Close and secure the reflector.
Record the average effluent opacity value indicated by the
transceiver meter and the "post cleaning" exact time (or effluent
opacity level indicated at the control unit). Wait at least two full
integration periods (12 minutes) before performing step (A) unless an
assistant records real time data.
(4) Transceiver Cleaning/Check - Record the average effluent opacity
indicated by the transceiver meter and the exact time (or effluent
opacity indicated at the control unit). Release the transceiver
latches, swing the transceiver open, and remove all accumulated
particulate matter from the optical path of the monitor. Clean both
the transceiver window and the zero/span chopper according to the
manufacturer's instructions. Close and secure the transceiver.
Record the average effluent opacity indicated by the transceiver
meter and the "post-cleaning" exact time (or the effluent opacity
indicated at the control unit).
(5) Install the "zero jig" on the transceiver and determine the initial
response of the monitor (i.e., before any adjustments are performed)
at a minimum of three test points (e.g., 0% opacity, 30%-70% opacity,
and 100% opacity). Adjustments to the monitor should be performed
and a Corretive Action Log completed if the monitor response exceeds
i 3% opacity of the correct test values.
(6) Return to the control unit/data recorder station and obtain the
6-minute average opacity values indicated by the chart recorder
corresponding to the times recorded on the data sheet (i.e. before
and after alignment adjustments, before and after cleaning of the
reflector, and before and after cleaning of the transceiver). Record
all data on the QA Log. (This step is not necessary if an assistant
records real-time opacity values indicated at the control unit during
the QA Check activities.)
-------
IV. FINAL MEASUREMENTS
(1) Note periods of cleaning on the strip chart record to ensure that
these periods will not be later mistaken for excess emissions. Reset
alarms if activated during QA Checks.
(2) Note that the periodic QA Check was performed in the "Part V
COMMENTS" section of the Daily Log.
(3) Upon completion of all the ahove steps, record the minimum 6-minute
average effluent opacity value displayed on the strip chart for the
hour period following completion of all adjustments, repairs, and
service for the monitor.
V. COMMENTS
All observations regarding monitor performance should be explained.
ENTER TIME OF DAY PERIODIC QA CHECK IS COMPLETED (PART I).
-------
I. Name:
Opacity Monitoring System
PERIODIC QA CHECK
COMPANY
Date:
' STATION, UNIT #
Time Start:
Time Complete:
ZERO value
Adjusted ZERO value
SPAN value
Adjusted SPAN value
% OPACITY
PANEL METER
CHART RECORD
Minimum 6-min. opacity value (hour preceding QA Check):
III. TRANSMISSOMETER CHECK/SERVICE
1. Alignment Status (Note position of Light Beam on Diagram)
Transceiver /*\ Reflector
Alignment Acceptable?
Transceiver
Reflector
YES
NO
See instructions if
alignment is not acceptable.
2.
Blower Status OK?
Transceiver
Reflector
YES
NO
3.
4.
Before reflector cleaning
After reflector cleaning
Before transceiver cleaning
After transceiver cleaning
TIME
STRIP CHART
(% opacity)
TRANSCEIVER METER
(% opacity)
5.Zero Jig Calibration Data
TEST VALUE
% Opacity
0%
100%
MONITOR RESPONSE
% Opacity
DIFFERENCE
% Opacity
IV. FINAL MEASUREMENTS
1. Minimum 6-min. opacity value (hour following QA Check):
V. COMMENTS:
-------
CO.,
CORRECTIVE ACTION INSTRUCTIONS
CONTRAVES GOERZ M400 OPACITY MONITORING SYSTEM
ArMo^ foliowinf/re step-by-step instructions for completing the Corrective
Action Log when adjustments and/or repairs of the opacity monitoring system
ar'Th
al bl«,, "erformlng ^e corrective action sould
all blanks on the Corrective Action Log as indicated below.
I. GENERAL INFORMATION
° fmonTh^H name °Vers°n P"forming repairs or adjustments, the date
(month day, year), and the time of day (24-hour clock) that the
corrective action is initiated.
II. SYSTEM/MONITOR FAULTS
o Enter "ON" or "OFF" for each fault lamp on the Log.
o If the "DIRTY WINDOW" lamp is illuminated, note the minimum 6-minute
average effluent opacity which occurs during the one hour period
preceding the initiation of corrective action. After cleaning both the
effJuenV f re^t0r Wind°WS' n°te the miniraum 6~min«te average
effluent opacity which occurs during the following one hour period!
M W*en..the fault is corrected. Describe all corrective
action taken in the "Part IV COMMENTS".
III. CALIBRATION DATA/ ADJUSTMENT
(1) Rotate the "MODE" switch on the control panel to the "ZERO" position,
a*™T°rdy 24erVheCk responses of the panel meter and chart
recorder (% opacity) .
Cleaning of the transceiver and reflector optics and/or other
adjustments are necessary when the zero check responses of either the
°r./he ^^ reC°rder 6XCeed "± 2% "P^y- Ascribe 111
and/or corrective action in "Part IV COMMENTS."
rrf . Panel to the <
-------
IV. COMMENTS
The reason for initiating corrective, action should be stated, and all
repairs and/or adjustments performed as a result of the above procedures or
as a result of other monitor malfunctions should be described. Sufficient
explanation should be provided to determine what was done and what effect it
had on monitor performance.
ENTER TIME OF DAY ALL CORRECTIVE ACTION IS COMPLETED. (Part I)
-------
Opacity Monitoring System
CORRECTIVE ACTION LOG
.. COMPANY
I. GENERAL INFORMATION
Name:
Date:
STATION, UNIT #
Time Start:
Time Complete:
II. SYSTEM/MONITOR FAULTS
FAULT LAMPS ON?
STACK POWER
DIRTY WINDOW
NO
YES
CORR!
Date
:CTED
Time
III. CALIBRATION DATA/ADJUSTMENT
ZERO value
Adjusted ZERO value
SPAN value
Adjusted SPAN value
"ZERO JIG" DATA:
Initial Values
Adjusted Values
% OPACITY
PANEL METER
0% OPACITY
CHART RECORD
100% OPACITY
IV. COMMENTS: (Describe adjustments to monitor and/or all other corrective action)
-------
-------
APPENDIX B.
QUALITY ASSURANCE DATA SUMMARIES
-------
-------
EXAMPLE A
OPACITY CEMS DAtt.Y CHECK RESULTS
MONTH:
10
11
12
13
14
15
16
17
18
19
20
21
22
2
2
2
2
2
3
2
2
0
0
0
0
0
0
0
0
23
MONITOR*
TIME
DAV REQ.
(MIN.)
1
2
3
4
5
6
7
8
9
2
2
2
2
2
2
2
BOILER
DOWN
(HRS.)
0
0
0
0
0
0
0
MONITOR FAULT ZERO
DOWN LAMPS CHART LOGGER
(HRS.)
0
0
0
0
0
0
0
8
9
9
9
9
11
9
9
9
8
8
8
8
SPAN
CHART LOGGER COMMENTS /OPERATOR(1)
61
61
61
61
61
61
61
61
61 Note: Power surge effect-
ing timer and emissions.
62
61
63
62 Note : Chart recorder gear
0
0
0
0
0
0
0
9*
9
9*
61*
61
62*
62
broken.
Note: Data logger not print-
ing 0; manual zero/span ok.
Note: Resetcal timer
10
9
9
9*
9
9
8
8
9*
9
61
62
62
61*
62
62
62
62
62*
62
9
62
62
61
Note: Data logger not
printing.
Note: Data logger not
printing.
24
25
26
27
28
29
30
31
2
2
2
2
—
3
0
0
0
0
0
0
0
0
0
0
0
0
9
9
9
10
10
10
8
8
8
9
9
61
61
61
62
61
61
62
52
62
62
62
Note : Data logger timer, off
Manual zero /span checks.
* Zero and span responses transposed on data sheet.
-------
EXAMPLE B
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00
1
ED
-------
MONTH:
EXAMPLE C
OPACITY CEMS DAILY CHECK RESULTS
DAY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
IS
16
17
18
19
20
21
22
*^*!4
23
24
25
26
27
28
29
30
31
TIME FAULT
REQ. LAMPS
(MIN.)
8:00 REF.on
15:30 REF.on
6
7
5
5
5
5
5
5
5
5
5
6
5
5
Dl A fill/
4
?
REFERENCE
CURRENT
(MA)
REF.on
18.3
20
20
20
20
20
20
20.3
20.4
20.3
20.4
20.4
—
20.5
20.5
Zl
METER
-1
-1
0
0
0
0
0
0
1.5
1.5
1.2
1.4
2.2
2
—
2
2
IRQ
CHART
-1
-1
0
0
0
0
0
0
1
1
1
1
2
1.5
—
1
1
ZERO
COMP
(OD)
-0.02
0
0
0
0
0
0.002
-0.005
-0.004
-0.005
0.004
-0.002
-0.002
—
-0.002
-0.002
SF
METER
32
29
32.4
32.4
32
32
32
32
32
33.5
33.1
33
34
33
34
34
—
33
>AN
CHART OPERATOR COMMENTS
32
29 Changed transceiver band
32.4 onRM41.
32.4
32
32
32
32
32
33.5
33
32
33
33
34
34
~
32.4
-------
MONTH:
EXAMPLE D
OPACITY CEMS DAILY CHECK RESULTS
MONITOR *
DAY
1
2
3
4
5
6
7
8
9
10
It
12
13
14
15
16
17
18
10
20
21
22
23
24
25
26
27
28
29
30
31
TIME
REQ.
-------
MONTH:
UNIT NO.:
DAY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
TIME
REQ.
(MIN.)
7
2
2
2
2
2
1
1
1
3
1
3
3
15
—
60
10
3
3
2
3
2
10
10
10
1
3
BOILER
DOWN
(HRS.)
7
10
21
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
MONITOR FAULT ZERO
DOWN LAMPS METER CHART
-------
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
68-02-3962
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
RECOMMENDED QUALITY ASSURANCE PROCEDURES FOR OPACITY
CONTINUOUS EMISSION MONITORING SYSTEMS
5. REPORT DATE
February 1986
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
James W. Peeler
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Entropy Environmentalists, Inc.
PO Box 12291
Research Triangle Park, NC 27709
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-3962
12. SPONSORING AGENCY NAME AND ADDRESS
U. S. EPA, Stationary Source Compliance Division
Waterside Mall
401 M Street, SW
Washington, DC 20460
13. TYPE OF REPORT AND PERIOD COVERED
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
This report presents recommended quality assurance (QA) procedures for opacity
continuous emission monitoring systems (GEMS's) installed at electric utility steam
generating stations. The recommended procedures are intended to provide a simple,
cost-effective approach to the development and implementation of opacity GEMS QA
plans. The approach described here allows for much flexibility in the selection of
monitor- and source-specific procedures, the establishment of QA control limits, and
the organization of the quality assurance elements. This report identifies and
describes the major elements of a QA plan: (1) daily QA checks, (2) periodic .QAchecks
and preventive maintenance,(3) corrective action procedures, and (4) accuracy checks.
This report also addresses, the organization and interaction of the elements of -the QA
plan, an approach for optimizing the QA plan, and the assignment of various QA
responsibilities.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Air Pollution
Monitoring
Opacity Monitoring Systems;
Continuous EtntLss ion
Monitoring
Quality Assurance
Procedures
18. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
81
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA F«m 2220-1 (R«v. 4-77) PREVIOUS EDITION is OBSOLETE
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