Report No. 73-CUS-2
CD
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PHELPS DODGE
Ajo, Arizona
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Emission Measurement Branch
r Research Triangle Park, North Carolina
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RE/PC
FINAL REPORT
Continuous Monitoring of a
Copper Smelter Acid Plant
Phelps Dodge
Ajo, Arizona
Scott Environmental Technology, Inc.
2600 Cajon Boulevard
San Bernardino, California 92411
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TABLE OF CONTENTS
SECTION PAGE NO.
I. SUMMARY AND DISCUSSION OF RESULTS 1
II. APPENDICES
A. Suggested Technique for DMA Analysis 13
B. Opacity Summaries 17
C. Minutes of Coordination Meeting 36
D. Field Data and Log 43
E. Summary of Instrument Problems 57
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I. SUMMARY AND DISCUSSION OF CONTINUOUS MONITORING
The objective of this program was to obtain continuous monitoring
data of a copper smelter plant emissions and evaluate the performance
of the SOp monitoring system. The Phelps Dodge copper smelter at Ajo,
Arizona, had recently installed a DMA (dimethylaniline) scrubbing unit
for conversion of low concentration SOp gases to a level suitable for
the production of both liquid SOp and sulfuric acid. The potential impor-
tance of this system is its ability to control SOp streams which are not
sufficiently strong for normal economical production of sulfuric acid.
A flow chart for the Phelps Dodge acid plant operations is contained
in Figure 4. The acid plant is operated as a sulfuric acid by-product
recovery plant. Emissions from the main plant pass through the acid
plant where SOp is removed by a DMA scrubber process before being emitted
to the atmosphere via a stack. Input from the converters is in the range
of 8 to 14% SOp. Final volumetric flow out the absorption tower stack is
nominally 40K CFM.
Both the ASARCO, El Paso, Texas, and Phelps Dodge, Ajo, Arizona,
smelter operated acid plants were presurveyed by Scott and EPA during the
period of April 2-5, 1973. The presurvey was covered in Scott's report
SRL 2113-01-0473 "ASARCO El Paso, Texas and Phelps Dodge Corporation New
Cornelia Plant, Ajo, Arizona, Acid Plants." During the presurvey it was
determined that scaffolding and sampling ports would have to be added to
the Ajo plant stack at the top of the demister tower. At this location
i
Phelps Dodge had installed a Dupont 400 SOp ultraviolet spectrometer
connected to a probe within the absorption tower.
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AT-3 e/z_
AT-4 DuPont Inst. - SO. inlet
AT-5 DaPont 'inst. - S02 outlet
AT-6 DUPont Inst. - DMA outlet
Figure 4
FLOW CHART PHELPS-DODGE ACID PLANT
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-3-
SET 2518 05 0675
Because of severe spectral interferences from DMA in the SO-
ultraviolet absorption region, DMA was measured separately, and a
correction factor is generated by a Fisher-Porter Adder/Subtractor
processor. When the Adder/Subtractor is properly adjusted, the net
S0ซ concentration is read directly on a recorder in the acid plant
control room. On June 14, 1973, Scott added additional recording
equipment to the basic plant DuPont DMA/SO- instrument and started
recording the acid plant emissions. The Phelps Dodge SO, acid plant
^ i
instrumentation configuration used during Task 10 is illustrated in
Figure 5. Concentration S02 levels at the S0_ absorption tower inlet
were analyzed by an additional DuPont ultraviolet analyzer located at
the base of the tower.
During the period that equipment was maintained by Scott at
Ajo under Contract 68-02-0233 for monitoring purposes, extensive and
persistent acid plant outages were experienced. An outage estimate
based on the monitoring log indicates that the Ajo acid plant was
operational less than 20 percent of the monitoring period during
June, 1973, to June, 1974. The monthly summaries of plant outages are
listed: .
Comment
Data equipment installed at start of program
DuPont field visit on analyzer problems
Meeting held at Ajo on instrument problems
Major modification of monitoring inst.
Month
6/73
7/73
8/73
9/73
10/73
11/73
12/73
1/74
2/74
3/74
4/74 '
5/74
6/74
6/74 - 75
Plant Outage
56%
97%
100%
100%
45%
100%
100%
90%
86%
100%
47%
71%
100%
100%
f\l SCOn ENVIRONMENTAL TECHNOLOGY, INC.
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Inst. performance tests w/Method 8, Method 9
Supplement test w/modified Method 6
Monitoring program was removed
Major acid plant modification of mist
ppt. equipment
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outle
sample
AT-1
Analyzer - S02
AT-5
Analyzer - DMA
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ACROMAG
Backset
Switch
AT-1
Control +
Converter
mv/ma
AT-5
Control +
Converter
mv/ma
ACROMAG
Backset
Switch
Inlet
sample
AT-4
Analyzer
0 - 15% SO,
ACROMAG
Backset
Switch
AT-4
Control +
Converter
mv/ma
Phelps
Dodge
Recorder
0-100 ppm
DMA
S02 Channel
DMA Channel
Phelps
Dodge
Recorder
0-2000 ppm
S00
Phelps
Dodge
Recorder
0 - 15%
SO,,
Not Used
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Scott Recorder
Blue Pen
Scott Recorder
Red Pen
Channel A
Westinghouse
Tape
Channel B
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-5-
SET 2518 05 0675
causes:
Most of the outages can be/attributed to one of several
!
oAdditional modifications to new plant
"Equipment malfunctions such as leak, etc.
olncompatability of DMA and S02 compressor system
(compressor could operate approximately 30% of time
without repair)
In addition to plant operational problems, persistent
instrumental problems were experienced during the program. A summary
of the instrument problems prepared for a project coordination meeting
at Ajo on Wednesday, October 31, 1973, is contained in Table 2.
The instrument problems included: fouling of aspirator and
cells windows, alignment of Adder/Subtractor S02-DMA signal, calibration
of DMA instrument, and needed electrical/mechanical improvement. The
fouling at flow aspirator and cell windows can be related to a similar
problem with the contamination and frequent failure of the plant's S02
compressor. During the weekly maintenance of monitoring equipment by
Scott personnel, liquid DMA or products have been observed to change
from a liquid film to a dark plastic-like coating in a relatively few
days. This could be the result of:
(a) Reaction of DMA with SO- at temperatures of greater
than 100ฐ F.
(b) Reactions similar to analine black
1 - Analine Black
Reaction
2 - Proposed DMA
Reaction
N
N
or \ouor TGI
SCOn ENVIRONMENTAL TECHNOLOGY, INC.
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Table 2
SUMMARY OF INSTRUMENT PROBLEMS AT AJO
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Problem
Resolution
Corrective Action
Status
1) Sample flow cannot be maintained
for longer than 1-4 days in AT-1,
AT-5, and AT-4.
2) Sample cell windows dirtied by
high concentration sample flow,
such that zero control is lost
' after a few days, AT-1.
3) AT-1 signal output erratic and
at times unable to get correct
response to calibration filter
even with SPAN control full CW.
4) Response of Adder/Subtractor
circuit to SO- and DMA signals
over the range of concentra-
tions being monitored is not
known.
5) No present means of verifying
span of AT-4 and AT-5 except
by calibration shutter.
Identified as fouling of
aspirator in AT-1 and
AT-5. Same in AT-4 along
with some sediment in
sample line.
Assumed caused by DMA
deposits on windows.
Not identified.
Clean aspirator and ' Still a
lines each time flow problem.
is lost.
Pull cell and clean Still a
windows every few problem.
days.
Moved sample cell May still
into better optical be a
alignment; changed problem.
source lamp; changed
tubes V-l & V-2.
Perform careful To be
alignment of Adder/ done.
Subtracter and the
signal current loops
which feed it. Measure
and plot response to
spread of expected
input signals.
Obtain SO calibration To be
gas in 6-10% range; done,
determine some way of
verifying calibration
of DMA analyzer AT-5.
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Table 2 (cont'd.)
SUMMARY OF INSTRUMENT PROBLEMS AT AJO
Problem
Resolution
Corrective Action
Status
3
to
Ln
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6) Very difficult to use the
manual calibration shutters
in AT-1, AT-5, and AT-4, for
either calibration or main-
tenance. Now requires two
men plus radios and consumes
much time.
7) No means of looking directly
at output of AT-1 when setting
zero and span, or to evaluate
analyzer performance.
8) Non-coordinated zeroing.
Westinghouse. recorder actuates
blanking signal every 15 minutes.
DuPont analyzer automatically
zeroes every 10 minutes.
Newer instruments are
equipped with a remotely
operated calibration
shutter.
DuPont analyzer zero is
timer actuated by internal
timer.
Install necessary To be
parts to make these done.
systems' calibration
shutters remotely
operable.
Add (temporarily) a To be '
strip chart recorder done. "
to monitor AT-1
output.
Trigger timing motor In
with a switch closure Process.
from the Westinghouse
clock.
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Table 2 (cont'd.)
SUMMARY OF INSTRUMENT PROGLEMS AT AJO
Problem
Resolution
Corrective Action
Status
9) Clogging of Aspirator of
AT-4
Due to moisture and dirt
Add additional Aspirator
for water trap
To be
done
Existing
Sample Cell |-
Sample Flow
,Water
Trap
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air
Aspirator
10) Clogging of Aspirator of
AT-1 and AT-5
Dump
Due to moisture and dirt
IAspirator
Proposed
Dump Dump
Add additional Aspirator
for water trap
Aspirator
Ir
1
T
urn
1
P
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Sample LS>7
Flow *^p
Water
Trap
s
CTI Sample
4*1 Flow ^
IT
Sample In
Existing
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'Sample |vp "yM Sample
Flow ^ ^P Flow
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^ Water Trap
*
Aspirator
V
<ป Sample In
F
| Proposed
ump ^
Dump
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-9-
SET 2518 05 0675
Although the DMA contamination problem persisted during the
program, the aspirators were kept operational by the addition of a
detergent flush during the instruments' automatic backflush sequence.
The Adder/Subtractor instrumentation used to correct the UV
S0ซ absorption spectrum for DMA contributions had uncertainties as to
establishing a correct factor ratioing the DMA value to the S02 input
and the problem of correcting for DMA vapor (3p 193ฐ C.) in the presence
of known liquid films or deposits on the cell window. Figure 6 illustrates
the relative absorption of S02 and DMA in the UV spectrum. The equivalent
interference ratio of DMA to S02 was approximately 4 to 1.
A technique suitable for establishing the DMA level in a gas
steam was supplied to Scott by DuPont. The method is included in
Appendix A for information. No check of the method was made during the
program.
Based on the instrument summary presented in Table 2, a major
instrument modification and checkout was conducted by Scott personnel
during the week of December 3, 1973.
In mid-April (16 - 20), 1974, sampling of the scrubber emissions
by Method 8 for S0ป and Method 9 for opacity were undertaken to evaluate
the performance of the continuous monitoring instrument system. The
Method 8 sampling data indicated that negligible S02 emissions were
present. However, the instrument system yielded one-hour average values
between 49 and 78 ppm SO- during the sampling periods. Between sampling
periods the instrument system responded normally to calibration gas at
several SO^ concentration levels. -' During the calibration sequence, the
process stream was closed out of the instrument sample loop.
During the week of May 15, 1974, a subsequent test program
designed to isolate probable causes of the discrepancy between the previous
Method 8 samples and the instrument system readings was conducted by Scott
personnel. Among the causes considered were:
SCOn ENVIRONMENTAL TECHNOLOGY, INC.
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-10-
SET 2518 05 0675 ' ;'' /
1 - Improper accommodation of known DMA interference
in the instrument system design,
2 - Interference of DMA through carryover in the
Method 8 sampling train, and,
3 - Interference of an unknown process stream
constituent with Method 8.
The supplementary test program consisted of collecting eight
Method 6 and modified Method 6 samples and operating an additional
electrochemical detector type SC^ instrument in parallel with the
existing instrument system. The modified Method 6 consisted of
omitting isopropanol from the first impinger. All samples taken
during the test were transferred to EPA for analysis. The results of
the supplementary testing program are contained in Scott's report SET
2518 02 0175 dated January 8, 1975.
Summarized, the results of the test were:
1 - Analysis of Method 6 and modified Method 6 samples
taken during the test indicated negligible S0?
emissions.
2 - Existing DMA/SC>2 instrument system indicated an
average of 10 - 20 ppm SO. levels and transient
level of 100 to 200 ppm SO- during Method 6
sample collection. .
3 - Electrochemical type SO- instrument installed in
parallel with existing instrument indicated virtually
zero S02 during Method 6 sample collection.
All instruments responded normally to calibration gases.
All data equipment was removed by Scott on June 11, 1974,
shortly after the acid plant went/down for extensive modification
involving the changeover and addition of mist abatement equipment.
The acid plant was not scheduled to go back in operation until some-
time in.1975.
In summary, the monitoring program at Ajo failed to provide
the objectives of continupus monitoring data of a DMA scrubbing unit
and evaluation data of the S02 monitoring system because of:
SCOTT ENVIRONMENTAL TECHNOLOGY. INC.
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-IT-
SET 2518 05 0675
1 - Intermittent operation of acid plant during
monitoring period:
"New plant construction startup
ฐNew DMA process
"Field modifications to plant
"Equipment failure
Inability to reach steady state condition
2 - Unstable instrument system operation during monitoring
period:
<>DMA contamination
ปDMA S02 Adder/Subtractor
"DMA calibration
3 - Inactivation of plant for majo.r modification during last
half of 1974 and first part of 1975.
SCOn ENVIRONMENTAL TECHNOLOGY, INC.
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SET 2518 05 067
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-12-
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APPENDIX A
Technique Suggested
for DMA Analysis
by DuPont
.
SCOn ENVIRONMENTAL TECHNOLOGY, INC.
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-13-
INSTRUMENT PRODUCTS DIVISION >* cc: S. D. Black
i W. E. Collins
/ C. S. Russ
' . r. ' ' ' I ' R. S. Saltzman
/ i J. R. Small
MEMORANDUM ;' ' DECEMBER 11, 1973
TO: . J. W. WILLIAMS1'
FROM: D. F.' BARRETT &%$- >
C. B. BLAKEMORE C1-
W. L. BONAM U
DMA ANALYSIS -
In conjunction with your request, we have completed work
to answer two questions that you had on DMA analysis:
(1) DMA/S02 analyzers such as those that are being presently
used on the Steams-Roger abatement processes at Phelps Dodge
at Ajo, Arizona: Verification of the computational system con-
stant (to account for DI-IA/S02 interference) . (2) A possible
analytical method for measuring DMA.
In answer to your first question, when Bob Saltzman started
up the DMA/S02 461C at Ajo, he operated when only DMA was present
in the system, and adjusted the constant with the DMA flowing
through both cells so that there was a zero signal coming from
the DMA/S02 photometer. For example, a gaseous sample is flowing
through both photometer A and photometer B-simultaneously.
Photometer A responds only to DMA. Photometer B responds to DMA
and S02 (measuring wavelengths differ in each photometer).
Photometer A gives you a pure DMA signal with an insignificant
interference from S02- Photometer B gives you a signal that re-
presents DMA and SC>2. Consequently, when you are only putting
DMA through the analyzer and you get a positive response on the
DMA photometer, a computational system constant (each set properly)
should provide a zero output for the S02 signal even though there
is a positive output signal from photometer B (input signal to
computational device) .
In case number 2, you wished us to develop or identify a
technique that would be suitable for DMA analysis from the
scrubber system. To the best of our knowledge, there was no such
method available; consequently, we had to develop one that is an
identifiable candidate for this, measurement. Figure 1 shows the
laboratory apparatus used and the typical experimental conditions.
Briefly, what was done in the laboratory is as follows:
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-14-
DMA Analysis
December 11, 1973
Page 2
Nitrogen was passed through a liquid nitrogen trap
to remove all moisture. The nitrogen was then sparged
through a pure dimethylaniline trap to saturate the nitrogen.
This was next passed through an ice trap which is used as a
coalescer and condenser to remove droplets of liquid. At
this point in the system, the nitrogen is saturated with DMA
at 0ฐC. Next, the saturated nitrogen sample was passed
through a preweighed flask emersed in a liquid nitrogen trap.
At this point, all the DMA was condensed from the nitrogen
into the liquid phase. In about one hour, approximately .05
grams were collected in the trap -- this was determined by
comparing the weight after collection with the taraweight.
The nitrogen exiting from the flask was then passed through
a wet test meter to determine flow rate. In this way, we
were able to determine the average mass emission flow (grams
per hour) and/or concentration vol. %.
To apply this method to a stack will obviously require some modi-
fication work, and my suggestion is as follows:
If the stack is under positive pressure, then it becomes
a relatively simple task to pass the gas through a liquid
nitrogen trap and a wet test meter to duplicate the collection
system we used in the laboratory. If.it is not under a posi-
tive pressure which is what I suspect, then I suggest that
you use a metal Bellows pump but be careful to use metal tubing
or Teflonฎ tubing on the wetted parts. . Another potential pro-
blem is the moisture content. The liquid nitrogen trap will
condense all the moisture.- Consequently, it would be better
instead of using the weighing technique to take methanol and
completely transfer all the DMA collected from a collection
flask to a volumotric flask v/ith several rinses and
spectrophotometrically measure the dimethylaniline. The
attached .spectrum is a spectrum of the dimethylaniline in
the liquid phase ( CHsOH ) v/ith a known concentration and cell
pathlength, and its extinction coefficient can readily be
determined.
Jim, I hope that this information is complete enough to help
your customer at this very important EPA evaluation site. If you
have any questions, feel free to call .any one of us, as we all are
familiar with the problem.
DFB/CBB/WLB:mc
Attachments
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JNSTRUMENT PRODUCTS DIVISION
_15_
E. I. DU PONT DE NEMOURS & CO. (INC.), WILMINGTON, DEL.
t> TH ft ti *J H ( \/ f j \T
, TITLE 'OF SUBJECT
SCALE
.DRAWN
DATE
H \/
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. F I Cr <-
REF.
SHEET No.
CHECKED
APPROVED.
'DRAWING No.
ft
I.
1) Liquid Nitrogen trap for condensate removal.
2) DMA sparger. ,
3) Ice trap for liquid DMA removal.
4) Preweighed collection vessel emersed in liquid Nitrogen trap.
5) Wet test meter. ' . ;
REVISIONS
A
r A -
REVISED BY
DATE
CHECKED BY
DATE
APPROVED BY
DATE
FOR IKJT
No.
REF. DRAWINGS
<- I
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APPENDIX B
Opacity Summaries
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-17-
Opacity Summary
Phelps-Dodge DMA-Acid Plant, A jo, Arizona
Performance:Tests
i ' '
Smoke Readers: M. L. Smith, J. Tucker, Environmental Science & Engineering
Date: April 18, 1974
Date/Test
Reader
Opacity
0
5%
10%
15%
Date/Test
Opacity
0
5%
10%
15%
April 18,
(Smith)
Minutes
3
38
18
0
Minutes
19
37
3
Seconds
15
15
0
30
April 18,
Seconds
15
15
30
1974, Run 1
(Tucker)
Minutes
3
41
12
2
1974, Run 2
Minutes
__
16
39
4
Seconds
30
30
30
0
Seconds
__
45
15
r
Date/Test
Opacity
0
5%
10%
15%
20%
Minutes
4
38
17
April 18, 1974, Run 3
Seconds Minutes
30.
15
15
5
42
12
Seconds
30
30
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".'/I
-18-
SUXM'.RY
RECOP.D OF VISI2LE EMISSIONS
Type of Plant T)ffl,}
Company '.'arr.2
Plant Address
Date
Type of Discharg
Discharge Location
Hours of Observation <5\sv-
Observer
Height of Point of Discharge <$QO '
Observer's Location:
Distance to Discharge Point
Height of Observation Point
Direction from Discharge Point
Background Description Cjl&cii^
-x^*""" ^
Weather-: (theatx Overcast Partly Cloudy Other
Color
Wind Direction \S
Plume Description:
Detached: Yes
Color: Black \ 'V.'hitej Other
Wind Velocity
mi/hr
Plume Dispersion Behavior: Looping <^Tom'ng) \Fanning
Lofting Fumigating Other
Estimated Distance Plume Visible
Summary of Observations:
9
Opacity Aggregate Ti~e ^ Qgacitv Opacity Aqarecatg Tins ? Opacity
0;
5
10
15
20
25
30
35
40
45
50
3 min. /^-sec.
g - - c -
-O--
55
60
65-
70.
75
.80
85
95
100
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-19-
RECORO OF VISIBLE EMISSIONS
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Plant Add res
Stack t.ocati
Weather Cond
-fiJuJ^-Ki - dfatf*. Date / g dfrUJL /97V
s (b0 UA^pTt.^ Observer .JrrrL^c-L-
~ff ' ^ -:.'. '
on 7>/r?A - >S^AH^A<^/(^AC/ Observer's 4
itions ^
, ^A., . Location ^^u^i^A^C
'SLC*-*-' '-fr&tJt-' yH&u '
TIME
HR
0^1
4
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00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
SECC.'IDS
00
10
0"
/d
s
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/d
0
0
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Company Name
Plant Address
RECORD OF VISIBLE EMISSIONS
Date
Obsnrvef >?2-c^f
Stack Location
- //_ ,<;&
-------
''i.
-21-
SUMMARY
RECORD OF YISI3LE EMISSIONS
Type of Plant
Company Narr.s
'Plant Address
Date
C_ฃ)/6f f A
ej Hours of Observation Q&f/
Observer
Type of Discharge
Discharge Location
Height of Point of Discharge
Observer's Location:
Distance to Discharge Point
Height of Observation Point
Direction from Discharge Point
Background Description
Weather-: M:isar/ Overcast Partly Cloudy Other
Color
Wind Direction
Plume Description:
Detached: Yes
Color: Black
Wind Velocity
mi/hr
Other
Plume Dispersion Behavior: Looping (^oning^/ Fanning
Lofting Fumigating Other
&
yy\
Estimated Distance Plume Visible _
Summary of Observations: ; -,.
Opacity Aggregate T1~g Q Opacity Opacity Aggregate h'ms o Opacity
55
65"
70
75
25 .80
30 85 .
35 " . SO '
40 - ' 95
45 v . 100
50 . '
o-
5
. 10
15
m3n.
w
/a
~ r
so
SO
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HPT
-
Company flame PJ
Plant Address
RECORD OF VISIBLE. EMISSIOKS
Date
4/C/
Observer
Stack Location
Heather Conditions
KJl
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ttJL; ". g-tb
Observer's
acation
O C
U
TIME
MIN
00
01
02
03
04
05
06
r
07
08
09
10
11
12
13
f
14
15
16
17
18
19
20
21
22
23
24
25
26
27
23
29
SECONDS
00 I 15
10
-------
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1
1
Company flame J>yye//>S
Plant Address
-23-
RECORO OF VISIBLE.EMISSION'S
Date
j ^ fcUSH /
V-tft-T'J
Stack Location
Weather Conditions
Observer
Observer1
Location
inn
om
~i'm
TIME
J-
00
01
02
03
04
05
06
07
08
09
10
n r
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
00
ฃ
r
/a
/D
fa
.***ฃ&
?9Jr
Ib
r
r
r
ฃ
/6
/o
20
r
-------
*}
-24-
SUXMARY
RECORD OF VISIBLE EMISSIONS
Typo of Plant
Company 'Jan-
Plant Address
Date
Hours of Observation /
' Observer
Type of DischargeQSTACK,
Discharge Location -/ay?
OTHER
Height of Point of Discharge
Observer's Location:
Distance to Discharge Point
Height of Observation Point a-uLn^
Direction from Discharge Point
Background Description
Weather-: (^CTiearj Overcast Partly Cloudy Other Color
Wind Direction 3ฃ - Su) V/ind Velocity /O'-AS"" nn'/hr
Plume Description: .
Detached: Yes
Color: Black C/tfhiteJ Other
Plume Dispersion Behavior: Looping (toning^^Fanning
Lofting Fumigating Other
Estimated Distance Pluraa Visible^
Summary of Observations:
Opacity Aqqrecf.ta Ti~e Q Opacity Opacity Agnreqato fimg 3 Qpscity.
0- . - - - min. /J"sec.
5 ซ - - - /o. .
10
15
20
25
30
35
40
45
50
55
60,
65
70
75
80
85
90
95
100
-------
1
Company flame J
Plant Address
Stack Location
Heather Conditions
-25-
RECORD OF VISIBLE EMISSIONS
Date /.f
Observer
HfT
TIME
Mill
.PJL
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
23
24
_2_5
26
27
"
29
SฃCc:;D3
00
10
10
15
v-r
so
/o
yf
/O
ID
?Vr
/o
10
/o
/o
/o
/p
ffl
10
^_
.-51JL
I*
30
$L
vf
id
/O
vT
/O
ฃD
j:<2
^o.
/^
Observer's
Location
x
COMMENTS
-------
j
.1
i
J
<
j
i
i
'ป
1
!
1
'
.":
Company flame
Plant Addres
Stack Locati
-26-
RECORO OF VISIBLE EMISSIONS ' .
sj^<
on &
' /; ^ r ' '
^ . /^CA^^,^_^^e_, Obsftrver ">?^ . ^t^c^ty^
rt*A- - S-S^SOf/ /aj2t<^ฑA' Observer's
Heather Conditions ฃ,
fl j . Location J^^-t^t^cJLjt^>-ซ^-
ฃjLCt-*~^ *~zi-C4xjซ_ ZL-^-V '
/ffO TIME
HR
' '
.
!
\
*i
i
f _
M I :l
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
SECONDS
00
4~
vT
sr
/o
Iff
/o
M
f
^
/D
^
/O
/o
/o
10
to
//
/o
10
fi
ID
AT
If
to
70
XT
/O
/O
15
sf-
rf-
*1*
/ฃ>
ฃ
/O
-V
/O
^
/e
JT
to
to
/o
to
/d
/0
/O
/0
13
to
tfi
to
/o
I o
/0
/o
to
f
/6 |#
30
ฃ>
/O
/
/4
/0
/O
v^
(0
S
^r
^>
j
M
to
tf
10
to
/ฃ>
to
fi
to
to
&
i$
ID
to
/o
AT
/*
/
-------
Typo of Plant
-27-
SU:-::--ARY
RECCED OF VISIBLE EXISSIO.'JS
' fi/Hl
Date
Company N'air.e J
Plant Address
Type of Discharge (STACK
Discharge Location
Hours of Observation
Observer
Height of Point of Discharge
Observer's Location:
Distance to Discharge Point
Height of Observation Point at
Direction from Discharge Point
&L^
Background Description _
Weather-: (ClelTr\ Overcast Partly Cloudy Other
Color
Wind Direction
Plume Description:
Detached: Yes
Color: Black
Wind Velocity
mi/hr
Other
Plume Dispersion Behavior: Looping Coning. /f-annin
Lofting Fumigating Other
Estimated Distance Plume Visible 2vS"/y7 .
Summary of Observations:
Opacity Aggregate Tirrg Q Opacity Opacity
0
Aggregate fir^s Q Opacity
sec.
-------
a
"i
Company Name _yfy&t/bL> ,~Ufr&A
Plant Address f),'Q /J&/Z.
Stack Location
Weather Conditions
-28-
RECORO OF VISIBLE EMISSIONS
/ 7
Firmr?
/o
-------
Hk
Company flame r ~J-3 -
Plant Address
-29-
RECORD 07 VISIBLE EMISSIONS
Dat"
Observer
Stack Location
Heather Conditions
^K
Observer's
Location
*T-
We.
TIME
Ml!,'
00
SECO:;DS
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
23
29
&
/o
/o
O
/o
t
D
f?
/O
sr
ib
0
/ft
/o
It
if
t
/O
/o
0
11
/a
If]
W
If
&-
30
r
to
/o
/b
'V
fa
ฃ
fD
r
o
r
'to
/s
/fi
/D
10
/f)
/o
0
to
'f
/olio
idl
in
zfe
p
COMMENTS
-LLHWGL
-------
. -30-
su:-::'ARY
RECORD OF VISIBLE EMISSIONS
Type of
Company fJame
Plant Address
/Z
S97t
Hours of Observation
Type of Discharge^TTACK,
Discharge Location
OTHER
Height of Point of Discharge
Observer's Location:
Distance to Discharge Point
Height of Observation Point
Direction from Discharge Point
Background Description
Heather-:
iear) Overcast Partly Cloudy Other
V/ind Direction ฃ/*} V/ind Velocity
Plume Description: .
Detached: Yes (Ucฃ> '
X^**^' N
Color: Black (White) Other
ini/hr
Plume Dispersion Behavior: Looping Coning- xFaflning
Lofting Fumigating Other
Estimated Distance Plume Visible "7<3~ '
Summary of Observations: ..^' .
Opacity Aggregate Ti~ef? Opacity
0-
Opacity Agcrenjite fir.is o Opacity
mn.
sec.
25
30
35
40
45
50
55
60
65
70
75
.80
85
90
95
100
-------
Company flame
Plant Address
Stack Location
Weather Conditions
-31-
RECORD OF VISIBLE EMISSIONS
Date
Observer
Observer's
Location
m
/
M I '.'(
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
2E
23
24
25
26
27
2?.
29
23*
Si.
00
/O
/O
/O
/o
W
/O
^
vT
/o
to
/O
/o
/f
tf
/r
/*-
M~
4f
XT
AS"
/o
/o
/o
lo
'/o
/f)
/o
/o
fO
CC.'US
15
/fj
/o
/o
/*'
/O
tt
vr
/o
/<-
/o
^
sT
/Q
Jo
t&
/&
/o
XT
/f
/O
/O
te~
/-ง"
10
10
l!>
/c
/O
v^
/o
/o
/<>
/O
E
',5
Af
/()
J
/o
M
0-
/^
\^
/O
xr
/^
#-
AT
xr
/r
/*
x,r
/>r
/o
/o
10
/o
/o
/o
/o
/o
/o
10
/o
COMMENTS ' .
t
^^ot-*
-------
1
i
1
:-:3
Company flame
Plant Address
-32-
RECORO OF VISIBLE EMISSIONS
Date
Observer
Stack Location
X, -54*
V/eather Conditions
I3oo
w
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
J?L
22
23
24
25
26
27
TEt
TIME
_00_
X*
/o
/ff
/o
15
/O
xr
X
XT
AT
XT
/c
/r
ID
29
2.0
Jo
/r
se
/O
X.'T
/o
XT
/ฃ>
/O
^2.
22.
[jo.
JL
30 45
/O
XT
/t
'Q
JO
xr
/r
xr
xr
X?
TJ
/ฃ
/o
/o
'4_^2_
i
/O
Observer's
Location
COMMENTS
-------
:j
-33-
SUMMARY
RECORD OF VISIBLE RMISSIOMS
Type of Plant
Company Name /Ifatlll
Plant Address
f)
ZM.
Date
cxte;
- /Is b
bur1
? /
Hours of Observation
Observer
OTHER
Type of Discharge
Discharge Location
Height of Point of Discharge
Observer's Location:
Distance to Discharge Point _,
Height of Observation Point
,
g
Direction from Discharge Point ooiaฃ2L>
Background Dascription
Heather-: CTelfr") Overcast Partly Clone
Wind Direction S(/J
Plun-e Description: . ;
Detached: Yes
Color: Black f-tffiTOi Other
Other
Color
V/ind Velocity
mi/hr
Plume Dispersion Behavior: Looping Coning. (Fanning
Lofting Fumigating
Estimated Distance Plurr.e Visible jTฃ)
Sunvnary of Observations:
Opac'ity Aggregate Ti-g ft Opacity Opacity
nin. sec. 55
60,.
65
70
75
.80
85
90
95
- 100
Other
Agnregsto fin',:? ft Opacity
-------
If
; '3
;i.
Company Name _
Plant Address
-34-
.RECOP.ODF7ISIBLE EMISSIONS
Date
Stack Location
Weather Conditions
TIME
00
01
02
SO
03
04
05
06
07
08
/o
09
10
11
12
13
/*ฃ.
14
15
16
17
18
19
20
21
22
23
24
25
_26
27
Jl
29
SECC.'.'DS
to
Lฃ.'il
10
r
&
'M
/t
00 15 iOI 45
'0
/O
r
/r
/Czฃ
/ri
/D
UL
Hi
yji
r
/r/r
y/
16
/r/r
/o
&
7
/r
^
/r
/D
/ft
jtf.
a.
/t
/a.
10
~/r~
&M2?)t.
fi&ssvy \^
Observer
fc
Location
COMMENTS
A&.
rปrป">>.'ป ". '.". i*'T"~'-*-r-- -:': iffW-f ?! tvnl'-mfr
-------
-35-
r.LXor:o or VISIBLE EMISSIONS
Company U:-.ms
Plant Address
Stack Location
Weather Conditions
Date ^M ฃ> 7'/
Observer
00
01
K
02
03
04
05
06
07
/-ฃ>-
a
08
09
10
11
iL
13
15
16
17
ii.
19
20
21
22
23
24
_25.
2ฃ
27
SฃCC:,DS
.^
^^/xt/s:.
/a
/o
/O
Ko
/4
zo.
,ฃ
/^
00 15 -Of --5
/a
LฃlA.
tfu&teL
/r
UP_
r
/a
fk^hjt^^<^ K
e^J&^J-lL)*' '
xzฑis_
Location
Z<2IZ^
/ฃ)
j^2_
2^
ISL
J$LJ&.\&.
&
ฃL
ฃ-jL
-------
APPENDIX C
Minutes of Coordination Meeting
-------
-36-
Scott Report
SRL 2113 11 1173
Minutes of Coordination Meeting;
October 31, 1973:
Resolution of Instrumentation
Problems in Preparation for
Continuous Monitoring by EPA
Phelps-Dodge
New Cornelia Plant
Ajo, Arizona
Environmental Protection Agency
Contract 68-02-0233
Task order Number 10
.November 5, 1973
SCOTT RESEARCH LABORATORIES, INC.
2600 Cajon Boulevard
San Bernardino, California 92411
-------
-37-
SRL 2113 11 1173
.H ''. . '
/
. ' 1.0 INTRODUCTION
i
( A coordination meeting was/held at the Phelps-Dodge New Cor-
nelia Plant in Ajo, Arizona to resolve problems-with the continuous moni-
toring S0_ instrumentation installed on the DMA scrubber. The EPA 6-month
continuous monitoring program at the site will commence following the
actions that are described in this report. Responsibility for the actions
is assumed by Scott Research Laboratories, Inc., as contractor to the
EPA. The participants in the meeting included:
1. Phelps-Dodge; D. Orr, F. Rickard, J. Ford, P. Chen,
J. Aldridge, R. Kirchner and K. McBiles,
2. Environmental Protection Agency; C. Darvin (Standards
Development Branch), and R. Martin (Emissions Measurement
Branch
3. Scott Research Laboratories, Inc.; W. Fuller (Program
Manager), D. Combe and T. Caldwell (Instrumentation
Technicians)
4. DuPont: J. Williams (Instrument Division - Monrovia, Calif.).
2.0 SUMMARY AND RECOMMENDATIONS
The recurring instrumentation problems in measurement of S0_
(inlet and outlet) and DMA at the DMA scrubbing process were discussed.
Phelps-Dodge, EPA, Scott and DuPont representatives participated in the dis-
cussion. Scott Research Laboratories, Inc., acting as a contractor for EPA,
will improve the instruments, data accuracy and maintenance requirements-
by:
A. Calibrating and verifying the adder/subtracter circuitry which
corrects for DMA interference in SO measurement wavelengths
B. Modifying .the sample flow system
C. Performing supplementary wet chemistry analysis of the stack
gas prior to performance evaluation of the analyzers
D. Installing remote actuation calibration shutters in all 3
analyzers used to monitor the scrubber
Phelps-Dodge has been requested to provide, control cables for the remote
actuation calibration shutters, to continue maintenance on DMA contaminated
sample cell windows, and to provide plant operating data as approved by Mr.
Fenzi through EPA request.
SCOTT RESEARCH LABORATORIES, INC.
-------
-38-
SRL 2113 11 1173
3.0 AGENDA
The.agenda was as follows;
Item 1. General Purpose of the Program
Item 2. Description of Program and Sequence
of Events
Item 3. Summary of Instrument Problems
(See Appendix for Detailed Summary)
Item 4. Discussion of Proposed Approaches
Item 5. Summary of Scott and DuPont Actions
to Provide Instrument Improvements
Item 6. Discussion of Plant Data Requested by EPA
C. Darvin, EPA
W. Fuller, Scott
Scott
All Participants
W. Fuller, Scott
C. Darvin, EPA
4.0 TECHNICAL DISCUSSION
4.1 GENERAL PURPOSE OF THE PROGRAM
Mr. Darvin outlined the objectives of the program as being:
evaluation of the performance of continuous monitoring instruments for pro-
cesses related to the nonferrous smelting industry and collection of data
representative of well-controlled and/or new processes being operated by that
industry for standards evaluations.
4.2 DESCRIPTION OF PROGRAM
The sequence of events was described by Mr. Fuller and included:
completion of instrument improvements by Scott and DuPont, demonstration
of unattended operation for 168 hours; performance evaluation testing of
the instrument using wet chemistry sampling methods and continuous monitoring
with periodic data reports for 6 months thereafter. The performance test
period is anticipated to occur in/December. Copies of all reports and data
acquired will be furnished to Phelps-Dodge through Mr. Orr.
4.3 SUMMARY OF INSTRUMENT PROBLEMS
An appendix attached to these minutes summarizes the problems
encountered with the instrument thusfar and potential approaches for
correction. Scott personnel outlined improvements needed. These were
supplemented by suggestions from plant personnel, EPA and DuPont participants
in the discussion.
SCOTT RESEARCH LABORATORIES. INC.
-------
-39-
SRL 2113 11 1173
.S ';
4.4 DISCUSSION OF PROPOSED APPROACHES -
! Item 1: Inability to maintain/proper sample flow in AT-1, AT-4
and AT-5 instruments
Scott's suggestion to decrease maintenance requirements by modi-
fying the aspirator system was supplemented by plant personnel discussions
of an L & N refrigeration unit on order. This unit might be inserted in
the sample line to trap moisture and DMA. , The effect on measurement accu-
racy is uncertain in this approach and would have to be resolved by com-
parison of source tests ahead and downstream of the refrigeration unit. In
addition, the plant has been cleaning the aspirator with a simple detergent
injection that might be automated very simply. The DuPont representative
indicated that moisture should not affect aspirator operation, but either
DMA or S0ซ might be adverse if backflushing sequences exposed aspirator
nozzle surfaces to sample flow. The aspirator nozzle is 316 stainless
steel and Kel-F inserts have been showing improved aspirator performance.
Further, the possibility was discussed that a throttling process cooling
the aspirator air might trigger local condensation of DMA. Correction
in that event might be accomplished by preheating aspirator air in a heat
exchanger located in the oven. :
The order of priority of potential corrections is:
A. Change inserts to Kel-F and observe operation
B. Automate the detergent injection process
Cl. Install L & N refrigeration unit, or
C2. Install aspirator air preheater, or
C3. Modify aspirator system to create parallel sample flow paths
and to promote condensate trapping.
Approaches A and B represent least cost, quickest response and
highest probability of success 'in attaining maintenance-free 168 hour
operating periods.
Item 2; Sample Cell Window Contamination by DMA, AT-1
Scott and plant personnel working, with the instrument have
observed this problem which is most severe when the plant is down. No approach
was discovered to reduce maintenance requirements without adding the pro-
bability of invalidating the sample. Since the observed effect is loss of
SCOTT RESEARCH LABORATORIES, INC.
-------
-40-
SRL 2113 11 1173
',' ;
analyzer zero control, which can be visually detected, and the effect is
not serious where the plant is operating well, the adopted approach was to
perform the maintenance as required. Plant personnel will check as appropriate
and note all adjustments or window cleaning maintenance in the Scott in-
strument field log.
Item 3: Erratic AT1 Signal Output and Loss of Calibration Filter
Response
Several alignment and electronic checks have been tried by plant
and Scott personnel to correct this problem. The DuPont representative
suspected that imbalances in the sensitivity of the DMA and S0_ analyzers
could cause the problem or that an internal DMA analyzer problem might be
possible. DuPont was requested to provide correction approaches from data
furnished on strip charts. Scott will implement recommended checks and modi-
fications .
Item 4; Proper Constant for Adder/Subtracter Circuit
The adder/subtracter circuit accepts inputs from the DMA and SO,,
analyzers and makes a correction for DMA interference in SO measurement.
The operation of this circuit and the proper magnitude of correction that
must be made for DMA interference has been suspected for some time but is
difficult to isolate. Scott outlined a task which would permit independent
calculation of the correction factor for comparison with DuPont recommended
values. The EPA personnel requested that supplementary wet chemistry tests
be performed on the sample during this task to eliminate all uncertainty
on instrument readings while the various signals in the circuit are examined.
Item 5; Calibration of Inlet SO., and DMA Instrument
Scott will obtain S(L calibration gas in the 6-10% range to verify
calibration shutter checks of the S0_ inlet instrument. Calibration of the
DMA analyzer has not been performed in the field except by calibration shut-
ter checks. The procedure for calibrating with DMA samples has been requested
from DuPont and will be implemented in the .field. DuPont and Scott recognize
that considerable uncertainty exists in the method for using DMA in calibra-
tions. However, the combined data from this exercise and that from the adder/
i
subtracter investigation is anticipated to improve the accuracy to the system.
SCOTT RESEARCH LABORATORIES. INC.
-------
-41-
SRL 2113 11 1173
Scott will install additional recorders to accept critical'input signals from
the DMA and SCL analyzers to the adder/subtracter which are not available
now for this investigation. Systematic introduction of SO calibration
gases with and without DMA in the sample should provide sufficient data
for calibration of the DMA instrument.
Item 6; Installation of Remote Actuation Calibration Shutters
Maintenance time for both Scott personnel during the continuous
monitoring period and plant personnel thereafter can .be reduced substantially
by installing remote actuated calibration shutters on the three analyzers
being monitored. Scott will install the systems but has requested the plant
to provide necessary control and signal cables for this purpose (2 were re-
quested at the coordination meeting but later design shows 3 may be necessary)
Scott has requested also that DuPont provide a controller connector schematic
to implement the electrical interface required.
4.5 SUMMARY OF ACTIONS TO PROVIDE INSTRUMENT IMPROVEMENTS
Scott
DuPont
o Plan and estimate cost of improve-
ments
o Provide S0_ inlet calibration gas
and calibrate instrument
o Validate adder/subtracter curcuit
o Calibrate DMA and SO outlet instru-
ment
o Preform wet chemistry tests in
calibration procedure of instrument
system
o Install temporary additional re-
corders
o Install remote calibration shutters
Provide DMA analyzer cali-
bration procedure using DMA
Process orders for remote
calibration shutters
Provide Kel-F inserts for as-
pirator modification
Provide technical advice for
erratic output signals and
improving sensitivity
Confirm K factor for adder/
subtracter
SCOTT RESEARCH LABORATORIES. INC.
-------
-42-
SRL 2113 11 1173
Phelps-Dodge ;' - EPA
p Provide cables' for remote calibrar- o ป Establish potential for DMA
tion shutter operation I interference with Method 8
_ ^. _... . , , , , SO,, wet chemistry determinations
o Continue DMA window contamination 2 }
maintenance and enter in field log \
o Provide approved plant data re-
. quests to EPA
4.6 'DISCUSSION OF PLANT DATA REQUESTED BY EPA
EPA requested plant operating data to supplement evaluation of the
DMA scrubbing process by continuous monitoring. The request was made through
Mr. Fenzi and approval has been received by plant personnel. With the ex-
ecption of purge flow data, all items are available and will be furnished
through Mr. Chen.
SCOTT RESEARCH LABORATORIES, INC.
-------
APPENDIX D
Field Data and Log
-------
-43-
7 J-
to 2 3 ,nr
SCOTT RESEARCH''^ LABORATORIES INC.
A SUBSIDIARY OF AMERICAN BIOCULTURE. INC.
2600CAJON BOULEVARD
SAN BERNARDINO, CALIFORNIA 92411
May 21, 1974
Mr. Robert M. Martin
Office of Air Quality Planning and Standards
Environmental Protection Agency
Research Triangle Park, North Carolina 27711
Dear Bob:
The supplementary testing program at Phelps Dodge in Ajo, Arizona was
completed on Saturday, May 18, 1974. The test crew cleaned up on Sunday
and returned to the San Bernardino lab Tuesday morning, May 21, 1974,
I have inspected the Field Data Forms and the Dynascience strip chart
record for these tests. A total of eight tests were performed by
Method 6 and a modified Method 6. Two tests were performed while the
DuPont was inoperative and the Dynascience instrument operation was
questionable. They may prove useful in later analyses. However, the
succeeding set of six tests were performed with both instruments operat-
ing and as you had instructed us (two by Method 6 with isopropanol in
the first impinger and four with Method 6 omitting isopropanol in the
first impinger). The samples are being transmitted to you under separate
cover and should arrive this week.
The strip chart records of the DuPont instrument showed traces which
we would have considered normal on our own inspection during the previous
test period. Several momentary transients of 100 to 200 ppm S02 were
recorded during the time samples were extracted from the stack. Further,
calibration on the DuPont instrument by standard cal gases appeared to
be normal as was the case previously. However, the Dynascience readings
indicating virtually zero detected S02 during the same periods. Before
each sample was taken the Dynascience instrument was spanned with cal gas
and responded in an expected manner. Consequently, we feel that the
instrument was operating properly during the test period, I have
included a copy of our field data with this letter for your use when
the EPA chemist finishes analysis of the samples. We will be very
happy to furnish any additional assistance you may require. We would
also appreciate very much receiving the results of the field analysis
for our own information.
-------
Mr. Robert M. Martin ~~ my 21, 1974
We will submit a formal final report to you; however, I believe the format
should be abbreviated for these tests and will discuss it with you on
my next visit to Durham May 24 for the contractor meeting.
Regards.
Sincerely,
William F. Fuller
Manager, Environmental
Services Department
WFF:bc
Enclosure
-------
Scf up
I") i
-45-
0800
1900
U',13
ISM"?
|5";38
r
sife
30 o
3 uoปu
-------
_46_
7. e
. -7
"2140 T^s- R^ e
zzoo ^^ , __ .
-------
FIELD DATA
PLANT pl,,~ /,-.:, -.1W-.
DAT E
SAMPLING
SAMPLE TYPE fy. r- -'. .-v-.'
P. =.6
BAR. PRESS. ?"?,. 9';; __ METER BOX NO. .S^ , ?.
STATIC PRESS. (P ) j---- METER AH@ j .. :;\ (,
FILTER NO(S) -S---- __ [1
'
C FACTOR
RUN NUMBER r ,,'t :>.*. r/,
OPERATOR
PROBE LENGIH/TYPE r>.
NOZZLE I.D.
bof.>'-/
ASSUMED MOIST.%
S KTR. SETG. -----
HTR.30X SSTG. -----
REF.AP ----
AMBIENT TEMP.
.SAMPLE BOX NO.
READ AND RECORD ALL DATA EVERY 7 MINUTES (TOTAL DURATION)
Schematic of Traverse
Point Layo.ut
TRAVERSE
POINT
NUMBER
\CLOCK TIME
\^ (24-Hr
N. CLOCK
SAMPLINGS.
TIME, MIN N.
-,
:\
f-
,
, ,.,
1 ':
!-'
K,
'?,
-;'.?>
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GAS METER
READING
(ป) .P.3
^'i ';."'! 8|
C/l i_i^i.ซ>-'(
^ d-jC| ( (^"g
" WKOI.!.
OQ-0-.-S16
VELOCITY
READ (AP ),
in. H20
7nl ,'^, ft 1
J)i5l , '?:! N
)02,1'?-O
"|0?,,"?M
ORIFICE
PRESSURE
DIFFERENTIAL
(AH), in.11^0
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Actual
t ^- o
1 1 "UO
i ") *s
,. ^ ''>
. ^o
'1 s,"
\ ?.$'
v \ 1 -C
J / 1 ^""
v ~i. -T
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PERATURE
/rp \ O TJ*
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TEMPERATURE
Inlet
"in
ฐF
-------
PLANT "P
DATE .
SAMPLING LOG.
SAMPLE TYPE
RUN NUMBER j
OPERATOR
BAR. PRESS.
FIELD DATA
"l METER BOX NO. ,\>>
STATIC PRESS. (P^-
FILTER NC(S)___^__
PROBE LENGTH/TYPE^
NOZZLE I.D. ' -J ..-:(; ;.,
METER Ai^
c FACTOR'
AMBIENT TEMP.
ASSUMED MOIST.%
SAMPLE BOX NO. "
iBE HTR. 8ETG.
HTR.BOX SETG. "
REF.AP .
READ AND RECORD ALL DATA EVERY "Z. MINUTES (TOTAL DURATION)
Schematic of Traverse
Point Layout
TRAVERSE
POINT
NUMBER
! '
'
\CLOCK TIME
N. (24-Hr
' S. CLOCK
SAMPLINGS.
TIME, MIN S.
r~>
?.,
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HEAD (AP ),
in. HO S
loft. 7 1 Si
lo&J, 77
70?. ! 1 1
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PRESSURE
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(AHj^_in^H 0
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1 1 V.">
.))/>
i i o
. \ 7 O
. 17 ;"
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. IK
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1
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-COMMENT S:
-------
FIELD DATA
?LANT -Purl ,,- r.-s I.-.* A, <-,
BAR. PRESS. 7.~?.'7(-
STATIC PRESS. (PJ
__
SAMPLING LOG. .?..-. \ * \ \n. Pu. V FILTER NO(S)_ ___
SA1-IPLE TYPE ,-,,r.\' C, PROBE LENGTH/TYPE 4^'
METER BOX NO. "'. '-. _
C FACTOR
RUN NUMBER 1.
OPERATOR ^
-w- -^ i NOZZLE I. P.-
to.
AMBIENT TEMP. _Q 7
ASSUMED MOIST.%_
SAMPLE BOX NO.
PROBE 1ITR. SETG.
HTR.BOX SETG. _
REF.AP
READ AND RECORD ALL DATA EVERY *"*-- MINUTES. (TOTAL DURATION)
, ..,._...
' Schematic of Traverse
Point Layout
CD
1
-TRAVERSE
POINT
NUMBER
SA h -\.v.J
& (r.j ?
r.( *.-.,<'
\CLQCK TIME
\, (24-Hr
SAMPLINGS.
TIME, MIN N.
,, .*)
7.
L "
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7 I3.0! 79
-|l4,^O
~7 14 *"i H 1
7, -r. -^?.
'lib "'-A\
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2_o,^
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TEMPERA-
TURE, ฐF
IMPINGES
TURE, ฐr
i
i
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1
i
_
i
COMMENTS:
-------
FIELD DATA.
PLANT _
DATE _
SAMPLING LOG. f>Ti.Tt ฃQ-.
SAMPLE TYPE : ;:;^^VQ /.-
OPERATOR i,.-) 1
STATIC PRESS.(P )
FILTER NO(S) S "
PROBE LENGTII/TYPE_
NOZZLE I.D. -^
METER BOX NO.rSRl.--.M--.
METER All@ y. P->
C FACTOR
ASSUMED MOIST.%
PROBE KTR. 15 i
HTR.BOX SETG.
REF.AP
^g-vj 3x)?o!-o
PRO^
AMBIENT TEMP.
SAMPLE BOX NO.
READ AND RECORD ALL DATA-EVERY 7_ MINUTES (TOTAL DURATION)
U\3 ' ;;.; -iZ .
Schematic of Traverse
Point Layout
INVERSE
POINT
NUMBER
\CLOCK TIME
N. (24-Hr
N. CLOCK
SAMPLINGS.
TIME, MIN N.
o 18(90
7
'A
(^
9
\n
n
\L
1$.
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GAS METER
READING
(Vm),Ft3
i"L7. .o.sr
"'> 7 .S'-AD
']15>. 0?,o
"?i?:>. -6 v>o
-^r;, 39-ฃ
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^.,'10
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, 1 U r>
, I I- 0
1 (,$
. 1 // 0
. I (, 0 .
. \:'.', ฐF
-, N-op
1
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s /
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TEMPERATURE
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'(Tn }
in
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-i >
9 "7
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<94.
7';'
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99
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ci 1
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-,r ;-;.
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( ซ^ , ,
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\ --7.1
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1 *}. O
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SAMPLE BOX
TEMPERA-
TURE, ฐF
IMPINGER
TURE, ฐF
J
i
i
1
LT>
I
-COMMENTS:
-------
FIELD DATA
PLANT
r>.', T '.
BAR. PRESS.
7."? . ฃ
STATIC PRESS. (P )_
FILTER NO(S) S-
METER BOX NO._?.;... V, S'A '
METER Ali<3 1 ~H ',-
C FACTOR
RATOR
A \TJ T " :>' T *** .;.
ru i;} J. i_.. 1 j. j-^i i
PROBE LENGTH/TYPE^^.-- >-<: PROBE HTR. SETG._
NOZZLE I.D. v - : ' _' HTR.BOX SETG. . .
ASSUMED MOIST. % Q %, REF.AP -
SAMPLE BOX NO.
READ AND RECORD ALL DATA EVERY ">,.. MINUTES (TOTAL DURATION)
^ , . .-j <
Schematic or Traverse
Point Layout
1 ^AVERSE
- POINT
NUMBER
\CLOCK TIME
\v (24-Hr
\CLOCK
TIME, MINN.
0 \hOO
7
4-
/.,
o
10 ' .
. i 4
!U
'' o ) I "2. CD
. .- - !
GAS METER
READING
130.100
~730.!-,H
"/\
"l\
'IT
"!\
(
?
77,
,A "!
\ <; ซ.
i.-i:' ;.o
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VELOCITY
HEAD (AP ),
in. H20 S
3,80
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"A . 8 ~
i , R N '
"i , ^1 O
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ORIFICE
PRESSURE
DIFFERENTIAL
(AH), in.H.,0
Desired
Actual
STACK TEM-
PERATURE
(Ts) , *F
j
nr i
, 1 R 0
, I ;:) \
,\r^'
,?J.^-'
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I."', n
\~i Q
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. 1
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TEMPERA-
TURE, ฐF
t
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IMPINGER
TEM?ERj\-
TURE, ฐr
.
t
1
<
i
I
-COMMENTS:
-------
FIELD DATA
PLANT T>!^k.-. 1V.-1-.- P;--> BAR. PRESS. T")/M
DATE s~"-'\-ป/. NOZZLE I.D.
OPERATOR V/ T\| O T^S ' ; ASSUMED MOIST.% Q%
AMBIENT TEMP. '' T^ F SAMPLE BOX NO.
READ AND RECORD ALL DATA EVERY ~t. MINUTES (TOTAL DURATION)
Schematic of Traversa
Point Layout
TRAVERSE
POINT
NUMBER
X.CLOCK TIME
X^ (24-Hr
N. CLOCK
SAMPLINGS.
TIME, MIN N.
O \~1 lS~"
7
A-
t."
/-? '
l .'')
i 'L
!!
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t ^
--. i "~y> >"
' i /.s ป
i
GAS METER
READING
TFป .ฐi\5T
"7-1 0, ^11
7/1 n, mi.
VELOCITY
HEAD (AP^),
in. H20
A ,00
^ O'">
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7-11. Si^
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7^; ,sS"2-
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4 . 00
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4,00
A , hV
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ORIFICE
PRESSURE
DIFFERENTIAL
(AH), in.H^O
Desired
Actual
\ '?..!.:>
, M r
\ rป r
,\DO
.no
. \ t") A
STACK TEM-
PERATURE
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TEMPERATURE
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out
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j
1
1
|
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SAMPLE BOX
TURS, ฐF
TURE, ฐF
|
' 1
1
!
1
OJ
-COMMENTS:
-------
PLANT -PV...-.I/V -Ty,,..U.-. Q; r;
DATE ' -'
SAMPLING LOG./,i-?-. 'fr'..-. .^- Qu
SA1-1PLE TYPE PP.
BAR. PRESS.
FIELD DATA
METER BOX NO. .J.v.. . "A"
STATIC PRESS.(P ) -
FILTER NO(S) S-
METER AH@
C FACTOR
RUN NUMBER **;-- v/y,,^.,4-
OPERATOR WMฃVA.
\.-.o cv^y-
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PROBE LENGTH/TYPE ^-r;! .-.'. PROBE HTR. 8ETG._
NOZZLE I.P.- -- _'_, HTR.BOX SETG. -)
ASSUMED MOIST.% Q-%, REF.AP -
SAMPLE BOX NO.
READ AND RECORD ALL DATA EVERY 2. MINUTES (TOTAL DURATION)
*V
Schematic of Traverse
Point Layout
o
1
OO
in
INVERSE
POINT '
NUMBER
.. -
\CLOCK TIME
X. (24-Kr
N. CLOCK
SAMPLINGS
TIME, MIN >.
^ \ R ?. N~
?...
~?
\ p.
(-.)
\A
!(. -
I ..;
''"} fc ".-'.. \
GAS METER
READING
(V ) ,Ft3
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ul
-7 -A 1,^-4 1
747,^0
"~V '' '*^ \ "^ ^*?
7Aฐ1,?. o"?
V''i-;. . Mฐ!
1 5"0 oc>^
75n ,c?. 5
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751^3,0
VELOCITY
HEAD (AP ),
in. H20 S
"S '^n
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4 . O o
-4 , or;
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ORIFICE
PRESSURE
DIFFERENTIAL
(AH), in.H.,0
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Actual
P. o"
, ;\, f
,
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\ \ 0
.l-V'O
1
1 3 i"
1 \~')
"l f'"'l
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PERATURE
fT ^ ฐ^
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,
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in. Hg
:'"i 1
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--
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TE-IPERA-
TURE, ฐF
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?. 0,0
,? c? , o
IMP ING ER
TEMPERA-
TURE, ฐF
i
i
1
1
- ..
-COMMEisTS:
-------
FIELD DATA
PLANT "p U.* i o \ - "h ~> /* - ฃ
DATE <:; ',. \ ('.,'- -i.-V
SAMPLING LGC./V), y1,/, i (
SAMPLE TYPE f-\o -U,,-? d 4
RUN NUMBERr~ (..-* . w i -; U - ... f "
OPERATOR lA/M '" T4 .
AftfRTTTMT TT7MT> ' ~7 "? & C
/J.U5 -Lr.iN l iฃ.rLrซ / ,5 p
.; n BAR. PRESS. 2. ? . V I
STATIC PRESS. (P )
.'...i ;.-/- FILTER NO(S) - *
PROBE LENGTH/TYPE ,-J '. : ;?,! >.
j /} ',; ./ ซ "* ,"".' ' - ฃ iN W A ^ป 1-* 11* JL U
' ' ASSUMED MOIST. % O %> .
^AT'lPTF ROV NO -
METER BOX NO. .''..: '-. ('
METER AKfl l,H'..->
C FACTOR
--, PROBE HTR. SETG-.
HTR. BOX SETG.
REF.AP - --:-.
READ AND RECORD ALL DATA EVERY 2- MINUTES (TOTAL DURATION)
Schematic of Traversa
Point Layout
TRAVERSE
POINT
NUMBER
i
N. CLOCK TIME
N. (24-Hr
N. CLOCK
TIME, MINN.
o \c\'\^~~
A:
I.-
:::
10
\.\
\ ^
1 ?:
:-o \-fi~S
GAS METER
READING
(Vm),Ft3
-is ^,>sr'
^ s~rป u<
^.s"(.-J,W.:
1 5"! . 1 \fi\
1 5"! (s'n
^ T-? , o ^ i
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'^V^-3'A
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,
VELOCITY
HEAD (AP ) ,
in. H20 S
. 3t 8 *T
V
ORIFICE
PRESSURE
DIFFERENTIAL
(AH), in.H^O
Desired
Actual
,i vr
,\ TO
. I A 0
ilS'O
.IA r
, 1 ro
, i 4 5"
. j .''?'>
STACK TEM-
PERATURE
(T ) ฐF
i .1
0
i
^
y
DRY GAS METER
TEMPERATURE
Inlet
' in
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?V7
lo B
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'1 "i
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PUMP
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",> '"), ( -
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x o, ;>
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;-'^M':.>
2..-:7. Q
i 0 , JO
2. y,c?
' ' ' ? ; :' 5
SAMPLE BOX
TEMPERA-
TURE, ฐF
.
IMPINGER
TURE, ฐF
COMMENTS:
-------
FIELD DATA
PLANT -.i-v-;..., -.. py-
DATE ^"-._. j : .
SAMPLING LOG. AQ-, y-;
SAMPLE TYPE
BAR. PRESS. >"/,. :^ /-
STATIC PRESS.(P )
FILTER NO(S) S
METER BOX NO. &.^ \>. "A
METER,
C FACTOR
\a
ir. *-.
RUN NUMBER-"' "7 Wi-H-0..A "!
OPERATOR 1.^70, ฃ
PROBE LENGTH/TYPE /lii
NOZZLE I.D. -
AMBIENT TEMP.
-1 I'p
ASSUMED MOIST.% O0/-.
SAMPLE BOX NO.
PROBE HTR. SETG.
HTR.BOX SETG. ~
REF.AP
READ AND RECORD ALL DATA EVERY 2.. MINUTES (TOTAL DURATION)
Schematic of Traverse
Point Layout
TRAVERSE
POINT
NUMBER
X.CLOCK TIME
N. (24-Hr
SAMPLINGS
TIME, MIN N.
0 -J 7VA 0
7. .
"I :\
(.-,
S
10
VI
\ ':
! l-i
! 3
?.. r? ") -, ,o o
GAS METER
READING
(Vm),Ft3
7dl.9i5"D
-;.^^ ,^ <-
7/---1 ,7
7 -.<,' \ 1
^
so
\ "
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7 Co7 , /-,"? r'i
-7^^, |oP>
VELOCITY
HEAD (AP ),
in. H00
\ ex s
;
N/
ORIFICE
PRESSURE
DIFFERENTIAL
(AH), in.H.,0
Desired
Actual
j
,t
t
i
,
40
>> O
iO
T, -j-
"i "S"
i i r
! '. ^
I ^ 0
3. >,-
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PERATURE
(T ), ฐF
s
T3o
!
/
/
/
/
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I
!
1
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DRY GAS METER
TEMPERATURE
Inlet
min
R(-
07
-^ ',->
R ^
*\ 0
('} \
'"I J
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=-) ...r
"7 "7
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out
OF
,C?^j
R1 ^'
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Bo
a 7
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'r1, c>|
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"
PUMP
VACUUM
in. Hg
? O. r;
"? n , o
If) , 0
:' n . !")'
7 0 i 0
'..' '"' , '."",
7 n , 'i
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7,o,D
SAMPLE BOX
TEMPERA-
TURE, ฐF
-;
IMPINGER
TEMPERA-
TURE, ฐF
I
in
un
. -COMMENTS:
-------
PLANT 'pi-.-
DATE
FIELD DATA
BAR. PRESS.. 1*"? . 'cj'L METER BOX NO. ฑ)ป~. fc. V
SAI-IPLING LOG. '-..-
STATIC PRESS.(P )
FILTER NO(S) S "
METER AH@
C FACTOR
SAMPLE TYPE fv-.;.;:.-,
RUN .NUMBER^'P? wily.,-,
OPERATOR '.,./ !\\ < T6
| V. ."1 ..-j v -j O .1 -A <> 1
AMBIENT TEMP.
PROBE LENGTH/TYPE -A1"..!'. Ci.v.-, PROBE HTR. SETG._
NOZZLE I.D. - HTR.BOX SETG. _^
ASSUMED MOIST. % O "/o REF.AP
SAMPLE BOX NO.
READ AND RECORD ALL DATA EVERY ?.. MINUTES (TOTAL DURATION)
Schematic of Traverse
Point Layout
TRAVERSE
POINT
NUMBER
-
..
I
\. CLOCK TIME
N. (24-Hr
\CLOCK
SAMPLINGS
TIME, MIN ^v
O > \ A -Q
2.
-1
(:>
"?
ID
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-------
APPENDIX E
Summary of Instrument Problems
-------
-57]
SRL 2113 11 1173
SUMMARY OF ..
INSTRUMENT PROBLEMS
AT PHELPS-DODGE ACID PLANT
AJO, ARIZONA
Environmental Protection Agency
Contract 68-02-0233
Task Order Number 10
October 24, 1973
By
SCOTT RESEARCH LABORATORIES, INC.
2600 Cajon Boulevard
San Bernardino-, California 92411
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Summary of Instrument Problems at Ajo
Problem
Resolution
Corrective Action
Status
1) Sample flow cannot be maintained
for longer than 1-4 days in AT-1,
AT-5 and AT-4.
2) Sample cell windows dirtied by
high concentration sample flow,
such that zero control is lost
after a few days, AT-1.
3) AT-1 signal output erratic and
at times unable to get correct
response to calibration filter
even with SPAN control full CW.
4) Response of Adder/Subtracter
circuit to S0_ and DMA signals
over the range of concentra-
tions being monitored is not
known.
5) No present means of verifying
span of AT-4 and AT-5 except
by calibration shutter.
Identified as fouling of
Aspirator in AT-1 and
AT-5. Same in AT-4 along
with some sediment in
sample line.
Assumed caused by DMA
deposits on windows.
Not identified
Clean aspirator and lines Still a
each time flow is lost. problem.
Pull cell and clean win- Still a
dows every few days. problem.
Moved sample cell into May still
better optical align- , be a
ment; changed source problem.
lamp; changed tubes ' ^
V-l and V-2.
Perform careful align- To be
ment of Adder/Subtractor done.
and the signal current
loops which feed it.
Measure and plot response
to spread of expected
input signals.
Obtain SO- calibration To be
gas in 6-10% range; deter- done
mine some way of verifying
calibration of DMA
analyzer AT-5.
to
M
I-1'
I
CJ1
co
I
-------
Summary of Instrument Problems at Ajo (Continued)
a
o
>
o
o
Problem
Resolution
Corrective Action
Status
co
ro
I-1
I-1
6) Very difficult to use the
manual calibration shutters
in AT-1, AT-5 and AT-4, for
either calibration or main-
tenance. Now requires two
men plus radios and consumes
much time.
7) No means of looking directly
at output of AT-1 when setting
zero and span, or to evaluate
analyzer performance;
8) Non-coordinated zeroing.
Westinghouse recorder actuates
blanking signal every 15 min-
utes. DuPont analyzer auto-
matically zeroes every 10
minutes.
Newer instruments
are equipped with
a remotely operated
calibration shutter.
DuPont analyzer:zero
is timer actuated by
internal timer.
Install necessary parts to To be
make these systems' cali- done.
bration shutters remotely
operable.
Add (temporarily) a strip To be
chart recorder to monitor . done .
AT-1 output.
Trigger timing motor with In
a switch closure from the Process
Westinghouse.clock.
. 1C
I
-------
Summary of Instrument Problems .at Ajo (Continued)
to
en
O
O
H
H
50
M
O)
o
90
O
ป
w
Problem Resolution Corrective Action Status
H
I-1
9) Clogging of Aspirator of Due to moisture and dirt Add additional Aspirator To be u>
AT-4 for water trap done
f-\ Sample Cell ( , . f| Sample Cell \-
jL
. Sample Flow >^-j S
v . a
Trap
Aspirator j_J . |_J Aspirator ' "v*
^*^IK n V V Proposed ... '
Dump Dump Dump
10) Clogging of Aspirator of Due to moisture and dirt Add additional Aspirator
AT-1 and AT-5 . fฐ* water traP
r \ SO? Cell I, f | DMA Cell [-,
j
Sample rev VTj Sample
A Flow "^ ^* Flow I
"
I A-Lt
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Aspirator ^^4
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Sample
Flow
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Proposed
Dump
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