ENVIROSCIENCE
MOBILE INCINERATION SYSTEM SOLIDS TRIAL BURN PLAN
Prepared By
IT Corporation
Edison, New Jersey 08837
EPA Contract 68-03-3069
For
U.S. Environmental Protection Agency
Municipal Environmental Research Laboratory
Solid and Hazardous Waste Research Division
Oil and Hazardous Materials Spills Branch
Edison, New Jersey 08837
February 24, 1983
312 Directors Drive • Knoxville. Tennessee 37923 • (61 5) 690-3211
Division of IT Corporation
-------
TABLE OF CONTENTS
Page
I. PROJECT DESCRIPTION 1-1
A. Introduction !_]_
B. Solids Incineration Scope 1-2
C. Proposed Trial Burn Dates 1-3
II. ENGINEERING DESCRIPTION OF THE MOBILE INCINERATOR II-l
A. Process Description II-l
B. Manufacturer's Name and Model Number II-l
C. Type of Incinerator II-4
D. Linear Dimensions II-4
E. Auxiliary Fuel Systems ' II-4
F. Solids Handling and Feed System II-7
G. Prime Mover Capacity II-8
H. Automatic Waste Feed Cut-Off II-8
I. Stack Gas and Pollution Control Monitoring System 11-11
J. Nozzle and Burner Design 11-16
K. Water Injection 11-17
L. Materials of Construction 11-17
M. Location and Description of Indicating and Control Devices 11-17
III. TRIAL BURN PROCEDURES III-l
A. POHC Selection Rationale III-l
B. Waste Preparation III-2
C. Solids Handling and Feed III-6
D. Sampling Analysis and Monitoring Procedures III-6
E. Detailed Test Burn Protocol 111-15
F. Emission Control Equipment Description and Operating
Conditions 111-24
G. Procedures During Equipment Malfunction III-26
H. Trial Burn Inspections 111-29
I. Trial Burn Recordkeeping 111-33
J. Trial Burn Schedule 111-33
K. Site Cleanup 111-38
L. Quality Assurance Project Plan 111-38
-------
TABLES
Table
No. Page
1 Safety Interlock System II-9
2 Interlock Set-Points 11-10
3 Continuous Stack Monitoring Analyses 11-15
4 Materials of Construction for Mobile Incinerator 11-18
5 Pentachlorophenol Physical Properties III-3
6 Stack Gas Analytical Methods III-ll
7 Trial Burn Analytical Summary 111-12
8 Oxygen Analysis Method 111-16
9 Carbon Dioxide Analysis Method 111-17
10 Carbon Monoxide Analysis Method 111-18
11 Oxides of Nitrogen Analysis Method 111-19
12 Sulfur Dioxide Analysis Method 111-20
13 Total Hydrocarbon Analysis Method 111-21
14 Trial Burn Operating Conditions 111-22
15 Operating Conditions for APC Equipment 111-28
16 Trial Burn Schedule 111-37
-------
FIGURES
Figure
No. Page
1 EPA Mobile Incineration System II-2
2 Block Flow Diagram of Mobile Incinerator II-3
3 Dimensional Sketch of Rotary Kiln II-5
4 Dimensional Sketch of Secondary Combustion Chamber II-6
5 Thermocouple Probe Detail 11-19
6 Stack Gas Sampling Locations III-7
7 Air Pollution Control (APC) Equipment) 111-25
8 Dimensional Sketch of APC Equipment 111-27
9 RK/SCC Operating Log Sheet III-34
10 APC Equipment Operating Log Sheet 111-35
11 Utility Operating Log Sheet 111-36
-------
1-1
SECTION I
PROJECT DESCRIPTION
A. INTRODUCTION
This project covers the solids incineration trial burn of the Environmental
Protection Agency's Office of Research and Development's Mobile Incinerator
System by the Environmental Emergency Response Unit (EERU) at the Kin-Buc land-
fill site in Edison, New Jersey. The system consists> of a rotary kiln, a secon-
dary combustion chamber, and an air pollution control train, each mounted on a
heavy duty over-the-road semitrailer. The system is designed for field use to
destroy/detoxify hazardous and toxic organic substances that have contaminated
soil or water at spill sites or at "orphaned" dump sites. Liquids, sludges, and
contaminated debris that have been shredded or otherwise prepared for processing
can be introduced into the system.
The system has previously undergone a rigorous three-phase trial burn liquid
incineration program which was designed to minimize the risk of any undesirable
emissions to the environment. The three-phase program involved the incineration
of the following liquids:
Phase I - Diesel oil only
Phase II - A blend of 20 to 23% carbon tetrachloride (CC14), and
25-31% o-dichlorobenzene (ODCB) dissolved in diesel oil
Phase III - A blend of 2% tetrachlorobenzene, 11% trichlorobenzene, and
18-22% PCBs as Arochlor 1260, dissolved in diesel oil
The Phase II evaluations were completed and showed destruction removal efficien-
cies (DREs) for all principal organic hazardous constituents (POHCs) well above
99.99%. The Phase III evaluations are not yet completed but preliminary indica-
tions show that the DREs for the PCBs were acceptable.
If, as expected, the Phase III Toxic Substances Control Act (TSCA) trial burn is
successful, and the mobile incinerator obtains both TSCA and RCRA permits, a
demonstration test of the mobile incinerator is scheduled for August 1983 at the
Kin-Buc landfill in Edison, New Jersey.
-------
1-2
During the Kin-Buc demonstration test, oily leachate from the Kin-Buc landfill
will be incinerated. During the Kin-Buc demonstration, EERU is also proposing a
three-phase program of solids incineration.
B. SOLIDS INCINERATION SCOPE
The scope of the three-phase solids incineration program would be as follows.
1. Phase I
During Phase I, clean soil will be fed to the incinerator while burning oily
leachate. The purpose of this phase would be to determine practical operational
ranges for the solids handling system, the inicnerator ram feed system, the
rotary kiln (inclination and rpm), and the rotary kiln ash handling system.
Phase I will not be either a RCRA or TSCA solids trial burn since the soil used
will be certified as nonhazardous.
2. Phase II
During Phase II a soil contaminated with less than 50 ppm of PCBs will be fed to
the mobile incinerator. During this phase diesel fuel will be used as auxiliary
fuel rather than the Kin-Buc oily leachate. The PCB contaminated soil will be
either a clean, artifically contaminated soil, or an actual PCB contaminated
soil from an existing site. Phase II will be a RCRA trial burn, but not a TSCA
trial burn because the PCB soil concentration will be <50 ppm. The purpose of
this phase is to demonstrate the mobile incinerator's capabilities for
detoxifying contaminated soil.
3. Phase III
During Phase III a mixture of pentachlorophenol (PCP) and sand will be fed to
the mobile incinerator. During this phase diesel fuel will be used as auxiliary
fuel rather than the Kin-Buc oily leachate. The PCP will be fed as a 50% mix-
ture of PCP in sand to prevent the formation of pools of molten PCP in the
rotary kiln. Phase III will be a RCRA solids trial burn. The purpose of this
phase is to obtain a flexible solids RCRA permit for the mobile incinerator.
The purpose of the trial burn is to evaluate and demonstrate the mobile
incinerator's ability to safely destroy hazardous and toxic solid materials in
-------
1-3
accordance with the requirements of the Resource Conservation and Recovery Act
(RCRA). This objective will be met by: (1) measuring the destruction and
removal efficiencies (DRE) for the specified test materials/ (2) determining
particulate and acid gas removal efficiencies for the air pollution control
equipment, and (3) continuously monitoring the system's operating conditions and
emissions. In addition to defining the performance capability of the system,
the data generated will furnish background information for subsequent permitting
associated with the on-going use of the mobile incineration system for cleaning
up spill and dump sites. As such, the data quality level objective for this
project is Level 2, requiring a high degree of quality coverage.
The trial burn will consist of 2 tests each having three runs. This trial burn
plan covers all 6 runs. The waste feed rates and trial burn protocol are
discussed in Section III-E.
C. PROPOSED TRIAL BURN DATES
The solids trial burn for the mobile incinerator is planned for the last 7 days
of the 30-day Kin-Buc demonstration which is scheduled to start in mid-August.
-------
II-l
SECTION II
ENGINEERING DESCRIPTION OF THE MOBILE INCINERATOR
A. PROCESS DESCRIPTION
The mobile incineration system has been designed and built to provide a mobile
facility for on-site thermal destruction/detoxification of hazardous and toxic
organic substances. The total system consists of: (1) major incineration and
air pollution control (APC) equipment mounted on three heavy duty, over-the-
road, semi-trailers; (2) combustion and stack gas monitoring equipment housed
within a fourth trailer; (3) ancillary support equipment. As illustrated in
Fig. 1, the mobile incineration system consists principally of a: (1) rotary
kiln; (2) secondary combustion chamber (SCC); (3) wetted-throat venturi elbow
and quench elbow sump; (4) cleanable high efficiency air filter (CHEAF); (5) MX
(mass transfer) scrubber; and (6) an induced draft (ID) fan. Auxiliary equip-
ment consists of bulk fuel storage, waste blending and feed equipment, scrubber
solution feed equipment, ash receiving drums, and an auxiliary diesel power
generator. A block flow diagram of the system is shown in Fig. 2.
The mobile incineration system is controlled and monitored via electrical relay
logic and conventional industrial process instrumentation and hardware. Safety
interlocks and shutdown features comprise a major portion of the control system.
Fuel, waste, and combustion air feed rates, combustion temperatures, and stack
gas concentration of carbon monoxide (CO), carbon dioxide (C02), and oxygen (02)
are continuously monitored, thus assuring compliance with regulatory
requirements.
B. MANUFACTURER'S NAME AND MODEL NUMBER
The design and procurement of the mobile incineration system was sponsored by
the Oil and Hazardous Material Spills Branch (OHMSB) of the EPA's Municipal
Environmental Research Laboratory (MERL-Ci). The initial design was developed
by MB Associates. Subsequent design, assembly, and modification was performed
by EERU's operating contractors — Mason and Hanger-Silas Mason Company, and IT
Corporation. IT Corporation is the current operating contractor for EERU and is
responsible for final assembly, inspection, and testing the system and its sub-
-------
BURNERS
KIIM-SCC DUCT
SOLIDS HAM
FEED SYSTEM
COMBUSTION GAS ANALYSIS
(Oj. CO. C02)
SECONDARY
COMBUSTION
CHAMBER
COOLING
SHROUD
FAN
.QUENCH ELBOW
CHEAF
REFLO DUCf
/STACK OAS ANALYSIS
(THC. NO,. SO], Oj. CO. COj)
7—IX-
t— I.D. FAM I
DESCniPTION
KILN
SCC
APC
OVERALL WIDTH: 2.4m
OVERALL LENGTH: 45.7 m
STACK HEIGHT. 9.1 m
OVERALL HEAT DUTY: 15 MILLION BTU/hr
ELECTRICAL REQUIREMENTS: 100 kW
WEIGHT TRAILER 1 - 42.000 Ib (19.051 kfl)
WEIGHT TRAILER 2 - 67.000 Ib (25,855 kg)
WEIGHT TRAILER 3 - 36.000 Ib (16.329 kg)
TEMPERATURE:
PRESSURE:
GAS RESIDENCE TIME:
EXCESS OXYGEN:
1.000C
- 1.000 Pa
2 sec
4 percent
FEED RATES (AT 20 PERCENT XS AIR)
AIR: aS
FUEL OIL: 285 L/hr
WASTE SOLIDS: 68 kg/min
WASTE OIL: 227 L/hr
WATER: 680 L/hr
DISCHARGES
ASH:
WASTE WATER:
NONE
1,200 C
- 1,500 Pa +
2 sec
4 percent
34m'/min
150 L/hr
NONE
NONE
NONE
NONE
NONE
80 C
- 10K Pa
4 percent
NONE
NONE
NONE
NONE
PARTICULATE FILTER MEDIA
H
to
+ 1.000 PASCAL « 4 in H, O
* DEPENDENT UPON FEED MATERIAL
FIG. 1 EPA MOBILE INCINERATION SYSTEM - DESIGN SUMMARY
-------
SAMPLE
AIR
OFF QAS
LI i_J
H
I
U)
FIG. 2 BLOCK FLOW DIAGRAM OF MOBILE INCINERATION SYSTEM
-------
II-4
sequent field operations as a mobile hazardous and toxic material destruction
system. The system, being one-of-a-kind and custom designed, has no model
number.
C. TYPE OF INCINERATOR
The mobile incinerator is a rotary kiln (RK) incinerator with secondary com-
bustion of the kiln combustion gases in a fuel oil fired secondary combustion
chamber (SCC) (see Fig. 1).
D. LINEAR DIMENSIONS AND CROSS SECTIONAL AREA OF THE MOBILE INCINERATOR
1. Rotary Kiln
The rotary kiln is a carbon steel shell lined with 6 inches of castable refrac-
tory. The RK is a cylindrical shell which is 16 ft long and has a 4 ft-4 in.
2
inside diameter (ID). The cross sectional area is 14.75 ft and the RK volume
3
is 236 ft . Figure 3 is a dimensional sketch of the rotary kiln.
\
2. Secondary Combustion Chamber
The secondary combustion chamber (SCC) is a carbon steel cylindrical shell lined
with 6 in. of castable refractory. The SCC is 36 ft long and has a 4 ft-4 in.
2
I.D. The cross sectional area is 14.75 ft
Figure 4 is a dimensional sketch of the SCC.
2 3
I.D. The cross sectional area is 14.75 ft and the SCC volume is 531 ft •
E. AUXILIARY FUEL SYSTEMS
Both the RK and the SCC have fuel oil-fired auxiliary fuel systems.
1. Rotary Kiln
The RK is fired by two 4-in. Maxon burners, each of which is capable of a 12:1
turn down and close fuel/air ratio compliance throughout this range. These bur-
ners have high-turbulence and short flames which result in high intensity com-
bustion. Each Maxon burner is rated at about 4 MM Btuh.
2. SCC
The SCC auxiliary fuel system consists of two tangentially fired fuel oil bur-
-------
• WATER INJECTION PORT
SOLIDS RAM
FEED SYSTEM
RAtA FCCO { (If*V»»«*.'
ROTARY KILN
H
I
01
Fig. 3. Rotary Kiln Sketch
with Dimensions
-------
I III
r 1 1
* *
3=
c— V
,' O '
\ v-' '
\^ ^/
1
L
a
i
SECONDARY
COMBUSTION
CHAMBER"
i
en
SECONDARY COMBUSTION CHAMBER AND QUENCH
Fig. 4. Secondary Combustion Chamber
Sketch with Dimensions
-------
II-7
ners which are used to increase the temperature of the incoming RK combustion
gas. The incoming RK gas enters the SCC axially through spin vanes which impact
a swirling and mixing action to these gases. The RK gases are mixed and con-
tacted with the hot gases from the two SCC burners because of the design of the
inlet spin vane and the tangentially fired burners. Sach burner is rated at
about 2.8 MM Btuh.
F. SOLIDS HANDLING AND FEED SYSTEM
The solids materials to be incinerated during the trial burn will be contained
in drums and will be fed to the ram feed hopper either by a drum handling
vehicle or by a drum loading mechanism. The ram feed hopper will have a dust
cover and seal which will allow dumping of the drum but prevent fugitive dust
emissions. The hopper will also be connected to the combustion air blower air
inlet and therefore under a slight negative pressure which will also prevent
fugitive dust emissions from the hopper.
A ram feeder processes all solid wastes into the kiln. The ram feeder is
hydraulically operated with a 31/4-in. diameter by 121-in. stroke cylinder. It
has the capacity of ramming up to 2 ft in 30 seconds as well as partial volumes
over longer periods. The rate of ram feed will be determined by the charac-
teristics of the material being destroyed and will be easily field controlled
for both volume and speed. The leading edge of the ram will have a shearing
edge to further reduce potential ram jam-ups.
The solids volume feed control will be effected by controlling the ram pullback
position so that the kiln can be charged frequently with partial loads and
thereby reduce combustion transients or localized starved air conditions to the
kiln. Swing-up gates have been incorporated in the trough bottom to isolate the
shredder from the kiln atmosphere. Each swing gate functions sequentially as
the ram advances and retracts. Swing gates were chosen in order to avoid slots
and slide grooves which can be easily fouled with sand, dirt, oil, or debris.
Gate postion switches control and limit ram movement in order to prevent the
possibility of uncontrolled air entering the kiln.
-------
II-8
G. PRIME MOVER CAPACITY
The mobile incinerator has three main fans: a RK combustion air blower, a SCC
combustion air blower, and a single-stage induced draft fan. The induced draft
fan is the system prime mover. The capacities of the three fans are as follows:
RK combustion air blower
SCC combustion air blower
Induced draft fan
2200 acfm at 30 in. w.c.
1760 acfm at 28 in. w.c.
9,100 acfm at 42 in. w.c. at 175°F
inlet
The induced draft fan is connected to a variable speed motor. The volumetric
flow rate to the fan is controlled by adjusting the variable speed motor which
drives the fan. The fan is driven by a 155-hp diesel engine and operates at a
nominal speed of 3,350 rpm.
H. AUTOMATIC WASTE FEED CUT-OFF
The mobile incineration system uses electrical relay logic and conventional
industrial process instrumentation and hardware. Instrumentation is designed to
monitor process conditions, provide data for assuring compliance with regulatory
requirements, and assure appropriate process response and control, operational
flexibility, and safety interlocking and shutdown features. The safety
interlocks and shutdown features comprise a major portion of the control system.
Safety shutdown responses identified in Tables 1 and 2 are relayed to various
equipment items when certain process limits are reached or not met. In general,
the process parameters that alert and initiate responses to alarm conditions
are:
1. High and low kiln temperature
2. High and low secondary combustion chamber temperature
3. Low secondary combustion chamber outlet oxygen (O2) level
4. Low flow in the quench, particulate scrubber, or mass transfer scrubber
sumps
5. Very low level in the quench, particulate scrubber, or mass transfer
scrubber sumps
-------
TABLE 1 SAFETY INTERLOCK SYSTEM
KILN
SCC
QUENCH
CHEAP I MX SCRUBBER
KILN BURNERS
SCC BURNERS
EMERGENCY VENT
ID FAN
CAUSTIC FEED PUMP
QUENCH SUMP PUMP
KILN RAM FEED
WASTE OIL FEED
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
o
X
X
X
X
X
X
X
X
X
X
X
X
X
X
s
X
X
X
X
0
X
X
X
X
KEY:
X -TURNS OFF
S - STARTS
0 - OPENS
D- BLANK INDICATES EQUIPMENT STAYS ON. ALARM BUZZER SOUNDS
H
H
-------
11-10
TABLE 2
SAFETY INTERLOCK ACTION VALUES
Kiln
High Gas Temperature
Low Gas Temperature
SCC
>1900°F
<1400°F
High Gas Temperature
Low Gas Temperature
Low Oxygen Concentration
Quench
Low Recycle Water Flow to Nozzles
Low Low Water Level in Sump
Low Make-up Water Flow to Nozzles
>2400°F
< 2060°F
< 40 gpm
< 5 in.
< 5 gpm
CHEAF
Low Water Flow to Nozzles
Low Low Water Level in Sump
High Gas Temperature
MX Scrubber
Low Water Flow to Nozzles
Low Low Water Level in Sump
< 8 gpm
< 4 in.
>240°F
< 100 gpm
< 6 in.
ID Fan
Loss of Vacuum
Excess Fan Vibration
>-20 in. W.C.
>0.003 in. amplitude
-------
11-11
6. High gas temperature or pressure in the quench section
7. High pressure at the induced-draft inlet
8. High vibration of the induced-draft fan
9. Insufficient burner air or fuel supply
The fuel oil burner system includes an internal interlock system that shuts down
the burner system (i.e., fuel oil flow) if: a flame is detected during
pre-ignition, the pilot fails to ignite, the burners fail to ignite, or there is
a loss of flame after ignition. A shutdown of the burners automatically stops
waste feeds.
During an alarm condition, waste and fuel oil feeds are immediately stopped.
When required the induced-draft fan shuts down and the emergency vent located
between the quench sump and CHEAP opens. All recycle and makeup water flows are
maintained, if possible, to prevent over-heating in the mass transfer scrubber.
The safety interlock system is designed to provide protection both for operating
personnel and for the incineration equipment.
During- the solids trial burn, the ram feed mechanism will be interlocked with
the carbon monoxide (CO) stack monitor. If, during solids feeding, the CO con-
centration in the stack exceeds 150 ppmv-dry gas basis, the ram feeding mecha-
nism will be shut down and an alarm will sound. The fuel oil burners in the RK
and SCC, however, will continue to operate since a volume of unburned solid
waste which requires secondary combustion will still remain in the kiln. The
interlock system will prevent any operation of the ram feed until the CO stack
concentration drops below 150 ppmv-dry basis.
STACK GAS AND POLLUTION CONTROL MONITORING SYSTEM
Since the mobile incineration system was designed to safely destroy or detoxify
a wide range of hazardous wastes, an important aspect of the design was to pro-
vide a monitoring system which would analyze the flue and stack gases for com-
bution components [carbon monoxide (CO), carbon dioxide (C02), and oxygen (02)]
and emission components [(oxides of nitrogen (NOX), sulfur dioxide (SO2), and
-------
11-12
total hydrocarbons (THC)]. The stack monitoring system principally serves two
critical functions: (1) it provides the operators with current data on the per-
formance of the incineration and gas cleaning processes; and (2) it generates
and records accurate data on the gas emissions from the process. This ensures
operator safety and compliance with operating permit requirements. Functional
requirements were met by the selection of a dual gas chromatograph (GC) system
that possesses a high level of reliability and versatility, and conforms to the
mobile nature of the incineration system.
The selection of a process GC over other available monitoring systems was based
on the ability of a single vendor to provide a complete analytical system that
could withstand the extreme operating conditions of the mobile incinerator. The
previously cited conditions, in conjunction with the very nature of chemical
waste, incineraiton, produce an extremely difficult gas sampling environment —
hot (2,200°F), wet (50 volume % water), and dirty (1-2 gr/scf). The stack gas
monitoring system selected consists of three subsystems:
• Gas sampling/conditioning
• Gas analysis/analyzer calibration
» System control/results reporting
Gas Sampling and Conditioning
The gas sampling conditions in the mobile incinerator present the most difficult
(hot, corrosive, wet, and dirty) aspect of the gas analysis. In order to
reliably and accurately extract, condition, cool, and dry gas samples under
these conditions, two Bendix Model 8901C Stack Prove/Conditioning Assemblies
were selected. Several favorable characteristics of this model are that the
materials of construction are highly resistant to corrosion and the assembly is
able to cool and dry gas samples with very little loss of sample components.
Two gas sampling/conditioning assemblies are used to provide separate gas
samples for the measurement of combustion parameters and emission levels. The
qas sampling/conditioning subsystem consists of two identical assemblies; one
assembly is mounted on the exit duct from the SCC before gas quenching and the
second assembly is mounted on the incinerator stack. The need for separate
-------
11-13
samples for each analysis arises from the desire to optimize the combustion gas
analysis (CO, C02/ and O2) by extracting the sample as close to the incineration
process as possible. These assemblies,feed conditioned gas samples through
umbilical tubes to the gas analyzer and control units which are housed in a
fourth trailer that is dedicated to analytical support.
Since the combustion gas sampler/conditioner assembly will collect a sample at
the SCC exhaust before gas quenching, the gas sampled: (a) will be relatively
dry which minimizes potential problems in the gas sampling/conditioning unit;
and (b) has not been diluted with ambient air from in-leakage through openings
in the negatively pressured air pollution control equipment.
The second stack probe/conditioning assembly is located on the incinerator stack
to collect gas samples for emission measurement. Construction and operation of
these assemblies is identical.
Gas sampling is done with a corrosion and temperature resistant ceramic probe
which extracts gas samples from the center of the process duct. The extracted
sample passes through a ceramic inertial filter, located inside the probe, to
remove particulate ir^terial (5pm) from the gas sample. Next, the filtered gas
sample is partially cooled in an air-air heat exchanger to lower the temperature
to 212-248°F (100-120°C); entrained liquids are collected in a liquid trap at
the bottom of the exchanger. The gas sample then passes through a vaporizer
248°F (120°C) to ensure that all entrained liquids from process or instrument
upsets are vaporized before the gas drying process. Gas drying is accomplished
in a Perma Pure dryer which removes water vapor from the gas sample without
using a condensation process that often scrubs key gas components from the
sample. The drying process transfers the water vapor from the gas sample
through a tubular plastic membrane to clean, dry [110°F (43.3°C) dew point],
sweep air on the outside of the dryer. The filtered, cooled, and dried gas
sample is then transported to the analyzers (discussed in the next section)
through Teflon tubing. Pressure switches in the stack probe/conditioning
assembly monitor gas sampling and conditioning operation for particulate build-
up or plugging. When appropriate, the unit automatically back-purges itself
with steam or compressed air to maintain reliable, long-term untended operation.
-------
11-14
2. Gas Analysis/Analyzer Calibration
The cleaned gas sample, from the combustion gas and stack sampler/conditioning
assemblies, enters the analyzer section of the system through a Bendix
Model 890B Dual Steam Transport Assembly. The transport assembly delivers the
gas samples from either gas sampling location to the appropriate analyzer. The
analyzer section operates in conjunction with the monitoring system controller
to divert gas samples: (1) to the thermal conductivity detector GC for analysis
of C02, 02/ and SO2; (2) through a methanizer to a flame ionization detector GC
for analysis of CO; (3) to the flame ionization detector GC for analysis of THC;
and (4) a chemiluminescent detector for analysis of NOX. The analyzer section
also introduces calibration gas (from cylinders) through the sampling/condition-
ing units to the appropriate analyzer. The analyses conducted by the continuous
analyzers are summarized in Table 3.
The decision was made to use process gas chromatographs to perform the majority
of the analyses for the following reasons: (1) The expensive analyzer detectors
would be protected from corrosive gases or submicron particulate, which may be
present due to process upsets or failure of the sample conditioning system, by a
relatively inexpensive GC column; (2) The front end components of a GC system,
such as tubing and sampling valves, are readily available in the corrosion
resistant materials that are required to transport gas samples; (3) The ver-
satility of a thermal conductivity/flame ionization GC system permits simple and
inexpensive modifications to the gas analysis to include additional or very spe-
cific components; (4) Gas chromatography offers the ability to more readily
remove interfering components from a gas sample before reaching the analyzers
than do spectrometric analyzers; and (5) The components of the analyzers are
more resistant to problems associated with a mobile field system, e.g., vibra-
tion. Calibration of the analyzers is accomplished using cylinder gas standards
which are injected into the monitoring system at the sample probes. This
calibration method not only calibrates the analyzers but accounts for component
losses that are related with sample conditioning and transportation.
Calibration of the analyzers is directed by the monitoring system controller on
a repeated, specified basis.
-------
11-15
Table 3. Continuous Stack Monitoring Analyses
Analysis
Combustion
Gas
Combustion'
Gas
Combustion
Gas
Stack Gas
Suck Gas
Stack Gas
Component
CO
CO,
o,
NO,
SO,
THC
Sample
Location
sec
sec
Stack
Stack
Stack
Stack
Analyisr
Mathanizar-GC/FlO
3endix .Modet 9220
GC/TC
Sandix Model 9120
GC/TC
Sendix Model 91 20
Chemiluminescsncs
Sandix Modal 3102
GC/TC
Sandix Modal 9120
GC/FtO
3«ndix Modal 9220
Anaiysia
Range
0-3SO ppm
0-10 parcsnt
0-3 peccant
0-200 ppm
0-2000 ppm
0-200 ppm
Analysis
Tima
S min
S min
S min
on line
S min
5 min
-------
11-16
3. System Control/Results Reporting
Two microprocessors control: (1) the two gas sampling/conditioning assemblies;
(2) the sample transport and calibration systems; and (3) the gas analyzers.
One of the microprocessors is dedicated to controlling the flame ionization GC.
The second microprocessor controls the thermal conductivity GC, collects data
from the chemiluminescence detector, and generates analytical reports on a
remote computer terminal.
In addition to controlling GC functions, the microprocessors continuously:
(1) control analyzer calibration (zero, span, and drift) and sequencing of
sampling probe back flush; and (2) monitor for low flow of calibration gases,
for low flow of gas sample, for high component concentration, and for system
utilities. The ability of the microprocessor to completely monitor and operate
the samplers and analyzers permits operation of the mobile incinerator in remote
locations with a minimum technical staff. As well as controlling the entire
analytical system, the microprocessors perform another important task. That
task is the generation of calibration reports, analytical result reports, time-
weighted average reports, analytical system alarm conditions, and incinerator
excess emission reports.
J. NOZZLE AND BURNER DESIGN
1. Rotary KiIn
The RK incinerator includes three burners — a waste oil burner which will not
be used during the solids trial burn, and two identical Maxon Multifire II
burner assemblies. The two Maxon burner assemblies will be fired with deisel
oil during the solids trial burn. Each burner is a 4-in. model No. 31534 and is
rated at up to 3.9 MM Btuh. The diesel oil is air atomized at a combustion air
pressure of about 14 ounces per square inch. The combustion air is supplied by
the combustion air blower described in Section III-G. Maxon bulletin 4200-77,
which describes the nozzle and burner design of these burner assemblies, is
included in Appendix B. The RK burner locations are shown in Fig. 3.
2. Secondary Combustion Chamber
The two secondary combustion burner assemblies are also Maxon Multifire II bur-
-------
11-17
ners. Each burner is rated at about 2.8 MM Btuh of diesel oil. The diesel oil
is air atomized at a combustion air pressure of about 14 ounces per square inch.
The combustion air is supplied by the SCC combustion air blower described in
Section III-G. Maxon bulletin 4200-77, which describes the nozzle and burner
design of these burner assemblies, is included in Appendix B. The SCC burner
locations are shown in Fig. 4.
K. WATER INJECTION
During liquids only feed to the RK, clean atomized water at 1 to 2 gpm is
injected into the RK for temperature control. During the solids trial burn
while water injection will probably still be done, the rate of water injection
will be lower than 1 to 2 gpm because of the moisture present in the soil. The
actual rate of water injection during the solids trial burn will depend on the
moisture content of the soil that is incinerated during the trial burn.
L. MATERIALS OF CONSTRUCTION
The materials of construction of the major mobile incinerator components are
summarized in Table 4.
M. LOCATION AND DESCRIPTION OF TEMPERATURE, PRESSURE, AND FLOW INDICATING AND
CONTROL DEVICES
The location of the mobile incinerator sensors can be found in the P&IDs
included in Appendix C. A description of the various sensors is as follows.
1. Kiln and Secondary Combustion Chamber Combustion Temperature
The combustion gas temperatures of the rotary kiln and secondary combustion
chamber are measured with a type S (platinum/10% rhodium) thermocouple.
Thermocouple accuracy is ±0.5% from 540 to 1480°C. The thermocouples are
located within a special thermowell designed to measure the combustion gas tem-
perature while avoiding the influence of radiant heat from the flame envelope
(see Fig. 5). This is achieved by aspirating the combustion gases through the
thermowell assembly and over the surface of the shielded thermocouple. The hot
gases are then returned to the combustion chambers. The output of the ther-
mocouple is converted and transmitted as a current signal to an analog process
-------
11-18
Table 4. Materials of Construction
Mobile Incinerator
Component
Materials of Construction
Rotary kiln
RK/SCC transition duct
Secondary combustion chamber
Quench elbow
Quench elbow sump
Duct, sump to cheaf
CHEAP
MX scrubber
ID fan
Stack
Carbon steel (A-36) lined with A.P. Green
Kast-0-Lite 30
Inconel 601
Carbon steel (A-36) lined with Kast-O-Lite 30
Inconel 625
Inconel 625
Inconel 625
Inconel 625
Fiber reinforced plastic (FRP)
Housing (347 stainless steel), shaft and
impeller (Inconel 625)
304 stainless steel
-------
11-19
Fig. 5
PIPE
-------
11-20
controller. A change from setpoint causes the controller to adjust the com-
bustion air flow in the kiln by means of a flow control valve. In the secondary
combustion chamber, however, a change in setpoint causes this controller to
adjust both tuyere (over fire) air and combustion air. In both cases a change
in combustion air flow causes a change in back pressure in the air lines to the
burners. This pressure change causes a change in fuel oil feed to the burners
by means of flow control valves, which are set to feed fuel oil to the burners
in the correct proportion based on the air feed back pressure.
The output from the controller is also sent to a recorder with high and low
alarm functions. A high or low temperature will activate an alarm at the
appropriate control panel. A high or low temperature in the kiln or secondary
combustion chamber will also shut down the waste liquid and solids feed by means
of an. electric signal from these alarms. This electric signal will close double
electric solenoid valves on the waste liquid feed line and deactivate the con-
veyor motor and timer/sequencer for the waste solids feed system. In addition,
a high temperature will also cause the shut off of auxiliary fuel to the auxi-
liary fuel burners.
2. Waste Liquid Flow
Waste liquid flow is measured by a micro-motion, gyroscopic/coriolis mass flow
meter. Optical measurements are processed electronically and the output is
displayed digitally. The waste liquid flow is controlled manually by a needle
valve located before the meter flow. Accuracy of the flow meter is ±0.4% from
0.68 kg/min (1.5 Ib/min) to 13.6 kg/min (30 Ib/min).
3. Waste Solids Feed
The feed rate of waste solids to the rotary kiln is controlled by a mechanical
timer/sequencer that cycles the positions of a hydraulically operated hopper
door, a hydraulic feed ram, and a pneumatically operated kiln entrance door.
The hopper door and feed ram are positioned by solenoid controlled hydraulic
valves. The kiln entrance door is positioned by a solenoid controlled ph'eumatic
valve. Positions are verified through electrical signals sent by position
switches. These position switches also provide lockout functions to ensure
-------
11-21
proper sequencing of the individual units. The desired feed rate is obtained by
adjusting of the cycle time and pull back position of the ram feeder (volume).
Manual switches for each of the three units are available for manual operation.
If a high pressure condition is met in the ram hydraulic system (ram feed jam) a
pressure switch will activate a panel mounted alarm. Solid feed stops and must
be reset manually. High CO stack concentrations will also activate an alarm and
stop the solid feed until reset manually.
4. Air Pollution Control Equipment Pressure Drop
Pressure drop is controlled across the filter medium in the CHEAP (cleanable
high efficiency air filter) by means of a differential pressure switch. When
the loading of particulate on the filter causes a pressure drop exceeding a set-
point, the differential pressure switch will activate and transmit an electric
signal to the filter advance motor. This motor will start and advance clean
medium until the pressure drop returns to normal, then the differential pressure
switch will de-energize and turn off the filter advance motor.
Pressure is also monitored at the exit from the mass transfer scrubber. Upon
detection of a loss of vacuum (high negative pressure) a pressure switch will
activate an alarm at the appropriate control panel and also shut down the waste
feeds.
5. Combustion Gas Flow
Measurement of combustion air flow is performed by a (Annubar) differential
pressure cell located at the inlet to the kiln air blower. Accuracy of the
measurement is dependent on the geometry near the sensor and can be determined
through field calibration. Output from the differential pressure transmitter in
the form of a current signal is sent to a square root converter and subsequently
to an analog process controller. The combustion air flow to the kiln supplies
combustion and atomizing air to the burners, air to the pilot burners, and purge
air to the burner flame detectors. These air usages are at set rates or are
controlled by other systems. The residual air flow is then sent to the kiln
tuyere (over fire). This kiln tuyere air flow is controlled at a constant rate
-------
11-22
by the kiln air process controller through a flow control valve. Therefore,
adjusting the tuyere air will maintain a constant total air flow when slight
changes occur in air usage by other systems. Additional air leaks into the kiln
through the front and rear kiln seals and the hot ash discharge.
Total air flow to the secondary combustion chamber is similar to the kiln.
However, tuyere air to the combustion chamber is held constant, thereby allowing
the total air flow to the combustion chamber to vary as other systems require
air. These systems are identical to the air-using systems in the kiln.
The total flow of combustion gases is the sum of kiln air flow, secondary com-
bustion air flow, combustion products, and any infiltration air.
6. Burner Control System
The combustion chamber pressure is used to regulate the fuel to air ratio for
the auxiliary fuel burners. Fuel is controlled by a pneumatic control valve
that uses as pneumatic inputs the combustion chamber pressure and the blower air
pressure. Therefore, a change in these pressures will cause a corresponding
change in the amount of fuel feed to the burners.
Fuel feed to the burners is monitored by a pressure switch. Upon detection of a
low fuel pressure to the burners, an electric signal will be sent to a normally
open solenoid valve to shut off fuel flow.
The differential pressure between the blower outlet and the combustion chamber
is monitored by a differential pressure switch. When a low differential
pressure is detected an alarm will sound in the appropriate control panel and
the fuel to the auxiliary fuel burners will be shut off. This is accomplished
by means of an electric signal from the differential pressure switch to the fuel
shut-off solenoid valves.
The presence of a flame is monitored by an ultraviolet flame detector. The
detector is purged with air to maintain a clear line of sight to the flame enve-
lope. Upon detection of no flame an alarm will sound at the appropriate control
-------
11-23
panel and the fuel to the auxiliary fuel burners will be shut off by means of
the fuel shut-off solenoid valves.
A second low-level sensor is used to monitor very low water levels in the recir-
culation sumps. Upon detection of a very low level the differential pressure
switch will transmit an electrical signal to activate an alarm and to shut off
waste liquid and solid feed streams. In addition a very low level in the quench
sump will shut off auxiliary fuel to the burners by means of the auxiliary fuel
solenoid valves.
Each of the sumps has provisions for gravity drains for high sump water levels.
These sumps are also equipped with high level sensors. Upon detection of a high
level above the drain outlet the differential pressure switch will transmit an
electric signal to an alarm at the appropriate control panel,
7. Scrubber Water Flow
Water is supplied to the air pollution control system by three separate cir-
culation systems. These are the quench, CHEAF, and mass transfer water cir-
culation systems, each of which has a dedicated recycle pump. Flow is measured
and indicated by rotometers for each system. Flow is assured by maintaining a
minimum water level in each of the sumps supplying each pump. Water levels are
measured by differential pressure level sensors using instrument air. Upon
detection of a low level, the differential pressure switch will transmit a
current signal to open a normally closed solenoid valve and allow makeup water
into the sump. In the quench system, however, a low level in the quench sump
will allow additional makeup water to be added to cool and saturate the com-
bustion gas stream.
Each of the rotometers, indicating flow for the three water circulation systems,
contain magnetic switches that will activate alarms under low flow conditions.
Upon detection of low flow, these switches will transmit an electric signal to
activate an alarm and to shut off waste feed. In addition, a low flow in the
recirculated quench water systems will also shut down all burners.
-------
11-24
8« pH of the Scrubber Water
The pH of the scrubber water in each of the three water circulation systems is
measured by a pH electrode system. The system consists of three electrodes, a
reference electrode (silver/silver chloride), a thermal compensator, and the pH
electrode. Accuracy of the electrodes is ±0.02 PH units from a pH of 2 to 12
from 0°c to 110°C. The potentials from the electrodes are amplified, processed
and transmitted as a current signal to an analog process controller. The
controller, upon detection of a PH below setpoint, will open a normally closed
solenoid valve and allow instrument air to activate a pneumatic control valve.
This then allows caustic solution to be pumped into the water circulation
system. Detection of normal operating conditions will deactivate these sole-
noids and subsequently close the control valves.
9. Miscellaneous Control Instrumentation
a. Hydraulic Systems — The hydraulic systems for the solid waste feed and the kiln
rotation are monitored for high hydraulic pressure. Upon detection of a high
hydraulic presure in either system, a pressure switch will transmit an electrical
signal to activate an alarm on the appropriate control panel.
b. Kiln and Secondary Combution Chamber Oxygen Analyzers (See Section I)
c. Kiln Ash Discharge — Ash discharged from the rotary kiln is controlled by a
mechanical timer/sequencer that alternates the opening of a double door
discharge chute. The timer transmits an electric signal to activate a solenoid-
controlled pneumatic, rotary actuator on each door. Instrument air is used for
the pneumatic actuators. Manual switches are available for manual operation of
the ash discharge system. Manual operation is required for waste liquids only
feeding, but can be automatic when solid wastes are fed.
d. Kiln Process Water — The addition of process water to the kiln is controlled by
the kiln oxygen analyzer. Flow is indicated by a rotometer.
e. Emergency Vent — An emergency vent is located before the combustion gas inlet
to the CHEAF to protect against high temperatures caused by loss of quench
-------
III-l
SECTION III
TRIAL BURN PROCEDURES
A. POHC SELECTION RATIONALE
1. Polychlorinated Biphenyls (PCS) in Soil at <50 ppm
One of the main uses of the mobile incinerator will be to incinerate soils con-
taining low levels of hazardous and toxic organics such as those caused by chem-
ical spills or those occurring at inactive sites. It is therefore important to
test the mobile incinerator capabilities for desorbing and destructing a low
concentration of a test chemical from a soil.
Two soil alternates are presently being considered for the trial burn; clean
soil which is artifically contaminated with Arochlor 1260, or actual PCS con-
taminated soil from a spill clean-up. The actual contaminated soil needs to
contain only PCBs at <50 ppm.
PCBs were selected as the test chemical for the following reasons:
a. High adsorption to soil - chlorinated organics such as PCBs are highly
adsorbed to soils as evidenced by high soil adsorption coefficients (KOC).
b. Wide range of KOCs - different PCB isomers have a wide range of KOCs.
Analysis for PCBs in the stack gas and RK ash will therefore result in
data which will indicate the importance of KOC for many different chemicals
as a function of KOC.
c. Existing PCB data base - In January 1983, EERU completed a TSCA PCB trial
burn in which diesel oil containing 18 to 22% Arochlor 1260 was incinerated
by the mobile system. Preliminary indications are that all TSCA require-
ments were met or exceeded durng this testing.
2. Pentachlorphenol/RCRA Permitting
Another use of the mobile incinerator will be the disposal of solid chemical
-------
III-2
wastes either in drums or in bulk. In order to do this it will be necessary to
obtain a national RCRA solids permit through the trial burn process. In order
to obtain a. flexible RCRA permit which will require a minimum of new trial burns,
an Appendix VIII solids constituent should be selected which is high up on the
EPA's Incinerability Ranking List. In selecting pentachlorophenol (PGP), the
following criteria were evaluated:
• Location on ranking list
• Melting point
• Boiling point
* Ambient vapor pressure
• Heat of combustion
« Analytical requirements
• Commercial availability in large quantities
• Toxicity
« Relevance of the chemical to actual past spill/clean-ups and contaminated
soils
Based on these criteria, PCP was selected as the trial burn Appendix VIII
constituent/principal organic hazardous constituent (POHC). Table 5 summarizes
physical property data relative to waste analysis and gives an approximate pre-
liminary composition of the PCP/sand mixture that will be used during the trial
burn.
The PCP will be fed to the mobile incinerator as a mixture of about 50% by
weight PCP and 50% sand. The sand is necessary to reduce refractory damage
caused by pools of molten PCP burning on the RK's refractory surface.
B. WASTE PREPARATION
1. PCBs in Soil (Artificial Mixture)
When a chemical spill occurs on a soil, two adsorption processes become impor-
tant. The first is true adsorption where the contaminant actually is adsorbed
by the organic and inorganic matter in the soil. Sometimes this component has
been called the "soil-bound" fraction. The organic matter offers a matrix in
which the contaminant molecules are physically captured. The inorganic com-
ponents provide surfaces for adsorption. The second process normally included
-------
III-3
Table 5. Pentachlorophenol Physical Properties
Structure C Cl OH
Molecular weight 266.5
Heat of combustion (Btu/lb) 3760
Melting point (°C) 188
Boiling point (°C) 310
-4
Vapor pressure @ 20°C (mm Hg) 1.1 x 10
Chlorine (wt %) 66.6
Approximate Trial Burn Composition:
wt. %
Carbon 13.5
Hydrogen 0.2
Oxyg en 3.0
Chlorine 33.3
Water 10.0
Ash (sand) 40.0
100.0
Btu/lb 1,880
-------
III-4
as soil adsorption is in reality the holding of the bulk contaminant phase be-
tween soil particles. Although this effect is normally considered together with
the adsorption component, it is in reality an adsorption process and will be
called such in this plan.
Since little chemical energy is involved in the adsorption compenent, this
material is relatively easily removed from soil and would rapidly volatilize and
be combusted in an incinerator. However, the soil-bound component is held by
powerful bonding forces and the rates of desorption of this soil-bound fraction
in an incinerator would be expected to be slower than the adsorbed fraction.
A soil preparation procedure is presented that focuses on maximizing the organic
and inorganic adsorption process so as to more closely simulate actual
"weathered" contaminated soil. This procedure is comprised of a preclassifica-
tion step, a PCS addition step, and a storage and aging step. These procedures
are as follows:
a. Preclassification — The existing EPA water knife unit will be used to
preclassify the soil. The soil will be fed into the unit and broken up by
the water knife action. The slurry produced will be allowed to settle and
then spread under a rain cover to air dry. Since clean soil will be used
for this test, the soil fractions rejected from the water knife and the
wash water will be discarded in a conventional fashion.
b. PCS Addition — Arochlor 1260 will be dissolved in a methylene chloride/
isopropanol mixture. This mixture will be fomulated so as to minimize any
flammability hazards. This mixture will be sprayed onto the soil while
undergoing mixing in a double arm sigma type mixer. The dry soil will be
weighed before addition to the mixer and the solvent will be added in quan-
tities so as to achieve 40 to 45 mg/kg of total PCBs in the soil. The
mixer will be operated for sufficient time to assure full mixing. The mixer
will be equipped with a steam jacket and a pressure cover and the solvent
will be evaporated from the soil while the soil remains in the mixer. The
solvent will be recovered with a water cooled condenser and reused to
-------
III-5
dissolve more PCBs for subsequent batches. Solvent recovery will also
reduce the air pollution impact of an organic solvent.
c- Storage-Aging — The solvent-dry soil will be transferred manually into
sealed 55-gallon drums for dry storage. These drums will be allowed to set
for several months, thus allowing the adsorption process to approach
equilibrium.
d. Sampling-Analytical — Several soil samples per drum will be obtained and
composited. This composite sample will be split with a suitable solvent,
and analyzed for PCBs (see Section III-D). Analytically it may be
necessary to use a soil digestion process for the PCBs in soil in order to
quantitatively determine PCBs since the soil-bound PCBs may not quan-
titatively extract from the soil.
e. Process Development — All of the above steps will be tested in a small-
scale laboratory program to determine the optimal process conditions and
the effectivenes of the approach. After development, those specific proce-
dures will be used for soil preparation.
2. Actual PCB Spill Clean-up Soil
If an actual PCB spill clean-up contaminated soil can be located, the soil will
need to be shipped to Edison and/or the Kin-Buc site where it will need to be
stored and analyzed. The soil, if shipped in bulk, will be analyzed, placed in
drums, and sealed until the Kin-Buc trial burn.
3. PGP/Sand Mixture
The PCP used for the trial burns will be commercial grade PCP manufactured
either by Vulcan Chemicals or Reichold Chemical Company. The sand will be ana-
lyzed and certified as clean sand without identifiable levels of PCP.
The PCP will be purchased in drums, analyzed, mixed with the sand, and stored in
sealed drums until the Kin-Buc trial burn. The PCP and sand mixture will be
metered into the ram feed hopper and fed to the incinerator. During the ram
-------
III-6
feed hopper loading, grab samples will be taken, composited, and analyzed for
PGP.
C. SOLIDS HANDLING AND FEED
1. PCB Contaminated Soil
The PCB contaminated soil will be loaded from drums to the ram feed hopper
either by a vehicle with drum handling capability or by a drum unloading mecha'
nism which will be part of the mobile incinerator solids handling system.
Fugitive dust will be controlled by a cover/seal on the hopper and negative
pressure in the hopper being vented into the RK.
2. PCP/Sand Mixture
The PCP and sand mixture will also be loaded from drums to the ram feed hopper
either by a vehicle with drum handling capability or by a drum unloading mecha-
nism. Fugitive dust will be handled in the same way as discussion for the PCB
contaminated soil.
D. SAMPLING ANALYSIS AND MONITORING PROCEDURES
1. Sampling Locations
a. Stack Sampling Location — During the trial burn the gaseous and particulate
emissions produced by the combustion process (flue gas and stack gas) will
be monitored at three locations. Two of these locations are primary
sampling locations to measure incinerator emissions. The remaining location
is to be used to provide a backup oxygen monitoring station for gaseous
emissions. The primary locations are located on the quench elbow duct,
before gas cooling, and on the mobile incinerator stack (see Fig. 6). The
quench elbow location will be used to continuously monitor the combustion
gases leaving the SCC. The actual sampling point will be positioned in the
center of the exhaust duct that leaves the SCC immediately upstream of the
spray nozzles. The concentrations of CO, C02, and O2 are monitored at this
location as it allows for their determination from a point that is unaf-
-------
III-7
4" Pore for
Combustion Gas
1/4" Pore cor
Concinuous Oxygen
Sensor
Discharge
30 fc. Above
Ground Level
REFLO DUCT
\
5-3" Pores for
Modified Method 5
Samp ling
4" Pore for
Concinuous Stack
Monitor
Silencer
DIESEL
I.D. FAN
DRIVE
Fig. 6
STACK GAS SAMPLING LOCATIOfS
-------
III-8
fected by air infiltration or interactions with alkaline scrubbing solu-
tions. Therefore, the results obtained for these three gases at this point
are expected to be more representative of the actual gas composition that
exists within the SCC. The SCC combustion gases are withdrawn from the
center of the quench elbow duct immediately prior to gas quenching through a
1/2 in. ceramic probe.
The second primary gaseous and particulate specie sampling location is
located on the upper section of the stack ducting. There are sample ports
for contnuous monitoring of emissions (NO , S00, and total hydrocarbon) and
X £•
for specialized stack sampling for particulate, HC1, and POHCs. One four-
in. port will be provided for the continuous monitoring of combustion gases
such as NO . SO.,, and total hydrocarbon. This port is located 24-in. down-
X ^£
stream from the stack silencer section. The design of the sample port and
sampling unit is identical to the combustion gas samples located on the
quench elbow duct. The samplers are described in detail in Section II-I.
The other sampling location on the stack consists of five 3-in. connections
mounted on a single face stack duct. The connections are spaced to allow
sampling for particulate matter in accordance with EPA Methods 1 and 1-5
protocols. The MM5 equipment will be used to measure particulate and orga-
nic emission rate using the methods described in Section III.D.3. The cen-
terline of these sample ports is 72-in. downstream of the stack silencer.
There are two additional gas sampling locations on the mobile incinerator.
The first of these points is located on the exit duct from the SCC. This is
a 1/4-in. connection for withdrawing a continuous gas sample which is chan-
neled to the backup oxygen monitor.
b. Waste Feed Sample Location — Both the PCB contaminated soil and the
PGP/sand waste mixtures will be fed to the ram feed hopper out of steel
drums. Before emptying a drum of PCB/soil or PCP/sand to the hopper, a
sample will be taken from each drum fed during a run and composited. The
run composites will be analyzed using the procedures discussed in
Section III.D.3.
-------
III-9
c* Scrubber Water Sample Location — Combined scrubber, CHEAP, and quench
effluents will be grab sampled on an hourly basis during each run. A com-
posite will be made from each 12 hour run and andlyzed according to the pro-
cedures discussed in Section III.D.3. The sample location will be located
in the wastewater purge stream line.
d. Ash Sampling Location — Ash from the RK ash discharge will be collected in
a bulk container located between trailer 1 and 2 (see Fig. 1) at the back
end of the RK. When cool, the ash will be sampled and analyzed according to
the analysis procedures discussed in Section III.D.3.
e. CHEAF Ash Sampling Location — Ash captured by the CHEAF fiberglass mat will
be collected in drums and sampled after each run.
2. Sampling Procedures
a. Waste Feeds — Each drum of PCB contaminated soil fed to the incinerator
will be sampled using acceptable techniques from SW-846 such as a trier, a
thief, or an auger. The actual sampling device will have to be determined at
a later date when the type of soil to be incinerated has been identified.
The sampling plan will also be determined at a later date when it has been
determined whether artificially contaminated or actual PCB contaminated soil
will be incinerated. The sampling plan will be based on sampling strategies
discussed in Section 1 of the 2nd Edition of SW-846.
Each drum of PCP and sand fed to the incinerator will be sampled using a
trier or a thief as discussed in SW-846. The sampling device and sampling
plan will be determined at a later date.
b. scrubber Water and Quench Water — Grab samples will be taken every 60 min.
during each test run from the purge line to the sewer. One composite
sample will be made for each test run. Two grab samples (blanks) will be
taken 30 min. apart and composited before the start of each test run.
Samples °f t^ie influeivt process (makeup) water will be taken before and
-------
111-10
after each test run and composites. The composites will be analyzed pri-
marily for Arochlor 1260 or PCP concentrations.
c. Stack Gas — A sample will be taken during each test run with an inert
sample probe, using the proper EPA method for each parameter, at a sample
port in the incinerator stack. Parameters to be measured are CC>2, ®2 an^
HC1. Particulate sampling and stack flue gas flow measurements will also be
performed. A modified EPA Method 5 (MM5) sampling train will be employed
for the collection of stack gas samples to be analyzed for Arochlor 1260 or
PCP content. Table 6 indicates the stack gas sampling schedule for the
various parameters of interest.
Sampling locations will meet acceptable standards for distance from duct
bends. Steady state operating conditions will be maintained for the
required duration (approximately 3 hr) during each test run while the stack
gas samples and flow measurements are taken.
d. Ash Sampling — After cooling, the ash from each run will be sampled with a
thief or trier from the bulk ash collection container. The sampling device
and sampling plan will be determined at a later date.
e. CHEAP Sampling — CHEAF mat samples will be taken from the used mats
collected from each run. The sampling plan will be determined at a later
date.
3. Analytical Procedures
During the trial burn, the following sampling and analytical procedures
which are summarized in Table 7, will be used.
a. Arochlor 1260 — During test 1, the soil, diesel fuel, makeup water, kiln
ash, purge water, alkaline scrubber solutions, CHEAF filter ash, and stack
samples will be analyzed for Arochlor 1260.
Because of the low level (40-49yg/g) of Arochlor 1260 in the soil that will
be used in the test and the predicted destructive efficiency (>99.99%), the
-------
Table 6. Summary of Trial Burn Sampling
and Analytical Methods for Stack Gas
Parameter
°2
co2
HC1
Particulates
Arochlor 1260
Pentachlorophenol
Sample Method
EPA 3
EPA 3
Impinger with
0.1N NaOH
EPA 5a
EPA 5
EPA 5
Time
Per Sample
30 min
30 min
15 min
2 hours
12 hours
12 hours
Analytical
Method
ORSAT
ORSAT
Ion-specific
electrode
EPA 5
ITAS SOP
EPA 8250
Samples
Per Run
4
4
4
1
3
3
EPA Method 5 includes measurement of stack gas temperature, flow rate, and moisture content.
H
H
i
-------
Table 7. Scope of Work - Details of Proposed Sampling
and Analysis for Tests 1 and 2
Sample
Spiked soil
feed and PCP
Diesel fuel
Make-up water
Kiln asli
Purge water
Alkaline
scrubber
sol ution
C1IEAF
Stack sample
Sampling Method
and Frequency
One composite sample
per run (2 grabs)
One grab sample per
delivery, composite
sample for one
analysis per lot
One sample per stage
One sample per DRE test
(if any)
One composite sample
per DRE run
Daily composite
(1 hr grabs)
Weekly grabs
Weekly grabs
Weekly composite
One grab sample per batch
Composite grab sample
One sample per DUE run
Modified Method 5
One sample per DRE run
Number of Samples
Analyzed for
Tests 1 and 2
6
6
6
2
2
1
1
3
3
3
3
15
2
2
2
2
3
3
3
3
Stack sample
(throe samples per test)
U.S. EPA Method 5
(three samples per test)
Gas bag, one per run
Analysis
Organic Cl, density
Heat value, ash, moisture
Arochlor 1260 or PCP
Organic Cl
Density, ash, moisture, heat value
Presence of Arochlor 1260, PCP
Presence of Arochlor 1260
Presence of PCP
Presence of PCP
Presence of Arochlor 1260
Presence of Arochlor 1260
Presence of PCP
Total organic carbon, pH, temperature
Total suspended solids
Total dissolved solids
PCBs, PCP
PCBs, PCP
Presence of Arochlor 12GO
Presence of PCP
Arochlor 1260 emission rate
PCP emission rate
HC1 emission rate**
Particulate emission rate
o2 , co2
Analytical Method
Standard method (where appropriate)
Standard method (where appropriate)
GC/EC or GC/MS
Standard method (where appropriate)
Standard method (where appropriate)
Extraction, concentrate, GC/EC or GC/MS
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/MS*
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/MS
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/MS
Standard methods (where appropriate)
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/MS
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/MS
Scrubbing, Standard Method 325.3
EPA Partiuulate Method 5
ORSAT
H
H
H
*Positive results confirmed by GC/MS -
**PCB runs will not be analyzed for IIC1 since IICl emission rate
will be <4 Ib/hr
-------
111-13
only practical detection device for the quantitation of Arochlor 1260 is the
electron capture detectors which are more sensitive than the GC/MS.
Samples and extracts representing discrete MM5 sampling train components
will be analyzed by GC/EC followed by compositing them together and then
further concentrating the extracts. The final extracts will be re-analyzed
by GC/EC. If the resulting concentration levels are adequate, the con-
centrated composite extracts will be analyzed by GC/MS using the selected
ion monitoring made for some of the discrete Arochlor 1260 isomers.
While aqueous samples will be extracted with solvent in a normal fashion,
the soil, the MM5 sorbent traps and particulates will be extracted by an
ultrasonic assisted desorption procedure using hexane.
Complete details of the analysis are described in the ITAS Standard
Operating Procedure for Analysis of PCBs (see Appendix 1 of Appendix A).
b. Pentachlorophenol — The analysis for pentachlorophenol in the test 2
samples will be performed using Method 8250, "GC/MS Method for Semivolatile
Organics: Packed Column Technique," Test Methods for Evaluating Solid
Waste, July 1982, SW-846, Second Edition.
c. Heat of Combustion — This parameter will be determined on the soil and
diesel fuel by ASTM Methods D240, D2015, or D3826.
d. Ash Content — The ash content of the soil and diesel fuel will be deter-
mined by ASTM Methods D482 or D3174.
e. Water Content — The water content of the soil and diesel fuel will be
determined by ASTM Methods D95, D1796, or D3173.
f. Total Organic Carbon, pH Temperature — Total suspended and dissolved
solids.
-------
111-14
These parameters will be determined in the purge water according to the
methods given in Table 7.
g. 02/C02 — These parameters will be determined by EPA Method 3 on integrated
bag samples of the stack flue gas samples taken from sampling train or
exhaust of the EPA Method 5.
h. HC1 — Using modified EPA Method 13, HC1 will be determined on stack flue
gas samples collected for each test run. This procedure uses NaOH impinger
solution and chloride selective ion-specific electrode for analyses.
i. Particulate — The stack flue gas samples will be analyzed for particulates
using EPA Method 5, as described in Federal Register, 42 (160); 41776-41782,
August 1977.
The ASTM, Standard methods and EPA methods cited above are referenced from:
* Annual ASTM Standards, Parts 23, 24, 25, 26, 29, 30, and 31. American
Society for Testing and Materials, Philadelphia, PA (1981).
* Standard Methods for the Examination of Water and Wastewater 15th
Edition, APHA-AWWA-^?PCF, Washington, DC'TfOSOj. '
• Standards of Performance for New Stationary Sources. A Compilation as
of October 1, 1977, EPA-340/1-77-015, NoVember 1977,"u.S. Environmental
Protection Agency.
« Test Methods for Evaluating Solid Wastes Physical/Chemical Methods,
EPA-846, 2nd Edition, July 1 982", USEPA Off ice" of Water Imd" ~Was te~ ~
Management.
4. Monitoring
During the incineration of the PCB/soil waste and the PGP/sand waste, the stack
and SCC flue gases will be monitored for the important gaseous components: 02,
CO2, CO, NOX, S02, and THC. The analyzer section of the monitoring equipment
operates in conjunction with the microprocessor to direct sample gases to
(1) the thermal conductivity detector GC for analysis of C02, O2, and SO2;
(2) through a methanizer to a flame ionization detector GC for analysis of CO;
(3) the flame ionization detector GC for analysis of THC (compared to a methane
-------
111-15
standard); and (4) a chemiluminescent detector for analysis of NOX- The
microprocessor generates printouts of all analytical results., A detailed
description of the gas analysis monitoring system can be found in Section II.I
of the Trial Burn Plan.
Summaries of the monitoring equipment used are given in Tables 8 through 13.
E. DETAILED TEST BURN PROTOCOL
There will be six runs made during the solids trial burn on two different
wastes. Three identical runs will be made with the PCS contaminated soil, and
three identical runs with the PGP/sand mixture. Table 14 presents the conditions
for each of the two tests and six runs.
The objectives of the first test (Test 1) is to show that the mobile incinerator
can effectively incinerate organically contaminated soil. The second objective
of the trial burn (Test 2) is to demonstrate that the mobile incinerator can
effectively incinerate a solid hazardous organic chemical (PGP) at a high rate
and thereby obtain a flexible RCRA permit for the incineration of solid hazar-
dous wastes.
1. Trial Burn Operating Condition
As can be seen from Table 14, only one set of conditions will be used for each
test. A description of the two tests is as follows.
a. PCB/Soil — The PCB/soil mixture will be incinerated in the RK at about 1600°F.
The combustion gas from the RK will enter the SCG and be subjected to a tem-
perature of about 2200°F and have a SCC combustion gas flowrate of about
14,500 acfm. The temperatures and combustion gas flowrate will be controlled as
closely as possible, but may vary somewhat from run to run because of normal
operational considerations.
The actual feed rate of contaminated soil used during runs 1-1, 1-2, and 1-3 may
differ from the 2000 lb/hr given in Table 14 because of the soil moisture con-
tent. The actual soil feed rate will be determined during the Phase I testing
-------
111-16
Table 8
ANALYSIS METHOD FOR OXYGEN
This method will be used for quantitative determination of oxygen in
the SCC flue gas for all nine trial burn tests. The Q£ results will be
used for calculation of combustion efficiency for the mobile incinerator.
Basic Method: Continuous Monitor System
Matrix Cool, dry, filtered stack gas (see •
Section III C).
Apparatus: Bendix Model 9120 gas chromatograph/thermal
conductivity detector
Gas chromatographic Column: 1/8" x 8' molecular sieve 5A
Conditions:
Carrier Gas: helium
Injector: Hastelloy C sampling
valve @ 11QOC, 40/jL
sample loop
Oven: 110 °c isothermal
Calibration Gas: Zero gas: Nitrogen
Span gas: 8% 02 in nitrogen
Analysis Range: 0-10% 02
Anticipated Detection 0.10% 02
Limit:
Anticipated Accuracy: ±0.10% 02 (or ± 1% of range)
-------
111-17
Table 9
ANALYSIS METHOD FOR CARBON DIOXIDE
This method will be usad for quantitative determination of carbon
dioxide in the stack gas for all nine trial burn tests. The C02 results
will be used for calculation of combustion efficiency for the mobile
incinerator.
Basic Method: Continuous Monitor System
Matrix: Cool, dry, filtered stack gas (see
Section III C)
Apparatus: Bendix Model 9120 gas chromatograph/
thermal conductivity detector
Gas Chromatographic Column: 1/8" x 4' Poropak Q 50/80 and
Conditions: 1/8" x 8' Poropak Q 50/80
Carrier Gas: helium
Injector: Haste Hoy C sampling
valve @ 110 OC,
40 juL sample loop
Oven: 110 OC isothermal
Calibration Gas: Zero gas:, nitrogen
Span gas: 10% C02 in nitrogen
Analysis Range: 0-10% C02
Anticipated Detection 0.1%
Limit:
Anticipated Accuracy: ± 0.1% C02 (or ± }% Of range)
-------
111-18
Table 10
ANALYSIS METHOD FOR CARBON MONOXIDE
This method will be used for quantitative determination of carbon
monoxide in the SCC flue gas for all nine trial burn tests. The CO
results will be used for calculation of combustion efficiency for the
mobile incinerator.
Basic Method: Continuous Monitor System
«
Matrix: Cool, dry, filtered SCC flue gas
(see Section III C)
Aparatus: Bendix Model 9220 methanizer coupled to
a gas chromatograph/flame ionization
detector.
Gas Chromatographic Column: 1/8" x 6' Poropak Q 50/80 and
1/8" x 12" Poropak Q 50/80
Conditions: Carrier Gas: Hydrogen
Injector.-"'Hastelloy C sampling valve
0 66°C,
0.25 mL sample loop
Oven: 66°C isothermal
Calibration Gas: Zero Gas: nitrogen
Span Gas: 100 ppm CO in nitrogen
Analysis Range: 0 - 200 ppm CO
Anticipated Accuracy: ± 2 ppm CO (or ± 1% of range)
-------
111-19
Table 11
ANALYSES METHOD FOR OXIDES OF NITROGEN
This method will be used for qualitative determination of oxides of
nitrogen in the stack gas for.all nine trial burn tests.
Basic Method: Continuous Monitor System
Matrix: Cool, dry, filtered stack gas..
(see Section III C)
Apparatus: Bendix Model 8102 chemiluminescent
NO - NOX analyzer
Calibration Gas: Zero Gas: nitrogen
Span Gas: ISOppm NOX in nitrogen
Anticipated Detection 1 ppm NOX
Limit:
Analyses Range: 1 - 500 ppm NOX
Anticipated Accuracy: -± 5 ppm NOX (or ± 1% of range)
-------
111-20
Table 12
ANALYSIS METHOD FOR SULFUR DIOXIDE
This method will be used for quantitative determination of sulfur
dioxide in the stack gas for all 9 trial burn tests.
Basic Method: Continious Monitor System
Matrix: Cool, dry, filtered stack gas (see
Section III C)
Apparatus: Bendix Model 9120 gas chromatograph/thermal
conductivity detector.
Gas Chromatographic Column: 1/8" x 4' Poropak T/Poropak Q 50/80 and
Conditions: 1/8" x 2' Poropak T 50/80
Carrier Gas: Helium
Injector: Hastelloy C sampling
Valve @ 110 °C
2 mL sample loop
Oven: 110 QC Isothermal
Calibration Gas: Zero gas: Nitrogen
Span gas: 2000 ppm S0£ in nitrogen
Analysis Range: 0-2000 ppm S02
Anticipated Detection 20 ppm S02
Limit:
Anticipated Accuracy: ±20 ppm S02 (or ± 1% of range)
-------
111-21
Table 13
ANALYSIS METHOD FOR TOTAL HYDROCARBON
This method will be used for relative determination of total
hydrocarbons (THC) in the stack gas for all nine trial burn tests. The
THC results will be used as an indirect indication of combustion
efficiency for the mobile incinerator.
Basic Method: Continuous Monitor System
Matrix Cool, dry, filtered stack gas
(see Section III C)
Apparatus: Bendix Model 9220 gas chromatograph/flame
ionization detector.
Gas-Chromatographic ' Column: 1/8" x 4' Poropak Q 50/80
Conditions:
Carrier Gas: Nitrogen
Injector: ^-Hastelloy C sampling
valve @ 66QC,
40 ,uL sample loop
Oven: 66°C isothermal
Calibration Gas: Zero Gas: nitrogen
Span Gas: 100 ppm CH4 in nitrogen
Analysis Range: 0 - 200 ppm THC
Anticipated Accuracy: ± 2 ppm THC (or ± 1% of Range)
-------
Table 14. Trial Burn Operating Conditions
Waste SCC SCC Gas
Peed Phys. Heat Value chlorine RK Temp. Temp. Velocity Aux. Fuel SCC
Test Runs Waste Feed POHCs (Ib/hr) Form (Btu/lb) . . {%). .. (°F) (°F) (ACFM) Range RK (MMBtuh)
1 1,2,3 Soil with PCBs 2000 Solid ^0 ^0 1600 2200 14,500 4.5-5.0 4.5-5.0
<50 ppm
PCB
2 1,2,3 PCP with PCP 500 Solid :1880 33.3 1600 2200 14,500 3.5-4.0 5.-5.5
sand
H
H
-------
111-23
with clean soil which is discussed in Section I. It is expected that the active
soil feed rate for the trial burn will be somewhere between 1500 and 2500 Ib/hr.
Because of the low heat value of the soil, auxiliary fuel will be used during
the PCB/soil trial burn. It is expected that about 5 MM Btuh will be needed in
the RK and about 5 MM Btuh in the SCC. The acutal values needed will depend on
the soil moisture content and will be in the 4.5 to 5.5 MM Btuh range.
b. PGP/Sand — The pentachlorophenol and sand mixture will be incinerated in the RK
at about 1600°F. The hot combustion gas from the RK will enter the SCC and be
subjected to a temperature of about 2200°F and have a SCC combustion gas flow
rate of about 14,500 acfm. The temperatures and combustion gas flow rate will
be controlled as closely as possible, but may vary somewhat from run to run
because of normal operational considerations.
2. General Trial Burn Considerations
In preparation for the trial burn, auxiliary fuel (diesel oil) will be used as
necessary to raise the combustion system to the desired test run temperatures,
assuming the incineration system has been operated at reduced fire conditions
between test runs. Recycle water sumps will be flushed clean within practical
limits. The solid waste will be received, and stored in a designated
receiving/storage area at the Kin-Buc site.
Each test run will require approximately 12 hours to complete. This means that
approximately six days will be required for the trial burn program, assuming
smooth operation of all test equipment and that all 6 runs are made. A typical
test run will include the following sequence of events;
• Raise temperature of RK and SCC to desired levels using auxiliary fuel
(approximately 2 hr)
• Check sampling and analytical equipment; standardize where necessary
« Adjust gas cleaning quench and scrubber water flows to desired levels
during this time
• Start appropriate scrubber water feed pumps through appropriate recycle
loops
-------
111-24
• After the system is up to temperature and lined out, conduct POHC blank
sampling for scrubber water and flue gas (approximately 1 hr)
• After blank sampling is completed, start waste feed to the ram hopper and
start ram feed mechanism; fine-tune waste feed rates and diesel oil
atomization by observation of the flame characteristics; monitor combustion
air blower, quench, recycle water system, and pH control; set system on
automatic temperature control and allow for steady-state conditions
(approximately 1 hr)
• After achieving steady-state conditions, conduct sampling and analytical
tests over an appropriate time period
• After completing the test run, empty ram feed and hopper, take final
readings; allow combustion system to cool down to low fire conditions
(approximately 2 hr)
« Clean up sampling and analytical equipment for next test run during this
period
« Clean out recycle water sumps in preparation for next run; prepare samples
for transport to laboratory; button down equipment for overnight storage
• Maintain system on auxiliary fuel at low fire overnight
F. EMISSION CONTROL EQUIPMENT DESCRIPTION AND OPERATING CONDITIONS
1. Description
As illustrated in Fig. 7, a skid-mounted quench surge sump and recycle pump is
located on the ground between Trailers 2 and 3. The quench system is the ini-
tial stage of the air pollution control (APC) system in that the cooling and
saturation of the gases preconditions them for the rest of the APC system.
Through pH adjustment with an alkalne solution, the excess water in the quench
removes part of the acid gases in the flue gas. If the quench water pH drops
below 7, alkaline solution is added to the quench sump from auxiliary alkaline
supply tanks. Some particulate is also removed in the quench.
Mounted on the third trailer are the particulate scrubber, mass transfer
scrubber, induced-draft fan, fan drive engine, flue gas stack, instrument air
compressor and control panel. The particulate scrubber is a commercially
available cleanable high efficiency air filter (CHEAF) constructed of
Inconel 625 for corrosion resistance. It operates with a 25 to 30 in. w.c.
-------
111-25
COMBUSTION CAS ANALYSIS
(Oj CO. C02> -7 EMEflCENCY
/ VENT
KEfl.0 OUCT
STACK GAS ANALYSIS
|TMC. NOj. SOj. Oj. CO. COjl
QUENCH ELBOW SUMP:
DUCT TO CHEAP:
EMERGENCY VENT:
CLEANA8LE HIGH EFFICIENCY AIR
FILTER:
MX SCRUBBER:
REFLO OUCT:
INDUCED DRAFT FAN:
DIESEL ID FAN DRIVE:
STACK:
Inconel 625, 35 in. (91.5 cm) width X 72 in. (183 cm) length X
30 in. (76 cm) height
Inconel 625, 20.4 in. (52cm) ID
Inconel 625, mechanical operated, includes butterfly shutoff valve
Anderson 2000, Inconel 625, Wetted glass fiber filter pad with auto-
matic controls to maintain 30 in. (76 cm) WC AP, pad is 100 ft (30.5
m) roll by 4 ft (1.2 m) width, moved by Inconel 625 chain mat
Ceilcote cross-flow irrigated scrubber filled with 2 in. (5 cm) plastic
packing, 7.8 ft (2.4 m) height X 6.5 ft (2 m) width X 29
ft (8.9 m) length, FRP
304 SS, 12 in. (30.5 cm) dia.
347 SS housing, Inconel 625 shaft and impeller, 36 in. (91.5 cm) dia.
rotor
155 hp, (1 16 kW) Allis-Chalmers 6-cylinder turbocharge diesel
engine, 6491 series, 300 in.' (0.0005 m3) displacement
Two sections
9 ft (2.7 m) noise attenuator, carbon steel
10 ft (3.1 m) section, 304 SS
Fig. 7. Air Pollution Control Equipment
-------
111-26
pressure differential across a wetted fiberglass filter mat to remove submicron
particulates from the flue gases.
The mass transfer scrubber is a horizontal, crossflow irrigated, packed bed
absorber tower appropriately designed and reinforced for this specific mobile
2
application. The packed bed has a 25 ft cross-section and is over 8 ft long,
with the last 9 in. of packing acting as a demister. The scrubbing media is
kept alkaline by automatic pH adjustment from an off-trailer alkaline solution
feed system. Sumps for the CHEAP and the scrubber are located in the bottom of
the packed scrubber. Recycle water pumps are utilized for both scrubber units.
The induced-draft fan is driven by a 155 hp diesel engine and operates at a
nominal speed of 3,350 rpm in order to maintain a negative pressure of
42 in. w.c. The fan is a single stage, heavy duty industrial unit with a
347 stainless steel housing and an Inconel 625 shaft and 36 in. diameter rotor.
The exhaust stack is mounted on top of the fan and is hinged so that it will lay
down in a horizontal position during transport. Part of the stack is a sound
attenuator designed to reduce the fan discharge sound pressure levels to 85 db
at 5 ft from the stack outlet. The overall height of the stack is 30 ft above
ground level. Also mounted on the third trailer is the control panel used to
operate all the equipment on the trailer. The air compressor on the trailer
provides instrument air for all three trailers. Figure 8 is a dimensional
sketch of the APG system.
2. Operating Conditions
Table 15 summarizes the expected operating condition ranges for the mobile
incinerator-air pollution equipment. Actual trial burn values will depend on
the waste being incinerated and will be within these ranges.
G. PROCEDURES DURING EQUIPMENT MALFUNCTION
1. Waste Feed Shutoff and Incinerator Shutdown
In the event of an equipment malfunction a system of interlocks will trigger
-------
COMBUSTION GAS ANALYSIS
(Oj. CO. COj)
STACK GAS ANALYSIS
(THC. NOX, SO2. Oj. CO, C02)
AIR POLLUTION CONTROL
H
H
I
NJ
Fig. 8. Dimensioned Sketch of APC Equipment
-------
111-28
Table 15. Operating Condition Ranges Air Pollution Control Equipment
Water Flow (gpm) AP (in. W.C.) pH
Quench Elbow 80-90 - 7-8.5
CHEAF 15-20 25-30
MX Scrubber 120-130 8-12 8-8.5
-------
111-29
rapid shutdown of the waste feed and/or the thermal oxidation system if abnormal
values of key parameters are measured. High combustion flue gas temperatures,
caused by loss of water, low scrubber water flows, loss of power, loss of ID
fan, etc., result in waste feed cut-off and the extinguishing of all burner
nozzle flames. The details of waste feed cut-off system shutdown are discussed
in Sections III-H and III-M.
During the feeding of solid wastes, a malfunction will cause the ram solids feed
mechanism to stop. If possible, however, the diesel fuel burners in the RK and
SCC will stay on in order to assure adequate destruction of the combustion gases
generated by the solid wastes still remaining in the RK.
2. Emission Control
During an equipment malfunction the SCC combustion gases will either be routed
to the APC equipment or to the emergency vent (see Section III-N). The actual
combustion gas routing will depend on the type of malfunction.
H. TRIAL BURN INSPECTIONS
1. Spill Inspection Plan
This general spill inspection plan for the USEPA mobile incinerator system was
developed to detect and respond in a systematic and timely manner to potential
equipment malfunctions, facility deterioration, operator errors, and waste
discharges that might release hazardous waste constituents to the environment or
threaten human health. It was specifically designed to meet the requirements
set forth in Standards for Owners and Operators of Hazardous Waste Treatment,
Storage, and Disposal Facilities, 40 CFR Section 264.15, and related sections;
and the Oil Spill Prevention Regulations, 40 CFR Part 112.
This plan will be reviewed, and amended annually or if necessary, for any of the
following reasons; (1) if there is a significant facility revision, (2) if a
significant incident occurs and the condition causing the incident was not ade-
quately detected and responded to, or (3) to comply with future requirements,
changes, or additions to the regulations.
-------
111-30
As a part of the Spill Inspection Plan, copies of the construction plans,
prestartup inspection procedures, housekeeping procedures, safety operations
manual, and inspection procedures for the facility are kept with the incinera-
tion system whenever it is mobilized and operated in the field. In addition,
the standard operating procedures for the facility require that the process
operators routinely walk through their operating areas (versus operating only
from the control panel) to visually observe/monitor and record the condition of
all equipment and the facility. Further, the facility will have an active pre-
ventive maintenance program in which schedules will be established for the
routine maintenance of equipment requiring such attention. A key part of this
program will be the record keeping on equipment items and systems. These
records cover such information as purchase date, manufacturer, specifications,
test results, past maintenance and repair history, and required maintenance
schedule. Although the above programs are not incorporated into this inspection
plan, they complement and supplement this plan to provide a comprehensive pro-
tection program.
2. Inspection Organization
Routine inspections will be performed under the direction of the Research and
Development (R&D) Group Leader by supervisory personnel who have operational or
equipment responsibilities in the area inspected.
The mobile incineration system will typically be set up and operated for periods
of less than 90 days. All equipment will be inspected before the system is set
up and when the system is dismantled after each operation. At the time inspec-
tions are made, written inspection forms will be filled out. A copy of the
completed inspection report will be sent to the project engineer and a copy
retained in the inspection area operating log. It is the responsibility of the
project engineer to maintain complete records for this inspection plan. These
records will be maintained for three years.
It is the responsibility of the R&D Group Leader to initiate and follow up any
response actions required by conditions discovered in an inspection. The pro-
ject engineer is responsible for reviewing the inspection reports and responses
-------
111-31
and taking any additional corrective actions required. The R&D Group Leader
will prepare a monthly summary report to the EERU Project Manager, covering such
i terns as:
• Inspections completed
• Problem conditions found
• Responses completed
» Responses pending
« Recommendations
3. Inspections
Once each day during operation, the shift supervisor will inspect all safety and
emergency equipment to ensure that all are operating properly. All information
will be entered into the operations record. The shift supervisor will remedy
any deterioration or malfunction of equipment or structures quickly enough to
avoid environmental or human health hazards. Where a hazard is imminent or has
already occurred, remedial action will be taken immediately.
At the beginning of each shift the shift supervisor will inspect the following
areas:
a. Tank overfilling prevention equipment (for example, waste feed cut-off
systems and by-pass systems) - to ensure that it is in good working order;
continuous monitoring by an operator shall be mandatory during times when
process tanks are being filled;
b. Data gathered from monitoring equipment (for example, pressure and tem-
perature gauges) where present, at least once each operating shift to
ensure that the equipment is being operated according to its design;
c. Monitoring equipment (for example, pressure and temperature gauges) used
continuously during uncovered operation;
d. Tank waste level at least once each day to ensure compliance with N.J.A.C.
7:26-10.5(c)2ii (NJDEP Hazardous Waste Facility Permit Requirements);
e. Condition of above-ground tanks to detect corrosion or leaking of fixtures,
pipes, and seams;
f. Area immediately surrounding the pre-existing on-site waste storage areas
(containers, valves, conveyors, piping) to visually check for malfunctions,
leaks, spills, and fugitive emissions. It should be noted that before the
mobilization of the treatment system, regional, state, and local emergency
-------
111-32
response personnel will have secured the waste storage areas, thus
affording a safe working environment.
At the close of the incinerator operation and before incineration dismantling,
the shift supervisor will ensure that the equipment and site decontamination
procedures are initiated.
4. Corrective Actions
The operator shall immediately notify the shift supervisor of any condition
requiring corrective action. The shift supervisor shall determine the correc-
tive action to be taken and see that the work is immediately initiated and pro-
perly carried out until completed. The shift supervisor will issue a written
order to the operator; when the work is completed the operator will date and
sign the work order and return it to the shift supervisor.
This corrective action will be dependent on the problems, but if a hazard is
imminent or has already occurred, remedial action will be taken immediately.
Some examples of conditions and corrective actions are:
Condition
Monitoring equipment
malfunction
Leaky valve
Eroded dike
Used or missing safety
or firefighting equipment
Corrective Action
Immediate maintenance by
instrument technicians
Immediate maintenance by
maintenance man; initiate
work order to repair or
replace if required
Make temporary repairs,
initiate work order for
permanent repair
Replace from stock,
follow up on reason for
equipment condition and
correct
Any drips, leaks, or spilled waste material shall be cleaned up immediately
after detection or after repair. Drip pans under the waste feed pumps and
-------
111-33
piping shall be vacuumed out immediately after a rain shower to prevent unne-
cessary contamination of the rain water if a leak should occur subsequent to the
rain fall. Discharge of rain water will be supervised to ensure compliance with
applicable water quality standards and to prevent a "harmful" discharge as
defined in 40 CFR, Part 110.
I. TRIAL BURN RECORD KEEPING
An operating log (see Pigs. 9 through 11) will be filled out once each hour for
all operations. These logs will be a record of operating conditions and provide
evidence that the operator has checked and is aware of the actual operating sta-
tus of the system. The time at which entries are made will be shown, as will
the actual instrument reading for each variable. If automatic shutdown occurs,
the log will state the nature of the shutdown, the time it occurred, and the
suspected cause. This will be noted in the "remarks" column along with any unu-
sual conditions or situations such as spills or leaks. The log will be dated
and signed by the operator. In addition, once each shift the shift supervisor
will inspect the facility for malfunctions and deterioration, operator errors,
and discharges which may be causing, or may lead to:
• Discharge of hazardous waste constituents to the environment
o A threat to human health
The completed log sheets will be kept in a three-ring binder under the control
of the shift supervisor. Once each day the shift supervisor will submit all
inspection reports, graphs, etc. to the R&D Group Leader. If it is determined
that a spill potential exists it will be brought to the R&D Group Leader's
attention immediately.
J. TRIAL BURN SCHEDULE
The current schedule for the trial burn portion of the Kin-Buc demonstration
test is shown in Table 16. Each test run is expected to last 8 to 12 hours. The
maximum amount of PCB contaminated soil incinerated will be about 72,000 pounds.
This soil will contain a maximum of 3.6 pounds of PCBs. The maximum amount of
pentachlorophenol and sand incinerated will be about 18,000 pounds, with about
9, 000 pounds being pentachlorophenol.
-------
Fig. 9
ROTARY KILN AND SCC OPERATING LOG SHEET
TRIAL BURN TEST DATA - Collect at 15 Minute Intervals During Waste Feed
DATE:
SHIFT:
OPERATOR:
ITEM
Kiln Temperature (KILN-OG )
Kiln Oxygen (PANEL KILN-02)
Kiln Comb Air Flow (PANEL)
Kiln Comb Air Flow (ANNUBAR)
Kiln Ambient Air Temperature
Kiln Water Flow (KILN-H20)
Kiln Waste Oil Flow(KILN-WO)
SCC Temperature (SCC-OG)
l
SCC Oxygen (THERMOX SCC-02)
SCC Comb Air Flow (ANNUBAR)
BuTv\€r H Fue\ "Flooo (.Ot-pp)
fWner 3>Fw.«A "Plov*j (.133, -pr)
turner / F~ad F7oco(Gi -r>Fj
' Gu
-------
Fig. 10
AIR POLLUTION CONTROL EQUIPMENT OPERATING LOG SHEET
HOURLY LOG
DATE i
SHIFT:
OPERATORz
ITEM
Quench Sump Level (QUE-LC)
Quench Water Temp (QUE-PW)
Quench £20 Press DNST(QUE-PW)
Quench H2O Press UPST (QUE-PW)
Quenched Gas Temp
CHEAF Exit Temp
Quench Water Flow (QUEP-PW)
CHEAF Water Flow (CHFP-PW)
Filter Roll
CHEAF Water Temp (CHF-PW)
CHEAF Filter Differ (CHFD-OG)
CHEAF Outlet Press (CHFO-OG)
CHEAF Inlet Press (CHFI-OG)
CHEAF H20 Press DNST (CHF-PW)
CHEAF H20 Press UPST (CHF-PW)
Scrubber Water Temp (MX-PW)
CHEAF Sump Level (CHF-PW)
Scrubber Sump Level (MX-WL)
Scrubber Water Press (MXP-PW)
Scrubber Water Flow (MX-PW)
ID Fan Inlet Press (FAN-OG)
Quench Water pH (QUE-PH)
CHEAF Water pH (CHF-PH)
Scrubber Water pH (MX-PH)
ID Fan Water Spray (FANH20)
ID Fan Vibration (FANVIB)
Stack Temperature
ID Fan Drive Speed (QUE-H20)
Makeup Water Press (QUE-H20)
Makeup Water Flow (MU-H20)
UNITS
%
OF
PSI
PSI
OF
oF
GPM
GPM
oF
inH20
inH20
inH20
PSI
PSI
OF
in
in
PSI
GPM
inH20
GPM
mil
OF
RPM
PSI
.GPM
TIME
H
H
H
1
U)
Ul
-------
Fig, 11
UTILITY OPERATING LOG SHEET
HOUR LOG
DATE:
SHIFT:
OPERATOR:
ITEM
Quench Sump Inst Air (QUE-IA)
Quench Pump Seal H20(QUEP-SW)
CHEAT Pump Seal H20 (CHFP-SW)
Scrubber Pump SealH20(MXP-SW)
Diesel Tank Level #1(DT1L-DF)
Diesel Pump Press (DFP-DF)
Fan Drive Temperature (FAN)
Fan Drive Oil Press (FAN -MO)
Scrubber Sump Inst Air(MX-IA)
CHEAF Sump Inst Air (MX-IA)
Alkaline Tank #1 (SATL-SA)
Alkaline Tank #2 (SATL-SA)
Alkaline Pump Press (SAP-SA)
Waste Water Tank Level (WWTL)
Steam Generator Temp (STG-SO)
Steam Generator Press (STG-SO)
Steam Gen Water Level( STG-SO)
Feed Water Press DNST(STG-FW)
Feed Water Press UPST(STG-FW)
Feed Water Tank Level ( STG-FW)
Dynactor Tank Level (DYNA-DF)
Dynactor Oil Temp (DYNA-MO)
Dyn Gen Engine Press { DYNA-MO)
Dyn Gen Engine Temp( DYNA-H20)
UNITS
SCFM
GPM
GPM
GPM
PSI
o
PSI
SCFH
SCFH
in
in
PSI
in
°F
PSI
inH20
PSI
PSI
inH20
in
°F
PSI
°F
TIME
,
,
,
-------
111-37
Table 16. Solids Trial Burn Schedule/Kin-Buc Demonstration (1983)
Date Scheduled Activity
August 13 Start-up incinerator on fuel oil
August 15 Start Kin-Buc oily leachate
August 29 Start Phase I testing; clean soil and oily leachate
September 5 Start Phase II testing; PCB's in soil with diesel oil
September 8 Start Phase III testing; PCP in sand with diesel oil
September 10 Finish last run (Test 2, Run 3)
-------
111-38
K. SITE CLEANUP
Following completion of the trial burn program, all residual solid wastes that
remain will be destroyed. Assuming that incineration operations went smoothly
based on on-site observations, and that preliminary analytical results are posi-
tive (e.g., as indicated by low CO values), EERU will destroy any trial burn
residual wastes in the mobile incineration system. During residual waste
destruction the unit will be operated under the trial burn conditions (see
Table 14). If the quantities of remaining solid wastes are too large to inci-
nerate, environmentally acceptable treatment/disposal procedures will be iden-
tified and utilized for the left-over wastes. The rotary kiln ash will be
either delisted according to 40 CFR 260 requirements or disposed of as hazardous
waste in a permitted secure landfill.
L. QUALITY ASSURANCE PROJECT PLAN
The Quality Assurance Project Plan which includes a QA operations plan
(Part A) and a QA Sampling and Analytical Plan (Part B) is given in
Appendix A.
-------
APPENDIX A
QUALITY ASSURANCE PROJECT PLAN
-------
Section No:
Revision No:
Date: Draft
Page 1 of 1
1.0 QUALITY ASSURANCE PROJECT PLAN
PROJECT TITLE:
DOCUMENT CONTROL NUMBER:
EPA PROJECT OFFICER:
EERU PROGRAM DIRECTOR:
PERFORMING ORGANIZATION:
DURATION:
TYPE OF PROJECT:
SUPPORTING ORGANIZATION:
The U.S. Environmental Protection Agency
Mobile Incinerator System Solids Trial Burn
EERU/QA-3
Ira Wilder
K. E. Honeycutt
IT Corporation - EERU, GSA Raritan Depot,
Edison, New Jersey 08837
February 1983 to December 1983
Work Order under EPA Contract 68-03-3069
U.S. Environmental Protection Agency
Municipal Environmental Research
Laboratory, Solids and Hazardous Waste
Research Division, Oil and Hazardous
Materials Spills Branch
APPROVALS:
IT CORPORATION
EPA
NAME: Victor KaIcevie
TITLE: QA Officer
SIGNATURE:
Date
NAME: Ira Wilder
TITLE: Project Officer
SIGNATURE: Date
NAME: K. E. Honeycutt
TITLE: Program Director
SIGNATURE: Date
NAME: Lawrence J. Kamphake
TITLE: QA Officer MERL
SIGNATURE: Date
NAME: R. A. Miller
TITLE: Demonstration Test Task Manager
SIGNATURE: Date
NAME:
TITLE: Sampling and Analytical Program Manager
SIGNATURE: Date
-------
CONTENTS
Section No: 2
Revision No: 0
Date: Draft
Page 1 of 3
SECTION NO.
1.0 Title Page
2.0 Table of Contents and Distribution
3.0 Project Description
4.0 Project Organization and Responsibilities
Part A - Operations
5.0A Quality Assurance Objectives
6.OA Sampling and Data Collection Procedures
7.0A Sample Custody
8.OA Calibration Procedures and Frequency
9.0A Analytical Procedures
10.OA Data Analysis, Validation, and Reporting
11.OA Internal Quality Control Checks
12.OA System and Performance Audits
13.0A Preventive Maintenance
14.OA Specific Procedures to be Used to
Routinely Assess Data Precision,
Accuracy, and Completeness
15.0A Corrective Action
16.OA Quality Assurance Reports to Management
Part B - Source Sampling and Analytical
5.OB Quality Assurance Objectives
6.OB Sampling and Data Collection Procedures
7.OB Sample Custody
8.OB Calibration Procedures and Frequency
9.OB Analytical Procedures
PAGES
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
Draft 2-22-83
-------
CONTENTS (Continued)
Section No.: 2
Revision No.. 0
Date: Draft
Page 2 of 3
10.B Data Analysis, Validation, and Reporting
11.OB Internal Quality Control Checks
12.OB System and Performance Audits
13.OB Preventive Maintenance
14.OB Specific Procedures to be Used to
Routinely Assess Data Precision,
Accuracy, and Completeness
15. OB Corrective Action
16.OB Quality Assurance Reports to Management
0 Draft 2-22-83
0 Draft 2-22-83
0 Draft 2-22-83
0 Draft 2-22-83
0 Draft 2-22-83
0 Draft 2-22-83
0 Draft 2-22-83
APPENDICES
-------
TABLES
Table
No. Page
Part A
1 Quality Assurance Objects for Precision, Accuracy, and
Completeness for Combustion and Operating Parameters 5A-2
Part B
2 Quality Assurance Objectives for Precision, Accuracy,
and Completeness 5B-2
3 Summary of Trial Burn Analytical Procedures 6B-2
4 Activity Matrix for Calibration of Equipment 8B-2
5 Activity Matrix for Calibration of Apparatus 8B-4
-------
FIGURES
Figure
No. Page
Part A
1 Overall Project Organization 4A-2
2 Sampling and Analysis Project Organization 4A-5
3 Data Flow and Reporting Scheme 10A-4
Part B
4 Organic Sampling Train 6B-3
5 Sample Bottle Label 7B-2
6 Chain of Custody Form 7B-3
"7 ID A
1 Sample Analysis Request
8 Sample Distribution Sheet 7B~6
9 GC/MS Directed Analysis Report Form 10B-6
10 GC/MS Survey Report Form 10B-7
11 LRMS Analysis Report 10B-8
12 Certificate of Analysis 10B-9
13 Proximate Analysis Reporting Form 10B-10
-------
Section No; 2
Revision No: 0
Date: Draft
Page 3 of 3
DISTRIBUTION OF TRIAL BURN QA PROJECT PLAN
IT CORPORATION:
W. D. King, IT Corporation President
K. E. Honeycutt, EERU Project Director
C. Pfrommer, EERU R&D Group Manager
R. A. Miller, EERU R&D Trial Burn Task Manager
J. H.. Exner, EERU Project Technical Coordinator
V. Kalcevic, EERU Project QA Officer
T. Geisler, Trial Burn QA Coordinator
R. Lovell, EERU R&D Senior Project Manager
, Sampling and Analytical Program Manager
, Sampling Coordinator
, Analysis Coordinator
EPA MERL:
I. Wilder, EERU Project Officer
L. J. Kamphake, MERL QA Officer
J. J. Yezzi, Jr., EERU Deputy Project Officer
-------
PART A OPERATIONS
D90STB
-------
Section No: 3A
Revision No: 0
Date: Draft
Page 1 of 2
3.0 A PROJECT DESCRIPTION
This project covers the RCRA solids feeds demonstration test burn
operation of the Environmental Protection Agency's Office of Research
and Development's Mobile Incinerator System by the Environmental
Emergency Response Unit (EERU) at the Kin-Buc landfill site in Edison,
New Jersey. The operation system and planned tests are described in a
separate document "Mobile Incinerator System Solids Trial Burn Plan",
February 24, 1983. The system consists of a rotary kiln, a secondary
combustion chamber, and an air pollution control train, each mounted on
.a heavy duty over-the-road semitrailer. The system is designed for
field use to destroy/detoxify hazardous and toxic organic substances
that have contaminated soil or water at spill sites or at "orphaned"
dump sites. Liquids, sludges, and contaminated debris that have been
shredded or otherwise prepared for processing can be introduced into
the system.
The incinerator system has undergone a previous trial burn incinerating
chlorinated liquids. The purpose of these demonstration tests is to
evaluate and demonstrate the mobile incinerator's ability to safely
destroy hazardous and toxic solids materials in accordance with the
requirements of the Resource Conservation and Recovery Act (RCRA).
This objective will be met by: (1) measuring the destruction and remo-
val efficiencies (ORE) for the specified test materials, (2) deter-
mining particulate and acid gas removal efficiencies for the air
pollution control equipment, and (3) continuously monitoring the
system's operating conditions and emissions. In addition to defining
the performance capability of the system, the data generated will fur-
nish background information for subsequent permitting associated with
the on-going use of the mobile incineration system for cleaning up
spill and dump sites. As such, the data quality level objective for
this project is Level 2, requiring a high degree of quality assurance
coverage.
-------
Section No: 3A
Revision No: 0
Date: Draft
Page 2 of 2
The solids feed demonstration test burn is planned for the last 7 days
of the 30-day Kin-Buc demonstration operation. The test burn will be
done in three phases:
Phase I
Clean soil will be fed to the incinerator while burning Kin-Buc oily
leachate. The purpose of this phase would be to determine practical
operational ranges for the solids handling system, the incinerator ram
feed system, the rotary kiln (inclination and RPM), and the rotary kiln
ash handling system. Phase I will not be either a RCRA or TSCA solids
trial burn since the soil used will be certified as nonhazardous.
Phase II
Will consist of three test runs feeding 2000 Ib/hr of a soil con-
taminated with less than 50 ppm of PGBs. During this phase diesel fuel
will be used as auxiliary fuel rather than the Kin-Buc oily leachate.
The PCB contaminated soil which will be either a clean, artificially
contaminated soil, or an actual PCB contaminated soil from an existing
site. Phase II will be an RCRA trial burn, but not a TSCA trial burn
because the PCB soil concentration will be <50 ppm. The purpose of
this phase is to demonstrate the mobile incinerator's capabilities for
detoxifying contaminated soil.
Phase III
Will consist of three test runs feeding 500 Ib/hr of a 50:50 mixture of
pentachlorophenol (PCP) and sand. During this phase diesel fuel will
be used as auxiliary fuel rather than the Kin-Buc oily leachate.
Phase III will be a RCRA solids trial burn. The purpose of this phase
is to obtain a flexible solids RCRA permit for the mobile incinerator.
-------
Section No: 4A
Revision No: 0
Date: Draft
Page 1 of 7
4.0A PROJECT ORGANIZATION AND RESPONSIBILITIES
The overall project organization and reporting relationships are shown
in Fig. 1. IT Corporation, the EERU operations contractor, has overall
responsibility for the demonstration test burn. This responsibility
includes the operation, sampling and analysis, accumulation of data,
and reporting the results. This Quality Assurance Project Plan covers
these activities. The following sections of this plan are divided into
two parts. Part A covers operation, data accumulation, and reporting
results while Part B covers source sampling and analytical. This trial
burn is a major task and therefore will have an assigned QA coor-
dinator. Descriptions of the responsibilities of key individuals are
given below:
The quality assurance officer, V. Kalcevic, has the primary respon-
sibility for reviewing and approving the QA Project Plan and for over-
seeing the project to assure that the QA objectives are met. He
reports directly to the IT Corporation president, W. D. King, who has
overall responsiblity for the organization's activities, including QA.
The quality assurance coordinator, T. J. Geisler, is responsible for
reviewing and advising on all aspects of QA/QC. He reports to the ESRU
project director, K. E. Honeycutt. Some responsibilities of the QA
coordinator are:
• Assisting the task manager, R. A. Miller, in specifying QA/QC pro-
cedures to be used for this project.
• Reviewing and commenting on the QA Project Plan for sampling and
analysis to ensure that the methodologies and QA/QC procedures
proposed will meet the overall quality objectives set forth in
this plan.
-------
QUALITY ASSURANCE
QA OFFICER
V. KALCEVIC
TRIAL DURN QA
COORDINATOR
T. J. GEISLER
I
IT CORPORATION
PRESIDENT
W. D. KING
EERU PROGRAM
PROJECT DIRECTOR
K. E. HONEYCUTT
EERU R&D
GROUP MANAGER
C. PFROMMER
t
MOBILE INCINERATOR
TRIAL DURN
TASK MANAGER
R. A. MILLER
USEPA/MERL
01IMS BRANCH
ITAS
JAMPLING & ANALYTICAL
PROGRAM MANAGER
HJ O JO W
(U PI (D (t>
O D
W H-
H- O
O 3
Fig.
Overall Project Organization
-J H> 0
rf ••
-------
Section No: 4A
Revision No: 0
Date: Draft
Page 3 of 7
• Conducting any required performance and systems audits.
• Reviewing data generated during the trial burn, including ex-
amining chromatograms, calculations, and data books.
« Submitting brief reports on field inspections and audits con-
ducted.
• Reporting, as a section in the final test burn report to the EPA,
the results of the Quality Assurance Program.
The task manager, R. A. Miller, has overall responsibility for the
mobile incinerator operations and for the coordination with the
sampling and analysis program manager during the test burn program.
For this purpose he reports to the EERU R&D group manager, C. Pfrommer,
who in turn reports to the ERRU project director, K. E. Honeycutt, who
has the overall responsibility for the EERU project to the EPA. Some
of the task manager's responsibilities are:
» Preparing, obtaining approval of, and distributing the QA Project
Plan for the mobile incinerator test burn.
• Managing the field operations of the mobile incinerator.
« Deciding when test run sampling shall be conducted.
• Calling to the attention of the quality assurance officers and
others, as appropriate, any problems arising during the test burn
that affect this QA Project Plan so that the problems can be
resolved in a timely manner. Responsible for properly documenting
any modifications to this plan.
-------
Section No: 4A
Revision No: 0
Date: Draft
Page 4 of 7
• Issuing a final test burn report to the EPA.
The sampling and analysis program manager, , has overall tech-
nical and management responsibility for the sampling and analysis
operations and for coordination with the mobile incinerator operations
task manager. For this purpose he reports to the EERU project direc-
tor, K. E. Honeycutt, who has overall responsibility for the EERU pro-
ject to the EPA.
The sampling and analytical project organization and reporting rela-
tionships are shown in Fig. 2.
Descriptions of the responsibilities of the individuals who will spe-
cify the elements of a QA/QC program are given below.
The Quality Control and Data Manager is responsible for QA/QC activi-
ties such as reviewing and advising on all aspects of QA/QC. This
includes:
• Assisting the Program Manager in specifying QA/QC procedures to be
used during the program.
• Making in-house QC evaluations and submitting audit samples to
assist in reviewing QA/QC procedures, and
• If problems are detected, making recommendations to the Program
Manager, Sampling Coordinator and Analysis Coordinator, concerning
repeat samples and analyses and/or procedure changes.
-------
ITAS
SAMPLING & ANALYTICAL
PROGRAM MANAGER
ANALYSIS
COORDINATOR
SAMPLING
COORDINATOR
QUALITY CONTROL
fi DATA MANAGER
YORK SUBCONTRACTOR
SUPPORT
Fig. 2. Sampling and Analysis Project Organization
pi p> (D Q>
Ul
o
W H-
H- O
O 3
25 O
0 "
O >
-------
Section No: 4A
Revision No: 0
Date; Draft
Page 6 of 7
« Receiving samples from the field and verifying that incoming
samples correspond to the packing list or chain-of-custody sheet;
• Maintaining records of all incoming samples, tracking those
samples through subsequent processing, analysis, and ultimately
appropriate disposal of those samples at the conclusion of the
program;
» Preparing quality control samples for analysis before and during
the program;
• Preparing QC and sample data for review by the Analysis Coor-
dinator and the Program Manager;
• Preparing QC and sample data for transmission and entry into the
computer data base.
The Analysis Coordinator is responsible for laboratory activities.
These include:
« Training and qualifying personnel in specified laboratory GC and
analytical procedures, before receiving samples;
« Verifying that laboratory QC and analytical procedures are being
followed as specified in the plant-specific S/A plan and reviewing
sample and QC data at least weekly. This weekly review will
include examination of raw data such as chromatograms and checking
of arithmetic calculations for a minimum of 5% of the samples ana-
lyzed, as well as inspection of reduced data, calibration curves,
and bound laboratory notebooks.
-------
Section No: 4A
Revision No: 0
Date: Draft
Page 7 of 7
The Sampling Coordinator is responsible for field activities. These
include:
• Interacting with YSC to ensure that the stack sampling is being
conducted in a manner consistent with this project plan.
• Determining, with the Analysis Coordinator, appropriate sampling
equipment and sample containers to minimize contamination;
• Ensuring that samples are collected, preserved, and transported as
specified in the plant-specific detailed S/A plan.
• Checking that all sample documentation (labels, field notebooks,
chain-of-custody records, packing lists) is correct and trans-
mitting that information with the samples to the analytical
laboratory.
The YSC Stack Sampling Manager is responsible for all stack sampling
activities. For this purpose he reports to the ITAS Sampling
Coordinator.
-------
Section No: 5A
Revision No: 0
Date: Draft
Page 1 of 3
5.0A QUALITY ASSURANCE OBJECTIVES
As part of the overall measurement objective of the test burn, the
mobile incineration system must be shown capable of operating at the
conditions set forth in RCRA regulations.
The test burn overall quality objective is Level 2 coverage, which
means that the test burn will provide extensive scientific data,
requiring regular QA audits and rigorous QC procedures.
5. 1 PRECISION, ACCURACY, COMPLETENESS
5.1.1 Combustion Parameters — The regulations require continuous monitoring
of contaminant mass flow rate and combustion temperature as well as
flue gas concentrations of CO, C02, O2, and NOX. In addition to these
parameters, the RCRA interim regulations require monitoring of the air
feed rate. Although not required by the regulations, the S02 con-
centration in the flue gas will be monitored to verify the low sulfur
content of the auxiliary fuel oil used. The data for these parameters,
as well as others measured by the source sampling contractor, must be
precise, accurate, and complete. The objectives for precision,
accuracy, and completeness of data for the parameters indentified above
are given in Table 1. Definitions of these terms are as follows.
Accuracy—The degree of agreement of a measurement (or an average of
measurements of the same thing), X, with an accepted reference or true
value, T, usually expressed as the difference between the two values,
X - T, or the difference as a percentage of the reference or true
value, 100 (X - T)/T. Accuracy is a measure of the bias inherent in
the system.
Precision—A measure of mutual agreement (or variability) among indivi-
dual measurements of the same property, usually under prescribed simi-
-------
Section No:
Revision No:
Date: Draft
Page 2 of 3
5A
0
Table 1, Quality Assurance Objectives for
Precision, Acuracy, and Completeness for
Combustion and Operating Parameters
Parameter
Method of Measurement
SCC temperature
Waste oil flow rate
CO
C02 d
Air feed rate
Total hydrocarbons^
Thermocouple
Electronic flow meter
Methanizer coupled to
gas chromatograph/
flame ionization det.
Gas chromatograph/
thermal conductivity
detector
Gas chromatograph/ •
thermal conductivity
detector
Chemilurainescent
analyzer
Annubar
Gas chromatograph/
flame ionization
detector
Precision3 (%) Accuracyb(%) Completenessc ("%T
5 5 90
5 5 90
5e 5e 90
90
90
10*
5
5e
10*
80
90
90
aExpressed in terms of the relative standard deviation as defined in Section 14.1.
^Expressed as the percentage difference from tire true (standard) value.
cExpressed as the amount of valid data obtained compared to the total amount expected,
^Based on experience during the incinerator shakedown test.
eBased on results of the liquid trial burn, the levels of CO and THC in the
combustion gases were very low. Precision and accuracy will need to be within +5%
or 5 ppra., which ever is greater.
^Based on results of the liquid trial burn, the level of NOX in the combustion
gases were very low. Precision and accuracy will need to be within _+10% or 10 ppm,
whichever is greater.
-------
Section No: 5A
Revision No: 0
Date: Draft
Page 3 of 3
lar conditions and usually expressed in terms of the standard
deviation. Various measures of precision exist, depending on the
"prescribed similar conditions."
Co_mpleteness_—A measure of the amount of valid data obtained from a
measurement system compared to the amount that was expected to be
required to fully evaluate and understand the system under optimum con-
ditions, usually expressed as a percentage.
5.2 REPRESENTATIVENESS
5.2.1 Definition — This term refers to the degree to which data accurately
and precisely represent a characteristic or a population, parameter
variations at a sampling point, or an environmental condition.
5.2.2 Combustion Parameters — The combustion parameters for which represen-
tativeness could be a problem are combustion temperature and the flue
gas component concentrations. The thermocouple for temperature
measurement will be shielded from flame radiation and will have com-
bustion gases circulated around it. The sampling points for flue gas
compounds will be located in the centers of the ducts. At test con-
ditions the gas flow at the sample points will be turbulent, ensuring
complete mixing.
5.3 COMPARABILITY
5.3.1 Comparability is defined as the measure of confidence with which one
data set can be compared with another.
5.3.2 Triplicate sampling runs will be conducted for each test. The com-
parability of the triplicate data sets will be addressed in the final
QA report. All data will be reported in consistent SI units.
-------
Section No: 6A
Revision No: 0
Date: Draft
Page 1 of 4
6'°A SAMPLING AND DATA COLLECTION PROCEDURES
6.1 COMBUSTION PARAMETERS
The sampling and data collection procedures for waste flow rate, fuel
flow rate, water flow rate, temperature, CO, C02, 02, NOX, air flow
rate, and total hydrocarbons are described below. Other parameters
required by regulations are covered in the source sampling and analysis
section.
The waste solids feed to the rotary kiln is controlled by a mechanical
timer/sequencer that cycles a hydraulic feed ram. The desired feed
rate is obtained by adjustment of the cycle time and pull back position
of the ram feeder (volume).
The incinerator operator will manually record the waste feed rate every
15 minutes. The solids feed for each test before being fed will be in
weighed drums and the amount used will be measured to confirm that the
instantaneous flow rates are consistent.
The flue gas composition will be continuously monitored at two loca-
tions. The first location is in the quench elbow immediately upstream
of the water spray; the second is at the stack. One advantage of moni-
toring at these two points is that the amount of air in-leakage from
the air pollution control equipment can be calculated.
A gaseous sample is withdrawn from the center of the duct through a
1/2-in. ceramic probe. The extracted sample passes through a ceramic
inertial filter, located inside the probe, to remove particulate
material (greater than 100 micron) from the gas sample. There is
another filter at the Perma Pure dryer. Filtration is required for
-------
Section No: 6A
Revision No: 0
Date: Draft
Page 2 of 4
instrument protection. Next, the filtered gas is partially cooled in
an air-air heat exchanger to lower the temperature to 10 to 20°C (50 to
68°F). Entrained liquids are collected in a liquid trap at the bottom
of the exchanger. The gas sample then passes through a vaporizer
(120°C) to ensure that any entrained liquids from the process are
vaporized before entering the gas drying unit. Gas drying will be
accomplished in a Perma Pure dryer that removes water vapor from the
gas sample without using a condenstion process, since condensation
often removes key gaseous components from the sample. The cooled and
dried gas sample is then transported to the gas chromatographs and
chemiluminescent analyzer through Teflon® tubing. The sampling and
sample transport functions are all controlled by a microprocessor. The
sampling function of the gas monitoring system is continuously
operating to provide fresh, up-to-date gas samples to the analyzers for
stack and flue gas analysis.
The temperature of the SCC will be monitored with a thermocouple, ANSI,
type S (Pt/Pt-Rh), in direct contact with the flue gases. The ther-
mocouple is located at the exit of the SCC and is shielded from the SCC
burner flames to eliminate temperature measurement error associated
with flame radiation. The millivolt thermocouple signal is converted
to a (4-20 ma) signal and is recorded on a strip chart recorder which
is in the control panel on the kiln trailer. System specifications and
calibration points are listed below:
-------
Section No: 5A
Revision No: 0
Date: Draft
Page 3 of 4
Temperature range: 0 - 2500°F
Linearity: ±1.3°F
Calibration accuracy: ±1%
Calibration points: 0% of full scale = 0°F = -0.092 mV
50% of full scale = 1250°F = 6.029 mV
100% of full scale = 2500°F = 14.018 mV
Several operating parameters not required in the TSCA and RCRA regula-
tions for monitoring incinerator performance will also be measured.
These include the auxiliary fuel feed rates to the kiln and the SCC;
the water injection rate to the kiln; the skin temperatures of the
kiln, SCC, and ducts; the quantity of wastewater blowdown collected;
and the alkaline water feed rate and concentration. These data will be
employed in heat and material balances calculations.
The fuel and water feed rates and air flow rates will be read from
rotameters and recorded hourly in the log sheets. These instruments
will be calibrated before the trial burn program according to manufac-
turer's recommendations. Skin temperature of the kiln, SCC, and
ducting will be measured at least once during each test using a digital
surface thermocouple. Wastewater collected during a test will be
measured at the end of each test by the change in liquid level in the
wastewater tank. An ORSAT analyzer will be used to obtain backup data
on Oo and COo concentrations. One ORSAT sample will be taken during
each test. The ORSAT analysis is described in EPA Method 3
(40 CFR 60).
6.2 SAMPLING PERIODS
Sampling using the MM5 apparatus must be conducted when the incinera-
tion system is at steady-state. The project task manager will deter-
-------
Section No: 5A
Revision No: 0
Date: Draft
Page 4 of 4
mine when sampling may begin, based on a review of data from the
continuous monitoring equipment. The sampling time will be sufficient
to process 5 dry standard cubic meters of stack gas through the MM5
apparatus. During sampling the task manager will periodically verify
that steady-state conditions exist. Steady-state operation is defined
as consistent operation with less than 5% drift during 1 hr on the
following parameters: SCC temperature, waste feed, and flue gas O2
concentrations. These parameters will be checked at least every
30 minutes. If a transient condition develops during sampling, the
task manager and QA coordinator will decide whether to temporarily
interrupt or terminate sampling.
6. 3 SAMPLING OF CONTAMINATED SOIL FEED
PCB contaminated soils, <50 ppm, for the Phase II tests will either be
on actual contaminated soil, if one can be located, or a prepared mix-
ture. The method of preparing a synthtic mixture is discussed in the
test burn program. Arochlor 1260 would be used as the PCB source
material.
The petachlorophenol (PCP): sand 50:50 mixture will be prepared by
mixing commerical grade PCP (mp.~180°C) manufactured by either Vulcan
Chemicals or Reichold Chemical Company with certified clean sand.
The prepared feed materials will be placed in sealed drums for storage
and handling. While being placed in drums several soil samples per
drum will be obtained and composited.
-------
Section No: 7A
Revision No: 0
Date: Draft
Page 1 of 1
7.0A SAMPLE CUSTODY
7.1 COMBUSTION SYSTEM PARAMETERS
Samples for CO, CO2, £>2' N<-*x' an(^ TH("' are 'fca^cen an<^ analyzed on-site
automatically. Sample custody procedures are not required because
samples are transferred to the analyzers in a sealed system.
-------
Section No: SA
Revision No: 0
Date: Draft
Page 1 of 2
8.0A CALIBRATION PROCEDURES AND FREQUENCY
8.1 COMBUSTION PARAMETERS
8.1.1 Temperature Monitoring System
The thermocouple converter and recorder are calibrated by inputting a
millivolt signal which corresponds to a given temperature signal
according to ANSI Standard Thermocouple Tables. The output signal is
then adjusted to proper temperature reading. The temperature moni-
toring system cannot be calibrated during operation of the mobile
incinerator, so calibration of the instrument will be done before the
start of the trial burn, during the shutdown periods, between tests 3
and 4, between tests 6 and 7, and after test 9. If the calibrations
show a significant drift (>2%) in the accuracy of the temperature moni-
tor, the deviation will be recorded and the instrument recalibrated.
The thermocouple will be calibrated before the trial burn program with
ASTM thermometers traceable to the National Bureau of Standards.
8.1.2 Waste Feed Rate
The hydraulic feed ram volume, stroke adjustment, and cycle timing will
be calibrated just before the test burns are conducted and will be
checked before the start of each test period.
8.1.3 CO, C02, 02, NOX, THC (Continuous Monitors)
The gas chromatographs and chemiluminescient analyzers used with the
continuous off-gas monitoring equipment will be calibrated by selec-
tively opening valves on certified gas standards that direct calibrated
gas mixtures into the sampling probe assemblies on the incinerator.
The calibration gas passes through the same sample conditioning and
transfer systems to the analyzers as the actual incinerator samples.
-------
Section No: 8A
Revision No: 0
Date: Draft
Page 2 of 2
This technique not only calibrates the analyzers but corrects for
losses that can occur during sample conditioning. The calibration of
the analyzers generates a four-point calibration curve for each gas
component using a zero gas, pure nitrogen, and three standard gases
with different concentrations. The gas mixtures used for calibration
will be certified gas standards traceable to the National Bureau of
Standards where possible. The concentrations of the calibration stan-
dard gases used will be close to and will span the expected values in
the gas stream.
A four-point calibration will be conducted daily before the start of
any testing operations. A single- point calibration check, using a
Standard gas near the measured concentration of each gas, will be
conducted between each test run.
8.2 SECONDARY PARAMETERS
Some operating parameters not requiring monitoring according to TSCA
and RCRA standards include: auxiliary fuel feed rates to the kiln and
SCC, the water injection rate to the kiln, the skin temperature of the
combustion chambers and ducts, the wastewater purge rate, and the alka-
line water feed rate. The instruments used to measure these parameters
will be calibrated before the trial burn according to the
manufacturer's specifications.
-------
Section No: 9A
Revision No: 0
Date: Draft
Page 1 of 1
9. OA ANALYTICAL PROCEDURES
9.1 COMBUSTION PARAMETERS
9.1.1 No analyses are required for the following: combustion temperature,
fuel oil rates to kiln and SCC, waste oil flow rates, water flow rate
to kiln and wastewater collected in each test. These are all direct
readings from the instruments.
9.1.2 The stack and SCC flue gases will be analyzed for the important gaseous
components: 02, CO2, CO, NOX, S02, and THC. The analyzer section of
the monitoring equipment operates in conjunction with the microproc-
essor to direct sample gases to (1) the thermal conductivity detector
GC for analysis of C02/ 02, and S02; (2) though a methanizer to a
flame ionization detector GC for analysis of CO; (3) the flame ioniza-
tion detector GC for analysis of THC (compared to a methane standard);
and (4) a chemiluminescent detector for analysis of NOX. The
microprocessor generates printouts of all analytical results. A
detailed description of gas analysis procedures can be found in
Section VI of the Trial Burn Plan, Appendix 17.1.
-------
Section No: 1OA
Revision No: 0
Date: Draft
Page 1 of 4
10.OA DATA ANALYSIS, VALIDATION, AND REPORTING
10.1 DATA REDUCTION
10.1.1 Combustion Parameters
The CO and CO2 data will be used to calculate combustion efficiencies
by the following equation:
[C02]
Combustion efficiency (%) = Trv-n IT71T X 100%
Where:
[CO] = concentration of CO, percent by volume
[CO2J = concentration of C02, percent by volume
The [CO] values recorded in ppm will be converted to percent for use in
the above equation.
The average mass flow rate of waste oil will be determined by dividing
the total mass flow for a sampling period by the sample time.
If the internal calibration checks described in Section 11.0 indicate
that instruments are operating within the accepted accuracy tolerances,
any drift in calibration will be taken to be linear with time and the
data will be corrected accordingly.
1 0. 1. 2 The combustion parameter and source sampling data will be reported to
the project task manager, who will calculate destruction and removal
efficiencies (DREs) for the specific POHCs fed to the incinerator. The
ORE for any material is defined as the efficiency of the system in
destroying or removing that material from the gaseous effluent of the
incinerator. It is mathematically defined as follows:
-------
Section No: 1 OA
Revision No: 0
Date: Draft
Page 2 of 4
DRE (%) . . x 100
Where:
W in = mass feed rate of a POHC in the waste stream feeding
the incinerator, based on mass feed of waste oil and
composition
W out = mass emission rate of the same POHC present in
exhaust emissions before release to the atmosphere,
based on stack gas flow rate and concentration
10.2 VALIDATION
10.2.1 Combustion Parameters
Backup measurements will help validate the primary data. The total
contaminated solids used during each test will be measured by the
weight and volume used from prepared feed drums. An ORSAT analyses of
the stack gas will be run and compared to the gas component con-
centrations determined by the continuous monitors. The backup measure-
ment for contaminated soil quantity used must agree within ±5% of that
measurement to be valid. The ORSAT and continuous monitor analyes must
agree within ±10%.
10.3 DATA REPORTING
10.3.1 Combustion Parameters
The incinerator operators' log sheets and the continuous monitoring
system operators' logs will be used for reporting data to the task
manager. These log sheets are shown in the Appendix. Calibration
check results will be recorded in the "Remarks" sections of the log
sheets. The results of calibration checks for all instruments will be
reported along with the data in the final report.
-------
Section No: 1OA
Revision No: 0
Date: Draft
Page 3 of 4
10.3.2 Data varying more than two relative standard deviations from the mean
values will be called outliers. The outliers will be investigated by
examination of of log sheets and by comparing the results from dupli-
cate samples and backup analyses to determine the cause of the
deviation. If these efforts are unsuccessful, the outlying data will
not be used in performance assessment of the incinerator system/-
however, outliers will be reported and discussed in the final report.
10.3.3 Figure 3 shows the sampling, analysis, and reporting responsibilities
for the test burn.
-------
REPORTS TO MANAGEMENT AND EPA
EMISSION RESUl.TS
ANALYSIS
FIELD SAMPLING
SOURCE SAMPLING AND ANALYSIS
M.m k G.isns ( Incl ud i n'j Flow)
- Wu:;l(! l'ci-d:i Coiri|K).si tion
- S<•> nli!>r r l.i <|ii ids
- K I I ii Ash
- Clir:AF Ash
• I'irM and l, Audit
1
TRIAL DURN
TASK MANAGER
R. A. Miller
I t,
-*J W-
£
INCINERATOR
OPERATIONS
PROJECT .RESULTS ANpJIEPORl-J NG
- Destruction and Removal Efficiencies
- Heat and Material Balancer*
- Operating Summarien
- Reports
OPERATIONS IjOGS
OPERATORS
:ONTINUOUS MONITOR
LOGS
OPERATORS
OPERATIONS AND MONITORING
IT CORPORATION
System Conditions
Waste Feed l-'Jow
Socondary Combust ion
Temperature
Comluiutlon Gau Com[>os J lion,
(Continuous Monilorlnq)
Field Audit Sampler,
V
0)
«
Fig. 3. Data 71ow and Reporting Scheme
O D
Ml ^
Qj
J^>. l""h
rt
V cn
(D (D
5 °
03 H-
M- O
O S
3
-------
Section No: 11A
Revision No: 0
Date: Draft
Page 1 of 1
11.OA INTERNAL QUALITY CONTROL CHECKS
11.1 COMBUSTION PARAMETERS
Calibration checks will be performed as described in Section 8.0. The
operators will perform these checks with standards .of known con-
centration.
Internal operating check samples for the continuous monitors for flue
gas CO, C02/ C>2' N0x' and THC wil1 be submitted by the QA coordinator.
The concentrations of the standards supplied by the QA coordinator will
not be known by the incinerator operating personnel. These calibration
checks will be conducted approximately once per eight-hour shift.
-------
Section No: 12A
Revision No: 0
Date: Draft
Page 1 of 2
12.0A SYSTEM PERFORMANCE AUDITS
12.1 COMBUSTION SYSTEM PARAMETERS
A system audit will be made by T. J. Geisler, IT Corporation trial burn
quality assurance coordinator, before the trial burn program starts.
12.2 SOURCE SAMPLING AND ANALYSIS
The following samples will be prepared and submitted by T. J. Geisler,
for analysis before the start of the trial burn program on contaminated
soils as a performance audit of analytical procedures for PCBs and PCPs
on solids. These samples will also be submitted to another laboratory,
approved by the EPA, for analysis.
(Note: These audit samples have not yet been determined.)
-------
Section No: 13A
Revision No: 0
Date: Draft
Page 1 of 1
13.OA PREVENTIVE MAINTENANCE
13.1 COMBUSTION SYSTEM PARAMETERS
The mobile incinerator operating logs and the monitoring equipment
operating logs will be used for early identification of potential
problems that may require correction during an operating period.
Normal equipment inspection and maintenance will be performed between
test operating periods according to the equipment manufacturer's recom-
mendations.
A spare secondary combustion chamber thermocouple assembly will be kept
on hand. An adequate inventory of the recommended supplies and spare
parts for the monitoring equipment will be maintained.
-------
Section No: 14A
Revision No: 0
Date: Draft
Page 1 of 2
14.OA SPECIFIC PROCEDURES USED TO ROUTINELY ASSESS DATA PRECISION, ACCURACY,
AND COMPLETENESS
14.1 COMBUSTION PARAMETERS
At the conclusion of each trial burn test period the data collected
from the monitoring systems will be assessed in terms of precision,
accuracy, and completeness. This is to ensure that the instrumentation
is operating properly and to initiate corrective actions if equipment
performance drifts beyond specified tolerance values. Precision of the
data will be expressed in terms of the relative standard deviation
under similar conditions. It will be calculated by the following for-
mulas .
1 r
Mean = x = - J x..
where n = number of replicate measurements
x = series of replicate measurements
-x)2
Relative standard deviation = X 100%
Accuracy of the data will be expressed as the percentage of the
measured value compared to the true or accepted value. The equation
for this calculation is shown below:
Accuracy = -~- X 100%
where x = measured value
T = true value from calibration standard
-------
Section No: 14A
Revision No: 0
Date: Draft
Page 2 of 2
Completeness of the data will be expressed as the amount of valid data
V
obtained compared to the amount expected.
The importance of maintaining the performance of the incinerator moni-
tors cannot be overstressed. This equipment provides the primary
measurements for ensuring proper incinerator performance and regulatory
compliance. The equipment will be maintained in accordance with manu-
facturers specification and an ample supply of critical spare parts
will be maintained to minimize disruptions to the operation of the
incinerator. If any modifications to the identified procedures become
necessary to improve operational performance or safety the project task
manager (see Section XII) will approve all corrective actions and docu-
ment them to the EERU QA Officer.
-------
Section No: 15A
Revision No: 0
Date: Draft
Page 1 of 3
15.0A CORRECTIVE ACTION
15.1 OPERATIONAL AND MONITORING PROBLEMS
15.1.1 Combustion Parameters
Calibration checks will be performed on the waste feed ram and the SCC
thermocouple at the end of each test period. If accuracy is outside
the limits specified in Section 5.0, the instrument will be reca-
librated and put back into service- If a second calibration check
shows that accuracy is once again outside the acceptable range, the
instrument will be replaced. The drift noted in each of the calibra-
tion checks will be taken as linear with time and readings will be
corrected accordingly.
As defined in Section 11.1, internal calibration checks will be per-
formed on the continuous gas monitors. If the accuracy of each gas
measurement is within limits, source sampling will continue. If
the calibration check shows that the accuracy of any instrument is out-
side the acceptable range, source sampling will be interrupted. The
flue gas will then be analyzed again for the concentration of the com-
ponent in question after which another calibration check of the instru-
ment will be performed. Two courses of action are possible depending
on the results of the sample analysis and second calibration check.
If the sample analysis and second calibration check agree with the pre-
ceding values, then the instrument has apparently stabilized. A four
point calibration of the instrument will be conducted and the
instrument will be put back in service. Source sampling will be
resumed and the data will be treated as follows:
• All data from source sampling and unaffected combustion parameter
instruments will be valid.
-------
Section No: 15A
Revision No: 0
Date: Draft
Page 2 of 3
• Data from the affected instrument will be invalid for the time
period during which calibration drifted.
• The invalid data will be replaced with the first data point
obtained from the flue gas after the recalibration. This single
value will be applied to the parameter for the entire time period
in question.
If the sample analysis and second calibration check disagree with the
previous values, there is continuing deterioration in the integrity of
the sampling or analysis trains. No further source sampling can be
conducted until the problem has been discovered and corrected and the
equipment has been recalibrated. The data taken prior to discovery of
the problem will be invalid, and the entire test will have to be
redone.
15.2 NONCONFORMANCE AND OTHER QA PROBLEMS
A specific corrective action program for each problem will be defined
as the need may arise. In general, this program would be a step-by-
step analysis to determine where the problem originates, what actions
are required to correct the problem, or, if it cannot be controlled,
what would be the impact on the program results.
The project QA officer, V. Kalcevic, has the responsibility to promptly
communicate to the IT Corporation president, W. D. King, and the EERU
project director, K. E. Honeycutt, these nonconformance or non-
compliance type problems. He is also responsible for ensuring that the
corrective actions taken produce the desired results. As appropriate,
the IT Corporation president; the EERU project director; the EERU R&D
group manager, C. Pfrommer; the task manager, R. A. Miller; or the
-------
Section No: 1 5A
Revision No: 0
Date: Draft
Page 3 of 3
source sampling and analysis program manager, , will be
assigned the responsibility to implement the appropriate corrective
action program.
-------
Section No: 1 6A
Revision No: 0
Date: Draft
Page 1 of 1
16. OA QUALITY ASSURANCE REPORTS TO MANAGEMENT
The project QA officer, V. Kalcevic, will meet with the task manager,
R. A. Miller, and the trial burn QA coordinator, T. J. Geisler, after
the test burn operating period to review all aspects of the projects
quality assurance performance. The project QA officer will assess and
summarize the results of this meeting in a memorandum that will be
distributed to the IT Corporation president, W. D. King; the EERU proj-
ect director, K. E. Honeycutt; the EERU R&D group manager, C. Pfrommer;
the trial burn QA coordinator, T. J. Geisler; and the task manager,
R. A. Miller.
The trial burn QA coordinator will be responsible for a separate sec-
tion of the trial burn program report, which will cover:
• Assessment of measurement data precision, accuracy, and complete-
ness
« Performance audit results
• System audit results
• Significant QA problems and solutions
-------
PART B SOURCE SAMPLING AND ANALYTICAL
D90SSA
-------
Section No. : 5B
Revision No.: 0
Date: Draft
Page 1 of 4
5.OB QA Objectives
The overall measurement objective is to determine, for each of the feed
materials selected for testing/ the effectiveness of the mobile incineration
facility in achieving thermal destruction of Arochlor 1260 in soil and penta-
chlorophenol (PCP).
At the present time, the Agency has not established quantitative guidelines as
to the precision, accuracy, completeness, representativeness and/or com-
A
parability criteria that must be met by data generated in a trial burn of hazar-
dous waste. However, some specific numerical QA objectives for accuracy and
precision of the sample preparation and analysis procedures used in the analyti-
cal laboratory have been developed for this project. These guidelines are based
on ITAS's previous experience in applying comparable procedures to a variety of
complex sample matrices. In the event that the QA objectives given in this sec-
tion are not achievable due to the fact that sample matrices are highly
variable as well as complex, revised objectives will be formulated in con-
sultation with the EPA.
a. Accuracy
Accuracy is defined in QAMS-005/80 as the degree of agreement of a measurement
or average of measurements with an accepted reference or true value. In
general, our accurach goals for this project are to use reference materials of
highest, inown purity for calibrations and spiking so that determinate errors
due to instrument response and incomplete preparation recoveries can be
corrected for, so that the primary uncertainties in the analytical data are due
to random errors not exceeding those in Table 2. For this project, the QA
objectives for accurach are expressed in terms of the following parameters:
(1) Reference materials; All reference materials used as calibration standards
will be the highest purity commercially available, usually >98%. Mass
spectra of Arochlor 1260 and PCP used as reference materials will be
obtained to confirm qualitative identification.
-------
Table 2. Quality Assurance Objectives for Precision, Accuracy, and Completeness
Analysis
PCP
PCBs
Arochlor 1260
HCl
Particulate
emissions
Measurement •<
Type Matrix Reference
GC/MS 1,4,5,6
GC/EC 1,4,5,6,7 ITAS-SOP
GC/MS 1,4,5,6,7 ITAS-SOP
Titrimetric 1 EPA 325.3
Gra vime tri c 2,6
Precision
Relative Accuracy As
STD/Dev. % Recovery
<30 >50
<30 >50
<30 b
<10
<10
Completeness
95
95
b
95
95
b
Matrix code
1 - MM5 train, discrete components except impingers
2 - EPA Method 5 train
3 - Ambersorb/Tenax traps
4 - Scrubber water
5 - Kiln ash
6 - CHEAP ash
7 - Arochlor spiked soil
GC/MS, operated in the select ion monitoring mode, will be used as a verification tool on select samples,
^d o ?d en
u> p> OP a>
tQ rt 2! 0
^ t-h O •
ft • ••
Ul
o dd
-------
Section No.: 5B
Revision No.: 0
Date-. Draft
Page 3 of 4
(2) Instrument Performance: Each instrument used in this project will be
checked on each day that samples are analyzed to demonstrate performance.
One of the QA objectives is that the absolute instrument response (e.g.,
area counts/ng injected for the internal standard(s) and/or surrogates in a
GC/MS analysis) can be within 50% of the value of comparable measurements
made subsequent to the most recent calibration of the instrument.
(3) Recovery of Arochlor 1260 and PCP; The recovery of Arochlor 1260 and PCP
will be defined as follows:
_ (ug P found in spiked sample - |ag P in native sample) v . nn
Recovery, % = -U—? *• ^ r^—;—*.— -'* ; — X 100
* ng P added to sample
b. Precision
Precision is defined in QAMS-005-80 as a measure of mutual agreement among indi-
vidual measurements of the sample property. For this project, the QA objectives
for precision are expressed in terms of the following parameters:
(1) Analysis of Standards: One of the QA objectives for this project is that
the correlation coefficient for each calibration curve, including all data
points for standards analyzed subsequent to the most recent recalibration
of the instrument, should be >0.90.
(2) Analysis of Surrogates: Another QA objective for this project is that the
standard deviation for analysis of surrogate compounds in replicate samples
from a given waste stream be within the limits specified in Table 2.
(3) Analysis of Replicate Samples: A final QA objective is that the results of
directed analysis of laboratory replicate samples (i.e., replicate samples
drawn from the same field composite sample) be within the limits specified
in Table 2, when at least three replicate samples are analyzed. At least
10% of all analyses performed will be duplicate QA checks.
-------
Section No. : 5B
Revision No. : 0
Date: Draft
Page 4 of 4
c. Completeness
The QA objective for this program is to obtain analytical results for at least
95 percent of the samples collected during this program.
d. Representativeness
The following factors are addressed elsewhere in this trial burn plan
(Sections III and IV) in order to ensure as much as possible a representative
sample: sampling sites, process cycles, catch flow rates (sampling frequency),
sample preservation, and sampling procedures and equipment.
e. Comparabili ty
All data will be reported in mg, ug or ng of analyte per kilogram, liter, or
cubic meter of original sample. When precise recovery values for a given com-
ponent are known, the recovery information and the corrected concentration data
will also be provided.
-------
Section No. ; 6B
Revision No. : 0
Date: Draft
Page 1 of 3
6. OB Sampling Procedures
a. Sample Collection
Sample locations and numbers of samples for soil (spiked with Arochlor 1260 and
PCP feed), diesel fuel, makeup water, kiln ash, purge water, alkaline scrubber
solutions, and CHEAP filter ash are detailed in Table 3.
b. Modified Method.5 (MM5) Sampling
ITAS recognizes the value of conducting modified method 5 (MM5) sampling with
the same train configuration which has been employed for previous performance
tests' on this mobile inicnerator. The MM5 train illustrated in Fig. 4 will be
utilized for the collection of stack gas samples.
c. Sorbent Trap Composition
The front sorbent trap in the MM5 Train (Fig. 4) will contain Florisil; the
backup sorbent trap will contain XAD-2 resin.
d. Particulate Sampling
Particulate sampling procedure will be in accordance with the U.S. EPA par-
ticulate method.
e. HC1 Sampling
HC1 samples will be collected by use of a sodium hydroxide solution in the
caustic scrubber traps of the MM5 Train (Fig. 4).
-------
Table 3. Summary of Trial Burn Analytical Procedures
Sample
soil
feed and PCP
Diesel fuel
Make-up water
Kiln ash
Purge water
Alkaline
scrubber
soluti on
CHEAP'
Stdck sample
Stack sample
Sampling Method
and Frequency
Number of Samples
Analyzed for
Tests 3 arid 2
Analysis
One composite sample
per run (2 grabs)
One grab sample per
delivery/ composite
sample for one
analysis per lot
One sample per stage
One sample per DRE test
(if any)
One composite sample
per DRE run
Daily composite
(1 hr grabs)
Weekly grabs
Weekly grabs
Weekly composite
One grab sample per batch
Composite grab sample
One sample per DRE run
Modified Method 5
One sample per DRE run
(three samples per test)
U.S. EPA Method 5
(three samples per test)
Gas bag, one per run
6
6
6
2
2
1
1
3
3
3
3
15
2
2
2
2
3
3
3
3
3
6
Organic Cl, density
Heat value, ash, moisture
Arochlor 1260 or PCP
Organic Cl
Density, ash, moisture, heat value
Presence of Arochlor 1260, PCP
Presence of Arochlor 1260
Presence of PCP
Presence of PCP
Presence of Arochlor 1260
Presence of Arochlor 1260
Presence of PCP
Total organic carbon, pH, temperature
Total suspended solids
Total dissolved solids
PCBs, PCP
PCBs, PCP
Presence of Aroohlor 1260
Presence of PCP
Arochlor 1260 emission rate
PCP emission rate
I1C1 emission rate**
Particulate emission rate
02 , co2
Analytical Method
Standard method (where appropriate)
Standard method (where appropriate)
GC/EC or GC/MS
Standard method (where appropriate)
Standard method (where appropriate)
Extraction, concentrate, GC/EC or GC/MS
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/MS*
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/MS
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/MS
Standard methods (where appropriate)
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/MS
Extraction, concentrate, GC/EC*
Extraction, concentrate, GC/MS
Scrubbing, Standard Method 325.3
EPA Particulate Method 5
'Positive results confirmed by GC/MS.
*«PCB runs will not be analyzed for I1C1 since HC1 emission rate
will be <4 Ib/hr
[D fU CD (D
uq ft < O
CD (D H- rt-
•• ra H-
KJ I-1- O
O 0
OOP
H) H 2;
P> 2! O
LO Hi O •
rt • ••
O
-------
FIGURE /|
ORGANIC SAMPLING TRAIN
SENSOR
ft
. LJw
HEATED AREA
\ I FAC*
___^y LJWALL
THERMOMETER
FILTER HOLDER
HERMOCOUPLE WELL
CONDENSER '
/ /80RBENT TRAPS
REVERSE TYf E
mOTTUBC
X
-r
^1
3
f ITOT MANOMETER
nECIHCULATION PUMP
CHfCK
VALVE
/
VACUUM LINE
KNOCK-OUT TRAPS
THERMOMETERS
£_J (^ J av-fAss VALVE
rt&i—^Q.
v>«3-
MAIN
VALVE
~O O ZQ CO
(D Q) CD CD
iQ n- < o
CD CD H- rt-
-• 0) H-
H- O
u>
O J _„
O hi 2
l-h pj 2 O
Hi ° •
co rt •
en
- W
o
DRYGASM£TE« AIR-TIGHT
-------
Section No.: 7B
Revision No.: 0
Date: Draft
Page 1 of 6
7.OB Sample Custody
The sample custody procedures to be used for this program conform to the guide-
lines of SW-846, Section 2.0. The Sampling Coordinator will be responsible for
sample custody in the field.
The Quality Control and Data Manager will be responsible for acting as the
sample custodian at the ITAS laboratories.
a. Field Chain-of-Custody
Before collecting samples in the field, the sampling coordinator will issue num-
bered sample tags to field samplers (Fig. 5). Field samplers will label each
sample collected, filling the appropriate information in waterproof ink. The
cap of each container will be sealed with a paper tape bearing the sample
number. The field sampler will be responsible for collecting the samples and
for logging the samples into assigned field notebooks until they are transferred
to the sampling coordinator. The sampling coordinator will acknowledge receipt
of the samples from the field sampler in writing and verify that chain-of-
custody procedures have been followed. He will then transcribe the field sample
information to the Chain-of-Custody record (Fig. 6) and assign an ITAS Labora-
tory Number. The original of the Chain-of-Custody record will remain with the
sample at all times. In addition, a sample analysis request sheet (Fig. 7) will
accompany sample.
b. Transfer of Custody
The sampling coordinator will transfer custody of all samples to the analysis
coordinator who will acknowledge receipt on the Chain-of-Custody record.
Samples which are to be shipped will be accompanied by the Chain-of-Custody
records, with appropriate signatures.
c. Laboratory Custody Procedures
The QC and Data Manager will immediately acknowledge receipt of sample in
-------
Section No. 7B
Revision No. 0
Date: Draft
Page 2 of 6
YORK RESEARCH CORP.
( SAMPLE
1.0.
Figure 5. Sample Bottle Label
IT ANALYTICAL SERVICES, IN(
-------
Date Sample Taken:
Time Sample Taken:
Person Taking Sample:
Sample Location:
Reason For Sampling:
CHAIN OF CUSTODY FORM
IT Analytical Services, Inc.
Stewart Laboratories Division
Section No. 7B
Revision No. 0
Date: Draft
Page 3 of 6
Sample Number:
IT Lab Number:
Other Related Samples (Taken by IT or other organization):
Type of Sample:
Container Size:
Liquid
Gas
Sludge Other (specify):
Container Type:
Quantity of Sample Taken:
Person whom results, original of this form and remaining sample should be returned to:
SAMPLE TRANSFER
1
2
3
Relinquished by:
Received by:
Relinquished by:
Received by:
Relinquished by:
Received by:
(Name)
(Name)
(Name)
(Name)
(Name)
(Name)
(Organization)
(Organization)
(Organization)
(Organization)
(Organization)
(Organization)
(Date/Time)
(Date/ Time)
(Date/Time)
(Date/Time)
(Date/Time)
(Date/Time)
ORIGINAL MUST BE RETAINED WITH SAMPLE AT ALL TIMES
FIGURE 6
-------
Section No. 7B
Revision No. 0
Date: Draft
Page _4 of 6
SAMPLE ANALYSIS REQUEST
Collector (s)
Company Affiliation:
IT Analytical Services, Inc.
Stewart Laboratories Division
5815 Middlebrook Pike
Knoxville, TN 37921
(615) 588-6401
Case Number
Location of Sampling:
Date 4 Time of Collection:
Collector's Laboratory Type of Analysis
Sample No. Sample No. Sample Requested
-Field
Information
Samples Received By
Comments
Title
Date
FIGURE 7
IT ANALYTICAL SERVICES, INC
-------
Section No. : 7B
Revision No.: 0
Date: Draft
Page 5 of 6
writing. She will verify that the information on the sample tags matches the
information in the Chain-of-Custody records. She will then log in all samples
by previously assigned laboratory identification numbers, every sample having a
unique, non-recurring laboratory number. The log notebook will include the
field number, date of receipt, condition of sample when received, a qualitative
description, the assigned laboratory number, sample preparation (spiking, etc.),
sample distribution, and any other information deemed appropriate. The QC and
Data Manager will be responsible for preparing and introducing control samples,
blanks, and check standards.
Samples will be kept in refrigerated storage when not being analyzed. Sample
distribution sheets (Fig. 8), will also accompany the samples. The analysis
coordinator will be responsible for preparing the sheets.
The analyst will be responsible for samples during analysis and for logging
laboratory analysis information.
-------
SAMPLE CATEGORY:
FROM:
Name
SAMPLE PREPARATION:
TO:
Name
SAMPLE NO.:
Section No. 7B
Revision No. 0
Date: Draft
Page 6 of 6
Project Code
'SAMPLE DISTRIBUTION SHEET
Emp.No. Signature
Emp.No.
Signature
Date
Name
ANALYSIS:
TO:
Name
STORAGE:
TO:
Emp.No. Signature , Date
i
Emp.No. Signature • Date
Cl
Date
FIGURE 8
IT ANALYTICAL SERVICES, INC
-------
Section No. : 8B
Revision No.: 0
Date: Draft
Page 1 of 5
8.OB Calibration Procedures and Frequency
a. Sampling
Calibration of stack sampling equipment will be performed within two weeks pre-
vious to initiation of field sampling. The procedures will conform to the spe-
cifications of the EPA document, Quality Assurance Handbook for Air Pollution
Measurement Systems, Volume III, Stationary Source Specific Methods (von Lehmden
£t ai., EPA-600/4-77-027b, January 1980). Dry gas meters, nozzles, orifices,
and pitot tubes will be covered in the calibration. Tables 4 and 5 summarize
the methods to be used.
The dipper (waste feds and scrubber water) and scoop (ash samples) require no
calibration.
b. Analytes
(1) Instrument Performance and Tune
i. At the outset of the analytical activity for this program, a perfor-
mance check on each instrument will be made to demonstrate compliance
with manufacturer's specifications.
ii. Before analysis of each set of samples and on a daily basis during the
analysis, the instrument will be tuned to meet an operating perfor-
mance standard. The tuning criteria for the organic analyses are:
GC/MS Federal Register, 12/3/79
Method 625
GC/EC ITAS-SOP
-------
Section No. SB
Revision No. 0
Date: Draft
Page 2 of 5
Table 4
ACTIVITY MATRIX FOR CALIBRATION OF EQUIPMENT
Apparatus
Acceptance limits
Frequency and method
of measurement
Action if
requirements
are not met
Wet Test Meter
Capacity >_3.4 nr/h
(120 ft 3/h); accuracy
within ±1.0?i
Calibrate initially,
and then yearly
by liquid dis-
placement
Adjust until
specifications
are met, or
return to manu-
facturer
Dry gas meter
= Y ±0.02 Y
Calibrate vs wet
test meter initially,
and when posttest
check exceeds
Y ±0.05 Y
Repair, or re-
place and then
recalibrate
Thermometers
Impinger thermometer
±1°C (2°F); dry gas
meter thermometer
±3°C (5.4°F)'. gver
range; stack tempera-
ture sensor ±1,5% of
absolute temperature
Calibrate each ini-
tially as a separate
component against a
mercury-in-glass
thermometer; then
before each field
trip compare each as
part of the train
with the mercury-in-
glass thermometer
Adjust; de-
termine a con-
stant correc-
tion factor;
or reject
Probe heating
system
Capable of maintaining
120° ±14°C (248° ± >
25°F) at a flow rate of
20£/min (0.71 ft3/min)
Calibrate component
initially by
APTD-0576; if con-
structed by APTD-
0581, or use
published calibra-
tion curves
Repair, or re-
place and then
reverify the
calibration
Barometer
±2.5mm (Q.I in.) Hg of
mercury-in-glass barom-
eter
Calibrate initially
vs mercury-in-glass
barometer; check
before and after
field test
Adjust to
agree with a
certified
barometer
Probe nozzle
Average of three ID
measurements of nozzle;
difference between high
and low _<0.1 mm
(0.004 in".)
Use a micrometer to
measure to near-
est 0.025 mm (0.001
in.)
Recalibrate,
reshape, and
sharpen when
nozzle becomes
nicked, dented,
or corroded
(continued)
IT ANALYTICAL SERVICES, INC.
-------
Section No. SB
Revision No. 0
Date: Draft
Page 3 of 5
Table 4 (continued)
Apparatus
Acceptance limits
Frequency and method
of measurement
Action if
requirements
are not met
Analytical
balance
± mg of Class-S
weights
Check with Class-S Adjust or
weights upon receipt repair
Source: EPA-600/4-77-027b
IT ANALYTICAL SERVICES, INC
-------
Section No. 8B
Revision No. 0
Date: Draft
Page 4 of 5
Table 5
ACTIVITY MATRIX FOR CALIBRATION OF APPARATUS
Apparatus
Type S pitot
tube and/or
probe
assembly
Stack gas tem-
perature
measurement
system
Barometer
Differential
pressure
gauge (does
not include
inclined
manometers)
Acceptance limits
All dimension speci-
fications met, or
calibrate according
to Sec 3.1.2, and
mount in an interfer-
ence free manner
Capable of measuring
within 1.5% of minimum
stack temperfture
(absolute)
Agrees within 2.5 mm
(0.1 in.) Hg of
mercury-in-glass
barometer
Agree within ±5% of
inclined manometers
Frequency and method
of measurement
When purchased, use
method in Sees 3.1.1
and 3.1.2; visually
inspect after each
field test
When purchased and
after each field
test, calibrate
against ASTM 3C or
Initially and after
every field use,
compare to a liquid-
in-glass barometer
Initially and after
each field use
Action if
requirements
are not met
Do not use
pitot tubes
that do not
meet face
opening
specifica-
tions; re-
pair or re-
place as re-
quired
Adjust to
agree with Hg
bulb thermom-
eter, or con-
struct a cal-
ibration
curve 'to cor-
rect the
readings
Adjust, re-
pair, or
discard
Reject test
results, or
consult
administra-
tor if post-
test calibra-
tion is out
of specifi-
cation
IT ANALYTICAL SERVICE'S, INC.
-------
Section No. : 8B
Revision No. : 0
Date: Draft
Page 5 of 5
iii. For directed analysis of Arochlor 1260 and PCP the daily performance
check will iclude analysis of at least one blank and one standard
prior to analysis of samples.
iv. The absolute instrument response to the internal standard (if any)
will be noted at the completion of each sample analysis. A variation
of >±50% will be a signal for recalibration/retune.
(2) Calibration Curve
.For directed analyses of Arochlor 1260, PCP, and HCE, the GC/EC and GC/MS
analysis procedures will be calibrated before the anaysis of each batch of
samples by analyzing known mixtures of the group of test compounds under
study at at least three concentration levels. Any tendency for the
calibration curve to drift will be monitored by reanalyzing at least one of
the standards daily. A new calibration curve will be established if the
response observed in the reanalysis of the standard varies by ±20% from
that predicted from the previous calibration curve.
-------
Section No. : 9B
Revision No. : 0
Date: Draft
Page 1 of 2
9.OB Analytical Procedures
The analytical procedures to be used in this program are given in Section VI of
this trial burn plan.
A general description of the analytical methodology is listed below:
a. Quantitation of Arochlor 1260 by Gas Chromatography/Electron Capture (GC/EC)
Because of the low level (40 to 49 ug/g) of Arochlor 1260 in the soil to be used
in this test and the predicted destruction efficiency (>99.99%), the only prac-
tical detection device for the quantitation of the Arochlor 1260 pattern is the
electron capture detector which is more sensitive that the GC/MS. Samples and
extracts representing discrete MM5 sampling train components will be analyzed by
GC/EC followed by compositing them together and further extract concentration
and re-analysis by GC/EC. If the resulting concentration level is adequate, the
concentrated composit extract will be analyzed by GC/MS using the selected ion
monitoring mode for some of the discrete Arochlor 1260 isomers.
b. Quantitation of Pentachlorophenol by GC/MS
The analysis of pentachlorophenol will be performed using Method 8250, "GC/MS
Method for Semivolatile Organics: Packed Column Technique," Test Methods for
Evaluating Solid Waste, July 1982, SW-846, Second Edition.
c. Sorbent Extraction Procedure
ITAS will employ an ultrasonic assisted desorption procedure for all sorbent
samples.
d. Analysis of Particulate for Arochlor 1260 and PCP
The filter will be extracted by an ultrasonic assisted desorption procedure
using hexane. This extract will be analyzed for Arochlor 1260 or PCP.
-------
Section No.: 9B
Revision No.: 0
Date: Draft
Page 2 of 2
e. Chloride Analysis
Impingers from the Modified Method 5 train, water rinse of these impingers, and
scrubber water samples will be analyzed for chloride by EPA Method 325.3.
Chloride results will be confirmed by use of ion chromatography.
-------
Section No.: 1 OB
Revision No.: 0
Date: Draft
Page 1 of 10
10.OB Data Reduction, Validation, and Reportings
a. Data Reduction
Raw data for the directed quantitative analysis procedure to be used in this
project (GC/MS) will consist of peak areas of characteristic ions for the analy-
tes of concern. Raw data will be converted to concentrations by use of a
calibration curve that related peak area to the quantity of analyte introduced
into the instrument. A calibration curve for each analyte/analytical method
will be constructed by fitting the results of the analyses of calibration stan-
dard solutions containing the analyte at three different concentration levels.
The raw data will usually be converted to concentration of analyte in the sample
by software in our Finnigan Incos Laboratory Data System or by the analyst.
Peak areas for the series of known calibration standards are first entered and a
regression line is computed. A plot of the calibration curve with the actual
calibration data superimposed on it is immediately generated on a high speed
printer/plotter for examination. Peak areas from the analyses of unknowns are
then entered, corresponding quantities of analyte are computed from the
regression line, and a summary of the raw and converted data is printed. The
original copy of the data summary will be included in the project work file and
be received by the Program Manager.
Raw data for the GC/EC quantitative analysis procedure to be used in this pro-
ject will consist of peak heights. Raw data will be converted to concentrations
by use of response factors that relate peak height to the ten quantity of
analyte introduced into the instrument after the response of standards have been
shown to be linear by developing three-point calibration curves. A minimum of
two standard checks will be run during each shift (at beginning and end of
shift) to assure that response is within 10% of calibration curve. See
Section 13 of the appended ITAS-Stewart Labs Div. SOP for details.
-------
Section No.: 1 OB
Revision No.: 0
Date: Draft
Page 2 of 10
As the possibility exists that incineration and sample collection and recovery
techniques could cause alteration of Arochlor patterns, the major peaks in the
Arochlor 1260 pattern will be quantitated; and both the average value and
highest value will be reported.
b. GC/MS Analyses
An internal standard (such as d-\ g-anthracene) will be added to each standard
solution or concentrated sample extract immediately before analysis. The quan-
tity added will be sufficient to give the same concentration (pg/mL) of internal
standard in all solutions/extracts analyzed.
The calibration curve will be based on the response factor (RF) where:
RF = (AsCis)/(AisCg)
Where:
A_ = Response for the parameter to be measured
s
AJ _ = Response for the internal standards
J. o
Cj_ = Concentration of the internal standard in Mg/1
GS = Concentration of the compound to be measured in pg/l
If the RF value over the working range is constant (less than 20% relative stan-
dard deviation), the RF can be assumed to be invariant and the average RF can be
used for calculations. Alternatively, the results can be used to plot a
calibration curve of response ratios, Ag/Aj_s, against RF.
-------
Section No. : 1 OB
Revision No.: 0
Date: Draft
Page 3 of 10
The concentration of analyte or surrogate in an unknown sample will be calcu-
lated as follows:
Concentration in Extract, C* (ng/uL)
C* (ng/pL) = As'Cis
Ais.RF
Where:
As = Response for the parameter to be measured
= Response for the internal standards
J0
J.O
J_ = Concentration of the internal standard in ng/yl
.L5
RF = Response factor for the parameter to be measured.
Concentration in Sample, C (mg/L or mg/kg)
C is calculated from C*; the volume of the concentrated sample extract, Vx;
and the initial quantity of sample extracted.
For awueous liquids, organics liquids, slurries:
C (mg/L) = C*-VX * 100Q
For solids, sludges:
W
s
-------
Section No.: 1 OB
Revision No.: 0
Date: Draft
Page 4 of 10
Where:
C* = Concentration in extract, ng/jjL = ug/mL
Vv = Volume of concentrated extract, mL
A
Vg = Volume of sample taken for extraction, L
Ws = Weight of sample taken for extraction, kg
c. Data Validation
The principal criteria that will be used to validate the data integrity during
collection and reporting of data are:
(1) Verification on a weekly basis by the QC and Data Manager that all raw data
generated in the preceding week have been stored on magnetic tape and/or in
hard copy and that storage locations have been documented in the laboratory
chain-of-custody records.
(2) Examination of at least 5% of the raw data (e.g. chromatograms, AAS
recorder outputs) on a weekly basis by the analysis coordinator to verify
adequacy of documentation, confirm peak shape and resolution assure that
automatic integrator was sensing peaks appropriately, etc.
(3) Confirmation that raw areas for internal standards and calibration stan-
dards are within 50% of expected values (see Section 5B).
(4) Reporting of all associated blank, standard, and QC data along with results
for analyses of each batch of samples.
-------
Section No.: 1 OB
Revision No. : 0
Date: Draft
Page 5 of 10
(5) Reporting of all analytical data for samples with no values rejected as
outliers, because of the small number of replicate samples for analysis.
d. Reporting
Results of directed analysis, survey analysis and proximate analysis will be
reported in the formats illustrated by Figs. 9 through 13.
Reports shall include documentation as outlined in Appendix 2. Protocol for
Sample Analysis Reports.
-------
Section No. 10B
Revision Mo. 0
Date: Draft
Page 6 of 10
GC/MS DIRECTED ANALYSIS REPORT FORM
Contractor
Analyst Responsible
Instrument
Date
Analysis Method
Column
Column Temo.
Preparation Method
Sample ID No.
Compound Identified
Surrogate
Concentration, yg/L(kg)
Corrected
Data
Recovery
Factor
Uncorrected
Data
Percent Recovery
Fig. 9
-------
Section No. ]_QB
Revision No. 0
Date: Draft
Page 7 of 10
MAJOR COMPONENTS
GC/MS SURVEY REPORT FORM
Contractor
Sample ID Number
Sample Description
Analyst Responsible
Instrument
Column
Date Analyzed_
Time
GC Temperature Program_
Observations
Results:
Compound
Identified
Peak Rel.
Intensity
RRT.
Goodness of
Fit Criterion
Fig. 10. GC/MS Survey Report Form
-------
Section No. 10B
Revision No. 0
Date: Draft
Pacre 8 of 10
MASS SPECTROMETRIC SURVEY ANALYSIS REPORT
Contractor
Sample ID Number
Sample Description
Analyst Responsible_
Instrument
Date Analyzed_
Time
Observations
Results
Major Categories, Subcategories, Specific Compounds:
Intensity
Category
MV Range
Fig. 11. LRMS Analysis Report
-------
Section No. 10B
Revision No. 0
Date: Draft
Page 9 of 10
IT CORPORATION
STEWART LABORATORIES DIVISION
CERTIFICATE OF ANALYSIS
TO:
DATE REPORTED:
CODE:
ORDER No.:
SAMPLE DESCRIPTION:
CONCENTRATION UNITS ARE
ITAS Samole No.
Identification
Aroclor
1242
and/or 1016
Aroclor
1254
Aroclor
1260
Total
Aroclors
Sworn to and subscribed before me this
day of
IT ANALYTICAL SERVICES, INC.
NOTARY PUBLIC
My commission expires
By
Subsidiary of IT Corporation
IT Analytical Services • 5815 Middlebrooic Pike • Knoxviile. Tennessee 37921 • 615-583-6401
. 12.
RGB Report Form
-------
Sample
Analyst or
Moisture, Solids, Ash Content % Laboratory Date
Moisture
Solids
Ash
Elemental Composition
Carbon
Nitrogen
Sulfur
Phosphorus
Fluorine
Chlorine
Bromine
Iodine
Total Organic Carbon
Total Organic Halogens
Tl O IX) CO
(U (U (D (D
CIQ rr < O
(D fU H- rr
•• W H-
(-< H- O
O 00
a 3
O ht 25
Hi P) & O
Fig. 13. Proximate Analysis Reporting Form (-. ^ °
O M
O
O M
-------
Section No.: 11B
Revision No.: 0
Date: Draft
Page 1 of 2
11.OB Internal Quality Control Checks
Section 5B specifies the guidelines for number and frequency of replicate and
spiked QC samples and calibration standards to be used in the project, including
identity and concentration of surrogate spike compounds to be added to each
designated sample.
Quality control samples will be analyzed in the same way as field samples and
interspersed with the field samples. The results of analyzing these samples
will be used to document the validity of data and to control the quality of data
within predetermined tolerance limits (see Section 5B). QC samples are as
follows.
a. Blank Samples
These samples are analyzed in order to assess possible contamination from the
field and/or laboratory, so that corrective measures may be taken, if necessary.
Blank samples include:
• Field Blanks - These blank samples are exposed to field and sampling con-
ditions, and analyzed in order to assess possible contamination from the
field (one for each type of sample preparation).
* Method Blanks - These blank samples are prepared in the laboratory and are
analyzed in order to assess possible laboratory contamination (one for each
lot of samples analyzed).
• Reagent and Solvent Blanks - These blanks are prepared in the laboratory
and analyzed in order to determine the backgound of each of the reagents or
solvents used in an analysis (one for each new lot number of solvent or
reagent used).
b. Analytical Replicates
Replicate analyses of specific samples may be undertaken by the analyst to check
on the validity of certain analogous samples. For example, if the internal
standard response for a specific sample changes drastically from its prior
-------
Section No.: 11B
Revision No.: 0
Date: Draft
Page 2 of 2
value, a problem could be present in the instrument or in the sample workup.
Repeat analyses of the sample in question and a previous "normal" sample will
serve to indicate which of the possible problems is, in fact, present.
Spiked Samples
All samples will be spiked with one or more selected surrogate compounds before
extraction and analysis. The data on surrogate concentration will be used to
calculate the recovery of the surrogate compounds as one measure of the accuracy
of the sample preparation and analysis procedures.
For direct analysis of Arochlor 1260 or PGP, one sample from each set of three
replicates will be spiked with the analyte interest at a concentration of 100 to
1000 ppm. Depending on the concentration of analyte in the unspiked sample,
these data may provide an estimate of the recovery of the species of interest
from the sample matrix. A spiked blank sample for each method will also be ana-
lyzed in order to assess the inherent accuracy of an analytical method.
-------
Section No.: 1 2B
Revision No. : 0
Date: Draft
Page 1 of 1
12.OB Performance and System Audits
A system audit by the Program Manager and the Quality Control and Data Manager
will be made before the implementation of any new experimental procedures in our
labortories.
System audits in this program will largely consist of a weekly review of all
recent data to ensure that all required QC checks are being made and evaluation
criteria followed. The Quality Control and Data Manager will participate in
these reviews on at least a monthly basis. Because of the anticipated dif-
ficulty in obtaining reference samples with matrices similar to the waste
samples we will be analyzing, performance audits will rely heavily on the repli-
cate analyses of real samples, spiked and unspiked. However, we will be alert
to opportunities to use standard reference materials as a means of auditing
performance.
During the course of systems audits, the Quality Control and Data Manager will
remain sensitive to the possible need for additional peer review of one or
another aspect of the program, and she will suggest the inclusion of other
appropriate ITAS staff in the audit process whenever necessary.
In addition, ITAS will participate in the analysis of audit samples supplied by
the Trial Burn QA Coordinator and control agencies or their representatives.
-------
Section No.: 13B
Revision No.: 0
Date: Draft
Page 1 of 1
13.OB Preventive Maintenance
The hardware associated with the GC/MS/DS and GC/EC systems used for analyses
require very little in the way of regularly scheduled preventive maintenance.
Chromatographic carrier gas purification traps and injector septa are replaced
on a regular basis. The pump seals need to be replaced more or less frequently
depending on the types of solvents employed.
Most maintenance, however, such as column replacement, detector cleaning, source
cleaning, filament replacement, etc. , must be performed on an as-needed basis
when performance begins to degrade as evidence by degradation of peak resolu-
tion, decreased ion sensitivity, shift in calibration curves, or failure to meet
one or another of the QC check criteria.
Adequate supplies of spares including GC columns, septa, syringes, and MS fila-
ments and separators are maintained so that they are available when needed.
-------
Section No. : 1 4B
Revision No. : 0
Date: Draft
Page 1 of 2
14. OB Specific Routine Procedures Used to Assess Data Precision,
Accuracy and Completeness
a. Calculation of mean values and estimates of precision
The mean, C of a series of replicate measurements of concentration, Cj_, for a
given surrogate compound or analyte will be calculated as:
n
C = J_ Z
n i
where n = number of replicate measurements; C, Cj_ are both in mg/L or mg/kg.
The estimate of precision of a series of replicate measurements will usually be
expressed as the relative standard deviation, RSD:
RSD SD X 100%
where SD = Standard deviation
n
SD = E (Cj_ - C)
i = 1
(n = 1)
Alternatively,' for the data sets with a small number of points (e.g. concentra-
tion of pesticide in duplicate samples of one waste stream), the estimate of
precision may be expressed as a range per cent, R:
-------
Section No.: 1 4B
Revision No. : 0
Date: Draft
Page 2 of 2
R = C1 - C2 X 100%
where C-j = highest concentration value measured in data set
C2 = lowest concentration value measured in data set
The standard deviations calculated will be compared on a weekly basis with the
respective goals identified in Section 5B.
b. Assessment of Accuracy
Accuracy will be evaluated by comparing the mean recovery of surrogate compounds
on a weekly basis against the goals identified in Section 5B. The recovery of a
surrogate compound will be defined as:
C . V (or W ) X 100
Recovery, % = s s s_
~tr
where C = measured concentration of surrogate compound in sample, mg/L (or
V (W ) = Total volume (or weight) of sample to which surrogate was
S S
added, L (or kg)
Q = Quantity of surrogate compound added to sample, mg.
5
-------
Section No.: 15B
Revision No.: 0
Date: Draft
Page 1 of 2
15.OB Corrective Action
For each analytical method employed in this program we will regularly track pre-
cision and accuracy by computing the standard deviation or range of the results
of replicate analyses. We will make periodic determinations of recovery of the
surrogates. The mean recovery and the standard deviation of the replicate set
will be computed. These data will be accumulated for each kind of sample matrix
analyzed, e.g., solid, stack gas sample, aqueous liquid, ash. These statistics
will be updated from lot to lot as additional analyses are geing performed and
more experience is gained. When either the relative standard deviation of
replicate results, the average recovery, or the relative standard deviation of
replicate recoveries exceeds twice the most recently updated acutal values for
those statistics or the performance goals, whichever is more stringent, correc-
tive action will be taken to improve performance before analyses of the next
lot.
If during system or performance audits, weaknesses or problems are uncovered,
corrective action will obviously be initiated immediately.
Corrective action will include, but not necessarily be limited to: recalibra-
tion of instruments using freshly prepared calibration standards; replacement of
lots of solvent or other reagents that give unacceptable blank values; addi-
tional training of laboratory personnel in correct implementation of sample pre-
paration and analysis methods; and reassignment of personnel, if necessary, to
improve the overlap between operator skills and method requirements.
Whenever a long-term corrective action* is necessary to eliminate the cause of
nonconformance, the following closed-loop corrective action system* will be
used. As appropriate the sample coordinator, analysis coordinator, or the
program manager will ensure that each of these steps are followed:
-------
Section No.: 15B
Revision No.: 0
Date: Draft
Page 2 of 2
The problem will be defined
Responsibility for investigating the problem will be assigned
The cause of the problem will be investigated and determined
A corrective action to eliminate the problem will be determined
Responsibility for implementing the corrective action will be assigned
and accepted
The effectiveness of the corrective action will be established and the
correction implemented
The fact that the corrective action has eliminated the problem will be
verified
*"Quality Assurance Handbook for Air Pollution Measurement Systems - Volume
Principles," EPA-600/4-76-005, January 1976.
-------
Section No.: 16B
Revision No.: 0
Date: Draft
Page 1 of 1
1 6B. Quality Assurance Reports
a. Quality Assurance Reports to Management
The Program Manager, the Quality Control and Data Manager, and the Sampling
Coordinator and the laboratory task leaders, meet on a regular basis to
assure that all QA/QC practices are being carried out and to review
possible or potential problem areas. It is important that all data anoma-
lies be investigated to assure that they are not a result of operator or
instrument deviation but are a true reflection of the methodology or task
function.
The Quality Control and Data Manager documents the results of blind spikes
and performance standards in a. central logbook which is also reviewed
periodically with the program manager.
b. Quality Assurance Reports to the EPA
The final report will contain a separate section or statement that covers
the data quality and validity. At a minimum, the following information
will be covered:
• Assessment of measurement data precision, accuracy, and completeness
• Performance audit results
• System audit results
• Significant OA problems and recommended solutions
-------
APPENDIX 1
STANDARD OPERATING PROCEDURE
FOR ANALYSIS OF PCBs
-------
I. Scope and Application
l.L This method covers the determination of polychlorinaced biphenyls
(PCB's) and certain organochlorine. pesticides, including some deg-
radation products and related compounds in all vater matrices —
i.e., drinking water, raw source water, wastewater and industrial
effluents. The following PCB's may be determined by this method:
Aroclor
(R)
1016
1221
1232
1242
1243
1254
1260
1262
EPA Storet No.
34671
39438
39492
39496
39500
39504
39503
Additional specific compounds which may be determined by this method
include:
Parameter
Aldrin
a-3HC
b-BHC
d-BHC
g-BHC
Captan
Carbophcnothion
Chlordane
4,4'-ODO
Storet No.
Parameter
Storet N'o
39330
39337
39338
39259
39340
39640
39350
39310
Endosulfan II
Endosulfan Sulfate
Endrin
Endrin Aldehyde
Heptachlor
Heptachlor Epoxide
T ff f\f^ r"^ *"i
LSOC L .. n
Methoxychlor
Mirex
34356
34351
39390
34366
39410
39420
39430
39430
39755
(continued)
41
revised 1/30
Stewart Laboratories, lac.
Knoxvllle, Tennessee 37921
-------
Parameter Storat Mo. Parameter Scorec !'o.
4,4'-DDE 39320 PCS 3 39029
4,4'-DDT 39300 Perchane 39034
Dichloran Strobane
Dicofol 39730 Toxaphene 39400
Dieldrin 39330 Trifluralin 39030
Endosulfan I 34361
1.2 This tnechod is. applicable to Che detaminacion of .chose compounds
specified above in municipal and industrial discharges. It is de-
signed co be used co meeC Che monicoring requiremencs of the" National
Pollutant Discharge Elimination System (NPDES). As such,'it pre-
supposes a high expectation of finding the specific compounds of
interest. When screening samples for any or all of the compounds
above, independent protocols for verifying the identity of che com-
pounds must be applied.
1.3 The limit of detection for this method is usually dependent upon
Che level of interferences rather than instrumental limitations.
Under favorable circumstances, the method- sensitivity is 0.05 yg/1
(for Aroclors ^ 1016, 1221, 1232, 1242 and 1248) and 0.10 ug/1
(for Aroclors ^ 1254, 1260 and 1262) when analyzing a 1 liter
sample with Che electron capture detector. The limits of detection
listed in Table 1 represent the limits for organochlorine pescicides
Chat can be achieved in wascewaters in che absence of interferences.
1.4 When PC3's and/or organochlorine pesticides exist as complex mixtures,
the individual compounds are frequently difficult to distinguish.
High, low, or otherwise unreliable results may be obtained chrough
misidencificacion and/or one compound obscuring another of lesser
concentration. Provisions incorporated in this mechod are intended
Co minimize che occurrence of such incerferences. Nevertheless,
chis sechod is recocsended for use only by experienced residue ana-
lyses or under, che close supervision of such persons.
42 Sceuart Laboratories, Inc.
Knbxville, Tennessee 37921
-------
2. Applicable Docunents
2.L US EPA Method 617 — "Organochlorine Pesticides and PCE's", Interim
Pending Issuance of Methods for Organic Analysis of Water and Wastes,
EMSL, Cincinnati, OH 45268.
2.2 National Pollutant Discharge Elimination System (NPDES) References:
Federal Register, -38., No. 125, Pt. II, (1973). "Method for Organo-
chlorine Pesticides in Industrial Effluents (11/28/73)".
Federal Register, M.., No. 232, Pt. II, (1976_) .
Federal Register, 44_, No. 233, Pt. Ill, (1979).
Federal Register, 44_, No. 244, Pt. IV, (1979).
3. Sucnarv of Method (1)
3.1 A L-liter saaple of wastewater is extracted with 15% methylene
chloride in hexane using separatory funnel techniques. The extract
is dried and concp^-frated to a volume of 10 nl or less. Gas chroaatro-
graphic conditions are described which allow for the accurate measure-
ment of the coapounds in the extract. An electron capture detector
or a halogen specific detector (tnicrocoulometric or conductivity) is
used for quantification.
3.2 The method incorporates selected general purpose cleanup procedures
to aid the analyst in the elimination of interferences.
4. Interferences
4.1 Solvents, reagents, glassware, and other saaple processing hardware
may yield discrete artifacts and/or elevated baselines causing mis-
interpretation of gas chrooacograms. All of these materials must
be demonstrated to be free frca interferences under the conditions
of the test by analyzing method blanks. Specific selection of re-
agents ar.d purification of solvents by distillation in all-glass
systems cay be required.
43 Stewart Laboratories, Inc.
Knoxville, Tennessee 37921
-------
4.2 Interferences coextracted from the samples will vary considerably
froa source to source, depending upon the diversity of*the indus-
trial complex or municipality being sampled. While general cleanup
techniques are incorporated inco this method, unique samples may
require additional cleanup approaches to achieve the detection linits
listed in Table 1."
4.3 Glassware must be scrupulously clean. Clean all glassware as soon
as possible after use by rinsing with the last solvent used. This
should be followed by detergent washing (7-X-O-Matic) in hot water.
Rinse with tap water, distilled-water, acetone, and finally, pesti-
cide quality hexane. Heavily contaminated glassware may require
treatment in a muffle furnace at 400 C for 15 to 30 minutes. Some
high boiling materials, such as PCB's, may not be eliminated by
this treatment. Volumetric ware should not be heated in a muffle
furnace. Glassware should be stored immediately after drying or
cooling to prevent any accumulation or dust or other contaminants.
Store inverted or capped with aluminum foil.
4.4 Interferences by phthalate esters can pose a major problem in PCS
and pesticide analysis. These materials elute in all fractions
of the florisil cleanup. They usually can be minimized by avoiding
contact with any plastic materials. The contamination from phthal-
ata esters can be completely eliminated with the use of a microcoulo-
aetric or electrolytic conductivity detector.
4.5 Elemental sulfur nay interfere with the determination of PC3's and
orsanochLorine pesticides when the electron capture detector is used.
44 Stewart Laboratories, Inc.
Knoxville, Tennessee 37921
-------
5. Apparatus and >taterials
5.1 Sampling equipment, for discrete or composite sampling.
5.1.1 Discrete samples — Amber glass bottles, (1-liter or 1-quart volume)
fitted with caps lined with Teflon. Foil may be substituted tor
Teflon if the sample is not corros'ive. French or Boston Round de-
sign is recommended. The container must be washed and solvent-
rinsed before use to minimize interferences.
5.1.2 Compositing equipment — Automatic or manual compositing system.
Must incorporate glass sample containers for the collection of a
minimum increment of 250 ml. Sample containers must be kept re-
frigerated during sampling. No Tygon or rubber tubing may be used
in the system.
5.2 Separatory funnels — 2000-ml, 1000-ml, 125-ml, with Teflon stopcocks.
j
5.3 Drying column — 20-mm ID Pyrex chromatogv . .:. - column with coarse
frit.
5.4 Kudema-Danish (K-D) apparatus
5.4.1 Concentrator tube — 10-ml, graduated (Kontes K-570050-1025 or
equivalent) .
5.4.2 Evaporative flask — 500-ml (Kontes K-57001-0500 or equivalent).
Attach to concentrator tube with springs. (Kontes K-662750-0012).
5.4.3 Snyder column — three-ball macro (Kontes K-503000-0121 or equivalent)
5.4.4 Boiling chips — solvent extracted, approximately 10/40 mesh.
5.5 Volumetric flasks — NBS Class A, 1-ml and 10-ml.
5.6 Water bach— capable of ternerature control (+ 2°C). Bath should
be used in a hood.
45 Stewart Laboratories, Inc.
Knoxville, Tennessee 37921
-------
5.7 Gas chromatograph — analytical system complete with gas chronaco-
graph suitable for on-column injection and all required accessories
including electron, capture or halogen-specific detector, column
supplies, recorder, gases, and syringes. A data system for measur-
ing peak, areas or peak heights may be used.
5.7.1 Columns and analytical conditions.
Primary Analysis Column (Column 1): Supelcoport (100/120 mesh)
coated with 1.57. SP-2250/1.95% SP-2401 packed in a 180-cm long
x 4-cm ID Pyrex glass column with Argon (95%)/methane (5%) car-
rier gas at a flow rate of 60-ml/min. Column temperature, iso-
thermal at 200°C.
Confirmation Column (Column 2): Supelcoport (100 x 120 mesh)
coated with 3% OV-1 in a ISO-cm long x 4-mm ID Pyrax glass column
5
with Argone (95/0/Methane (5%) carrier gas at a *^J rate of 60-ml/
tain. Column temperature, isothermal at 200 C.
5.8 Chromatcgraphic column — Pyrex, 400-mm. x 25-mm. OD, with coarse
fritted plate and Teflon stopcock (Kontes K-42054-213 or equivalent).
6. Reagents
6.1 Sodium chloride — (ACS) saturated solution in water (pre-rinse
crystals with hexane).
6.2 Sodium hydroxide — (ACS) 10 N in distilled water.
6.3 Sodium sulfate — (ACS) granular, anhydrous (purified by heating
at 400°C for 4 hrs. in a shallow Cray).
6.4 Sulfuric acid (1+1) — (ACS) concentrated (Sp. Cr. 1.34) mix equal
volumes with distilled water.
6.5 Mercury — triple-distilled.
6.6 Boiling chips'— Her.gar granules (Hengar Co.; Fisher Co.) or equivalent-,
6.7 Acetone — pesticide residue analysis grade.
46 Stewart Laboratories, Inc.
rLnoxviile, Tennessee 37921
-------
6.3 Acetonitrile — pesticide residue analysis grade.
6.9 Diethyl ether — Nanograde, redistilled in glass if nec.essary.
6.9.1 Muse be free of peroxides as indicated by EM Quant test strips
(Test strips are avilable from EM Laboratories, Inc., 500 Execu-
tive Blvd., Elasford, New York, 10523).
6.9.2 If test indicates positive, remove peroxides by eluting over "basic
or neutral grade aluminum oxide as recommended in instructions
provided with the test kit. Re-test before using.)*
6.9-3 Distill de-peroxidized ether in glass. Preserve with 2% (V:V)
nethanol.
6.10 Hexane — pesticide residue analysis grade.
6.11 Isooctane (2,2,4-trimethyl pentane) — pesticide residue analysis
grade.
6.12 Methylene chloride — pesticide quality or equivalent.
6.13 Aluminum oxide — basic or neutral, active.
6.14 Florisil — PR grade (60/100 mesh); purchase activated at 1250 F
• and store in glass containers with glass stoppers or foil-lined
screw caps. Store at 130 G or activate each batch at least 16 hours
at 130 C in a foil-covered glass container before use.
6.15 Standard stock solutions.
6.15.1 Prepare stock standards by dissolving a carefully weighed amount
of a pure standard Aroclor in pesticide grade isooctane and di-
lute to volume in a ground glass stoppered volumetric flask.
6.15.2 Transfer concentrated standard to a septum vi«l, seal and store
in a refrigerator. Check frequently for signs of degradation or
evaporation, especially just prior to preparing working standards
froa them.
47 Stewart Laboratories, Inc.
Knoxville, Tennessee 37921
-------
6.16 Calibration standards.
6.16.L Prepare calibration standards by serial dilution of-,the stock
standards.
6.16.2 Transfer solutions Co septum vials and seal. Re-seal vials im-
mediately after removing an aliquot for analysis.
7. Calibration
7.1 Prepare calibration standards (6.16) that contain the compounds of
interest, either singly or mixed, together. The standards should
be prepared at concentrations covering two or more orders of mag-
nitude that will bracket the working range of the chroma tographic'
system.
7.2 Establish operating parameters equivalent to those indicated in.
Section 5.7.1. By injecting calibration standards, establish the
detection limit of the detector and the linear range of the analyti
cal system for each compound. Typical gas chromatograms of select
organochlorine pesticides and PCB's are shown in Figures 1 to 11.
7.3 The cleanup procedure in Section 11.3 utilizes Florisil chromatog-
raphy- Florisil from different batches or sources may vary in ab-
sorptive capacity. To standardize the amount of Florisil which is
used, the use of a lauric acid value (Mills, 1968) is suggested.
The referenced procedure (2) determines the adsorption from hexane
solution of lauric acid (mg) per grain Florisil. The amount of
Florisil to be used for each column is calculated by dividing this
factor into 110 and multiplying by 20 grams.
7.4 Scfore using any cleanup procedure, the analyst nust process a
series of calibration standards through the procedure to validate
elution patterns and the absence of interferences from the reagents.
43 Stewart Laboratories, Inc.
Knoxville, Tennessee 37921
-------
8. QuaI icy Control
3.1 Before processing any samples, the analyse should demonstrate through
the analysis of a distilled water method blank, that all glassware
and reagents are interference-free. Each tine a sec of samples is ex-
tracted or there is a change in reagents, a method blank should be
processed as a -safeguard" against chronic laboratory contamination.
8.2 Standard quality assurance practices should be used with this method.
Field replicates should be collected to validate the precisian of
the sampling technique. Laboratory replicates (7 to 10/i) should be
analyzed to validate the precision of the analysis. Fortified
samples should be analyzed to validate the accuracy of the analysis.
Where doubt exists over the identification of a peak on the chro-
matogram, confirmatory techniques such as mass spectroscopy should
be used.
9. Sample Collection, Preservation and Handling
9.L Crab samples must be collected in glass containers. Conventional
sampling practices (3, 4) should be followed, except that the bottle
\
must not be pre-washed with sample before collection. Composite
samples should be collected in refrigerated glass containers in ac-
cordance with the requirements of the program. Automatic sampling
equipment must be free of Tygon and other potential sources of con-
tamination.
9.2 The saaples must be iced or refrigerated from the time of collection
until extraction. Chemical preservatives should not be used in the
field unless more than 24 hours will elapse before delivery to the
laboratory. If the samples will not be extracted within 48 hours of
collection, the sample should be adjusted to a pH range of 6.0 to
8.0 with sodium hydroxide or sulfuric acid. Prior to adding acid
49 Stewart Laboratories, Inc.
r-rTo/H i o. 7jnr-.es see 37921.
-------
or base, sark Che water meniscus on the side of the sampling hoc tie
for later determination of sample volume.
9.3 All samples must be extracted within. 7 days and completely analyzed
within 30 days of collection.
10. Sanple Extraction
10.1 Pour the entire"sample into a two-liter separatory funnel. Check
the pH of the sample with wide-range pH paper and adjust to within
the range of pH 5 to 9 with sodium hydroxide or sulfuric acid.
10.2 Add 60-al of 15% methylene chloride in hexane to the sample bottle,
seal, and shake 30 seconds to rinse the inner walls. Transfer the
solvent into the separatory funnel, and extract the sample by shaking
the funnel for two minutes with periodic venting to release vapor
pressure. Allow -,the organic layer to separate from the water phase
for a minimum of ten minutes. If the emulsion interface between
layers is more than one-third the size of the solvent layer, the
analyst must employ mechanical techniques to complete the phase
separation. The optimum technique depends upon the sample, but
may include stirring, filtration of the emulsion through glass wool,
or centrifugation.
10.3 Drain the water layer into a second two-liter separatory funnel.
Collect the solvent extract in a 250-ml Erlenmeyer flask.
10.4 Add a second 60-ml volume of 15% methylene chloride in hexane to
the sacple bottle and complete the extraction procedure a second
time, combining the extracts in the 250-ml Erlenmeyer flask. Pour
che water layer back into the first separatory funnel.
10.5 Perform a third extraction in the same nanner. Pour the combined
extract through a drying column containing 3 to 4 inches of anhy-
drous sodium sulfate, and collect it in a 500-al Kuderna-Danish
50 Stewart Laboratories, Inc.
Kr.oxville. Tennessee 37921
-------
K-D) flask equipped with a. 10-ml concencracor Cuba. Rinse che Er-
lenmeyer flask, and column Cwice with 20- Co 30-col hexane co complece
the quanticacive cransfer.
10.6 Add 1 or 2 clean boiling chips Co Che flask and attach a chree-ball
Snyder column. Pre-wet the Snyder "column by adding_ abouc L tnl mechyl-
ene chloride to the top. Place the K-D apparatus on a. hot water
bath (80 to S5°C) so that Che concentrator tube is partially immer-
sed in the hot vater, and the entire lower rounded surfaca of the
flask is bathed in vapor. Adjust the vertical position of the ap-
paratus and the water temperature as required co complece Che con-
centration in 15 Co 20 minuCes. Ac Che proper race of distillation
the balls of the column will actively chatter but the chambers will
not flood. When Che apparenC volume of liquid reaches 1 nil, remove
the v-^ '-apparatus aad allow it to drain for at lease 10 minutes
while cooling.
10.7 Remove the Snyder column and rinse the flask and its lower joint
into the concencracor tube wich 1 Co 2 ml of hexane, and adjust Che
volume Co 10.0 ml. A 5-ml syringe is recommended for chis operacion.
Scopper che concencrator>Cube and store refrigerated if further pro-
cessing will not be performed immediately. If che sample extract
requires no further cleanup, proceed with gas chromatographic analy-
sis. If che sample requires cleanup, proceed Co Seccion 11.
10.3 Determine che original sample volume by re-filling che sample bottle
to che mark and Cransferring che liquid co a 1000-tal graduaced cyl-
inder. Record che sample volume Co che nearesc 5 ml.
51 Scewart Laboratories, Lnc.
Knoxville, Tennessee 37921
-------
11. Cleanup and Separation
11.1 Cleanup procedures are used to extend the sensitivity of a method
by minimizing or eliminating interferences that mask the gas chro-
oatographic response to the pesticides and PCB's. The hexane-
acetonitrile partition procedure is useful for removing gross amounts
of fatty acids and oils from the extract. The Florisil column'al-
lows for a select fraorionation of the conpounds and will eliminate
polar materials. Elemental sulfur, which interferes*with the elec-
tron capture gas chromatography-of certain pesticides, can be re-
coved by treatment with mercury as described below.
/
11.2 Hexane-acetonitrile partition. (5) — this procedure is applicable
to all of the pesticides and PCB's except mirex.
11.2.1 Quantitatively transfer the previously-concentrated extract to a
125-ml separate., '. jmel with enough hexane- to bring the final volume
to 15 ml. Extract the sample four times by shaking vigorously for
one ninute with 30-ml portions of hexane-saturated acetonitrile.
11.2.2 Combine and transfer the acetonitrile phases to a one-liter sepa-
ratory funnel. Add 650 ml of distilled water and 40 ml of satur-
ated sodium chloride solution. Mix thoroughly for 30 to 45 seconds.
Extract with two 100-tal portions of hexane by vigorously shaking
aboutlS seconds.
11.2.3 Combine the hexane extracts in. a 1-liter separatory funnel and
wash twice with 100-ml portions of distilled water.. Discard the
vater layer and pour the hexane layer through a 3 to 4 inch anhy-
drous sodium sulfate column into a 500-ml K-D flask equipped with
a 10-ml concentrator tube. Rinse the separator-/ funnel and column
with three 10-ml portions of hexane.
52 Stewart Laboratories, Inc.
, Tennessee 37921
-------
11.2.4 Concentrate the extracts to 6 to 10 31! by standard K-D techniques
(10.6). Analyze by gas chrqmatography.
11.3 Florisil Column Cleanup (6)
11.3.1 Add a weight of Florisil, (normally 21 g) pre-determined by cali-
bration (7.3, 7.4), to a chromatographic column'. Settle the Flori-
sil by tapping the column. Add sodium sulfate to the top of-the
Florisil to form a layer 1 to 2 eta deep. Add 60 ml of hexane to
wet and rinse the sodium sulfate and Florisil. Juat prior to ex-
posure of the sodium sulfate to air, stop the elution of the hex-
ane by closing the stopcock on the chromatography column. Discard
the eluate.
11.3.2 Place a 500-ml K-D flask and clean concentrator tube under the
chromatography column. Transfer the 10 ml sample extract volume
from the K-D concentra4. ->ibe to the Florisil column. Drain
the solvent into the K-D flask. Then rinse the tube twice with
1 to 2 ml of hexane, and each time just prior to exposure of the
sodium sulfate layer to the air, rinse the column with this solvent.
11.3.3 Drain the column into the flask until the sodium sulfate layer is
nearly exposed, then elute the column with 200 ml of 62 ethyl ether
in hexane (Fraction 1) using a drip rate of about 5 ml/min. Remove
the K-D flask and set aside for later concentration. Elute the
column again, using 200 ml of 157. ethyl ether in hexane (Fraction
2), into a second K-D flask. Perform the third elution using
200 ml of 50% ethyl ether in hexane (Fraction 3). The elution
patterns for the pesticides and PCB's are shown in Table 2.
11.3.4 Concentrate the eluates by standard K-0 techniques (10.6). Ad-
just final volume to 10 ml with hexane. Analyze by gas chrcmaccgraphy
53 Stewart Laboratories, Inc.
Knoxville, Tennessee 37921
-------
11.4 Removal of Sulfur
11.4.1 Elemental sulfur will eluta in Fraction I of the Florisil column
cleanup procedure. If a large amount of sulfur is present in the
extract, it may eluta in all fractions. If so, each fraction must
be further traaCid to remova the sulfur. To remove sulfur inter-
ference from this fraction or the original extract, pipet I'.OO al
of the concentrated extract into a clean concentrator tube or
Teflon-sealed vial. Add 1 to 3 drops of mercury and seal. Agi-
tate the contents of the vial for 15 to 30 sec'nds. Place the
vial in an upright position on a reciprocal laboratory shaker an.d
shake for up to 2 hours.~ This treatment may need to be repeated
several tines. Analyze by gas chromatography-
12. Gas Chromatography
12.1 Section 5.7.1 summarizes the recomp- • - *«.d gas chromatographic column
materials and operating conditions for the instrument. Table 1 lists
retention times and detection limits that should be achieved by this
method. Examples of the separations achieved by these columns are
shown in Figures 1 through 10.
12.2 Analysis of Calibration Standards
12.2.1 The chromatographic system is calibrated with a minimum of three
standards of each required Aroclor or Aroclor mixture (see Sec-
tion 13-Calculations).
12.2.2 A standard calibration curve is plotted of response (peak height
or peak area) versus ng using an appropriate peak (or peaks) from
a pure or mixed Aroclor standard. The largest or most clearly
separated peak is chosen if the standard is a single Aroclor. If
the standard is a mixed Aroclor, the peak or peaks with the least
interference or mutual contribution are chosen.
54 Stewart Laboratories, Inc.
Kr.oxville, Tennessee 3/921
-------
12.2.3 If Che calibration curve shows that response is Linear, a.
response factor R may be calculated for the peaks chosen.
„ ng of standard ng of standard
?k he (mm) °r Pk area
12.3 Analysis of Samples
12.3.1 Inject 2 to 5 jil of the-sample extract 'using the solvent-flush
technique (7). Smaller (1.0 ul) volumes can be injected if auto-
matic devices are employed. Record the volume injected to the
nearest 0.05 ul, and the resulting peak size, in area units or
peak height in mm.
12.3.2 If the peak area (height) exceeds the linear range of the system,
dilute the extract and re-analyze.
12.3.3 If interferences prevent the quantitation of the sample, cleanup
procedures must be followed (Section 11).
13. Calculations
13.1 Qualitative Analysis
In order to identify the Aroclor or Aroclor mixture present in the
sample, the peak height and retention time pattern exhibited by the
sample chromatogram is compared to the patterns exhibited by the
single Aroclor standards and/or mixed Aroclor standards. The con-
taminant is identified as the Aroclor or Aroclor mixture whose pat-
tern matches or mast-closely matches the sample chromatogram.
13.2 Quantitative Analysis — Peak Height Procedure
13.2.1 Determination of appropriate peak(s) to use for quantitation.
Any peak measured for quantitation must be free of interference.
Case 1: When the sample chromatogram is identified as a single Aroclor,
the largest or most cleanly separated peak of the Aroclor pat-
tern is used for analysis.
55 Stewart Laboratories, Inc
lie, Tennessee 379Z
-------
Case 2: When the sample is Identified as an Aroclor mixture, peaks that
are unique to the single Aroclors in the mixture are used for
quantitation.
Case ,3: .»iieu c.:^ a-i-z^-ii j.j a mi.-, ^u.'i ci .-....'uo_wCc. cue -i-vis ;xo z i-:l".^.b.l;
peaks that can be attributed uniquely to each single Aroclor,
appropriate peaks are chosen; and peak height ratios are used
Co determine the contribution of each single Aroclor (se'e 13.2-.2).
13.2.2 Calculation using standard curves
Calibration curves: At least three standards are used to fora
a calibration curve. Calibration curves are determined from single
Aroclor standards or from mixed Aroclor standards which have peaks
unique to the single Aroclors present in the mixture.
The peak height of the largest or most cleanly separated peak(s)
is measured. Peak height is measured from common b-" Line. The
calibration curve is determined by plotting peak height versus
nanograms.
Calculation of Aroclor concentration:
Case L: The sample chromatogram base line is drawn to match the base
line of the standard Aroclor chromatogram. The height of the
appropriate peak is measured. The amount (ng) of PCB corres-
ponding to the peak height is read off of the calibration curve.
The Aroclor concentration is then calculated as follows:
PC3 ppm _. (A) x (V) x (D)
(V) x (V)
56 Stewart Laboratories, Inc.
KnoxvLlle, Tennessee 37921
-------
Where A » ng from curve
V = voluae of final.extract (ml)
D = dilution factor, if any
V = volume injected into chromatograph (ul)
W = weight of soil used for analysis (g)
Case 2: The peak heights of the peaks unique to the individual Aroclors
present in the mixture are measured. Quantitation is performed.
as in Case 1.
Case 3: When the sample is a mixed "Aroclor and no mutually exclusive
peaks can be used, quantitation is more difficult. The contri-.
bution of each Aroclor to the peak chosen for quantitation must
be determined. This is done by using peak height ratios calcu-
lated from single Aroclor standards and then mathematically
determining the peak height to be attributed to the single A1*-*-
clor. After peak heights are calculated, quantitation is as in
Case 1.
13.2.3 Alternative Calculation Procedure
Calculate usin% response factors: When the response of the stand-
ards have been shown to be linear over a period of time, response
factors may be used for quantitation in place of the standard
curve. A response factor (R) is calculated by dividing the amount
of standard (in ng) injected by the peak height of the appropriate
peak. Peaks for quantitation are chosen and measured as above.
Quantication is performed exactly as when using standard curves,
with che following substitution.
A (ng) is replaced by M x R.
57 Stewart Laboratories, Inc.
Knoxville, Tennessee 37V21
-------
The equation becomes:
?C3
(V2) x (W)
M = peak height (ran)
R = response factor (n*/mm)
13.3 Quantitative Analysis — Peak Area Procedure
13.3.1 Determine the concentration of individual compounds according to
the formula:
(A) (B) (V )
Concentration, ug/1 =»
CV (VS)
Where A = calibration factor for chromatographic system, in
nanograas material per area unit
B = peak size in injection of sample extract, in area units'
V. = voluae of extract injected (ul)
V «» voluae of total extract (ul)
V = volume of water extracted (ml)
13.4 Report results in ug/g (ppm). Round off data to the nearest yg/g
or two significant figures.
13.5 Calculate the limit of detection (LOD) for each Aroclor not detected,
assuming a 2 ran peak height or an equivalent peak area.
-------
REFERENCES
1. "Determination of Organochlorine Pesticides in Industrial Effluents,
Federal Register, Volume 38,' Number 125, Part II, Appendix II, p. L731,
Friday, June 29, 1973."
2. Mills, P- A., "Variation of Florisil Activity: Simple*Method for Mea-
suring Absorbent Capacity and Its Use in Standardizing Florisil Columns,"
Journal of the Association of Official Analytical Chemists, 51, 29 (196S).
3. ASTM Annual Book, of Standards, Part 31, D3370, "Standard Practice for
' Sampling Water," p. 68, 1979.
4. ASTM Annual Book, of Standards, Part 31, D3694, "Standard Practice for
Preparation of Sample Containers and for Preservation," p. 601, 1979.
5. Pesticide Analytical Manual, Vol. I, Food and Drug Administration,
Washington, D. C., Revised.1969, Section 1.11.14b.
6. "Development and Application of Test Procedures for Specific Organic
Toxic Substances in Wastewaters. Category 10-Pesticides and PCB's."
Report for EPA Contract 68-03-2606.
7. Burke, J. A., "Gas Chromatography for Pesticide Residue Analysis; Seme
Practical Aspects," Journal of the Association of Official Analytical
Chemists, 43, 1037 (1965).
59 Steuart Laboratories, Inc.
Knoxville, Tennessee 37921
-------
TA31E 1
GAS CHROMATCGRAPHY GF PESTICIDES AND ?C3's
Perimeter
Retention Time (nin)
Column 1 Column 2
Cetection Lirni t°
Aldn'n
4-3HC
b-oKC
d-oHC
g-3KC
Captan
Carbopner.othi on
Chlordane
4,4'-OCO
4,4'-OC£
4,4'-OOT
Oi en lor an
Oicofol
0 i e 1 dr i n
tndosulfan I
Endosulfin II
"Endosuifan sulfata
Endrin
Endrin aldehyde
HepticMor
Heptachlcr epoxide
Isodrin
Methoxychlcr
Mi rex
PCN3
Perthane
Strobane
Toxapher.e
Triflural in
PC3-1Q15
PC3-1221
PC3-1232
PC3-1242
PC3-12i3
PC3-1254
PC3-126G
2. 40
1.35
1.90
2.15
1.70
6.22
1Q.SO
c
7.33
5.13
9.40
1.35
2.35
5. ^5
4. SO
8.00
14. 22
6. 55
11.32
2. CO
3.50
3. CO
18.20
14.50
1.53
c
c
c
0.94
c
c
c
c
c
c
c
4.10
1.32
1.97
2.20
2.13
5.00
10.90
c
9.QS
7.15
11.75
2.01
4.59
7.23
6.20
8. 28
10.70
8.10
9.30
3.35
5.00
4.33
26.50
15.50
2.01
c
c
c
1.35
c
c
c
c
c
c
c
O.C03
O.CC2
O.GQ4
O.CC4
O.C02
NO
NO
O.'Qi
0.012
O.C06
0.015
NO
NO
o.ccs
O.CC5
0.01
0.03
O.CC3
O.GZ3
O.C02
O.G04
NO
NO
NO
NO
NO
NO
0.40
NO
0.04
0.10
0.10
0.05
O.G3
- 0.03
0.15
^Column pac'xing ar,d analytical conditions given in Section 5.7.1.
^Cetacticn limit is calculated frcm t.u.e minimum detachable GC response
volume ~r"
being equal to five times the GC background noise, assuming a 10-^1 rinal
f t.*.e 1-liter sample extract, and assuming 3 GC injection of 5
roli tars.
Sceuarc uaboracories, Inc.
lie, Tennessee 3/92L
^Vultip'e ?ei< resccnse. See figures 3 to 11.
NO » Mot der.er-ii-sc.
60
-------
TA3LS 2
QIST3I3LTION AND RECOVERY OF CHLORINATED PESTICIDES
A.NO ?C3s USING FLCRISIL COLUMN CKRC^ATCGRAPHY (5)
Parameter Percent Recovery by Fraction3
1(-«r 2(15X1 3(-5C^
Aldrln 100
a-3HC ICO
b-3HC 97
d-BHC 93
g-8HC 100
Captan >
Carbofenthicn TOO
Chlordar.e 100
4.V-CQO 99
4,4'-CO£ 98
4,4'-DOT ICQ
Qlcofol •*• •*•
Oieldrin 0 100
Endosulfan I 37 64
Endosulfan II 0 7 91
Endcsulfan sulfate 0 0 1C6
Endrin 4 96
Er.drin aldehyde 0 63 25
Heptachlcr ICO
Heatachlcr ejcxida ICO
Isodrin 1GO
Methoxycnlor ICO
Mirex ICO
Perthane ICO
Toxaphene 96
PC3-1016 97
PC3-1221 97
PC3-1232 95 4
PC3-1242 97
PC3-1243 103
PC3-1234 90
PC3-1250 95
a£lu*lng solvent ccrrposi ticn given in Section 11.3.3.
occurs in both 6i and 152 fractions.
61 Scewarc Laboracories, Inc.
Knox'/illa, Tennessee 37921
-------
COLUMN: 1.53 SP-2250*
1.353 SP-2401 ON SUPS.CGPORT
TEMPSATURE: 2QO*C.
DETECTOR: ELECTRON CAPTURE
at
a
LU
8 12
N TI.Mc-Ml.NUTcS
Figure 1. Gas chromatograrn of pesticides
62
Scevarc Laboracories, Inc.
Knoxville, Tennessee 37921
-------
COLUMN: 1.Sy. SP-2250-
1.95X S7-2401
TEMPERATURE: *2QQ*C.
DETECTOR: ELSCTSCN CAPTURE
SUPELCCPORT
0 ^ 4 3 12
RETENTION TIME-MINUTES
Figure 2. Gas chrcmatogram of chlcrdane
63
Scewarc Laboratories, Inc.
Knoxville, Tennessee 379ZL
-------
COLUMN: 1.5r, SP-22SQ
1.35:-i SP-2401 'ON SUPS-CQPQRT
TEMPERATURE: 200'C.
DETECTOR: ELECTRON CAPTURE
10
22
25
RETENTION TIME-MINUTES
Figure 3. Gas chromatogram of toxaphene
64
Scevarc Laboracori.es, Cnc.
Kno:cviLLa, Tennessee 37921
-------
COLUMN:- 1.5S SP-2250* 1.35K SP-24QT ON SUPELCCPOHT
TEV.PE3ATURH: TSQ'C.
DETECTOR: ELECTRON CAPTURE
TO
14
13
22
:^ Tl.V.EiMI.NUTES
Figure 4. Gas chromatogram of PC3-T016
65
Scewarc LaboracorLas, Inc.
iCnoxville, Tennessee 3792L
-------
COLUMN: I.Sr. S?-22SQ»1.S5ri SP-2401 ON SUFSLCOPGHT
TEYiPSARJRS: 1SQ*C.
QE7ICTOR: ELECTRON CAPTURE
5_ 10 14 13
RETENTION T1.Y.E-,V,INUTSS
- 22
Figura 5. Gas chromatogram of PC3-122T
66
Scevarc Laboracories, Ir.c.
lle, Tennessee J792L
-------
COLUMN: 1.5K SP-222&* LSS^, SP-2401 ON SUPELCOP03T
TEMPERATURE: ISO'C,
DETECTOR: ELECTRON CAPTURE
u
u
10 U .18
RETENTION TIME-,V,1NUTES
22
24
Figure 6. Gas chromatogram of PC3-1232
67
Scevarc Laboracories, Inc.
Knoxville, Tennessee 3792L
-------
COLUMN: 1.5?t SP-22SQ »1.95 SP-2401 ON SUPSLCOPORT
TEMP S3 A TU RE: IStfC.
DETECTOR: ELECTRON CAPTURE
S 10 14 13
RETENTION TlME-MINUTcS
Figure 7. Gaa chromatogram of PC3-1242
68
Sceuarc Laboratories, lac.
Kno,-c/iLle, Tennessee 37921
-------
COLUMN: 1.5y, SP-22SQ* 1.35* SP-2401 ON 3UPELCOPCRT
TB1PEHATURE: ISO'C.
DETECTOR: ELECTRON CAPTURE
5 10 14 IS
RETENTION TIME-aiNUTc
22
25
Figure 8. Gas chramaiogram of PC3-1243
69
Scewarc Laoocacories, Inc.
KnoxviiLe, Tennessee 37921
-------
COLUMN: 1.5% SP-2250* 1.35?', SP-2401 ON SUP51.CCFORT
TEMPERATURE: 200'C.
DETECTOR: ELECTRON CAPTURE
8 10 14.
RETENTION TIME-,V,INUTE5.
13
FTgura 9. Gas chromatogram of PC3-1254
70
Scewarc.Laboracocles, Inc
Knox*/ille. Tennessee
-------
COLUMN: T.SX SP-22SO* 1.35?'. SP-2401 ON SUPELCQPQRT
TEMPERATURE: 200* C.
DETECTOR: ELECTRON CAPTURE
10 14 13 22
"RETENTION TIME-MINUTES
Figure 10. Gas chromatogram of PC3-12SO
71
Scewarc Laboracories, Inc.
Knoxville. Tennessee 3792L
-------
APPENDIX 2
PROTOCOL FOR SAMPLE ANALYSIS REPORTS
The following section was taken from
"Protocol for Sample Analysis",
OHMS Branch Chemistry Staff
-------
Page 10
APPENDIX 0
PKOTOlOL FOR SAMPLE ANALYSIS REPORTS
1. INTKOLJUCI [ON:
The following procedure must be used when preparing a sample analysis report.
In order for all documentation and data to be understandable and easily
reviewed, the report must be sectioned as outlined below:
REPORT TITLE: On front cover of report
TABLE OF CONTENTS: First page^ot Section I
SECTION I: OHMS8 sample documentation
SECTION II: Chain of custody records
SECTION 111: Evaluation of calibration range data sheets
SECTION.IV: Evaluation of calibration range chromatograms and/or spectra
SECTION V: Recovery studies chromatograms and/or spectra, and data sheets
SECTION VI: Quantitative analysis by chromatography and/or spectroscopy data sheets
SECTION Vil: Sample chromatograms and/or spectra
SECTION VII4: Service laboratory chromatograms and/or spectra
^cte 1: If both chromatographic and spectroscopic analyses are performed on
the samples, Sections 111 thru VIII are each to be subdivided into
two sections, labeled A and 8.
Note 2: If the contents of any one or more of the sections was not generated
for the project, delete that section in the report, making note of
this in the table of contents.
2. DETAIL OF EACH REPORT SECTION, I THRU VIII .
Listed below are the specific contents of each section of a sample analysis
report. Each report must have a title, recorded on the front cover, and a
table of contents must appear as the first page of Section I. The sections of
the report must be kept separate through the use of dividers. These should be
labeled with the title of the represented section, and should also have listed
any further organizational method used within that section.
-:, *. SECTION I: OHMSB sample documentation
:. Chemistry Staff Sample Analysis Form (see Attachment 1)
2. Technical Services Report (see Attachment 2). The final version of
this report, after being reviewed by U. frank, must be typed and must
reflect the Chemistry Staff's updated overtime hours.
3. Chemistry Staff Sample Report (see Attachment 3).
-------
Paye 11
<*. A copy of final memo sent to Requestor (attachment 4)
t>. Method of analysis used by service lab. This should be included if"
the sample is contracted out.
o. Chemistry Staff procedure. This should be included if the sample
analysis is concurrently done by R&O.
/. Service lab report of analysis.
8. Tabulation of results.
9. QC program which is used by the service lab.
10. A Quality Assurance procedure used by the Chemistry Staff to
validate the service lab results should be included.
2.2 SECTION II; Chain of custody records
1. Polaroid pictures of the samples are taken upon receipt. These
must be included, and each must be signed and dated.
2. Chain of Custody Receipts listing the source of the sample, date
collected, and by whom.
3. Federal Express receipt(s)
4. Record of Communication with EERU for sample to be contracted out.
2.3 SECTION III: Evaluation of calibration range data sheets
1. Al1 data sheets must be signed by the verifying R&D member.
2. Spot check the data entries from the chromatograms to the data sheets,
and from the data sheets to the tapes to make sure that they are
correct. ;
3. Make certain the Ei calibration errors are within ±10%. This will
assure that, all of the samples are within the calibration range.
Otherwise, discuss with Mike Gruenfeld or Uwe Frank.
2.4 SECTION IV: Evaluation of calibration range chromatograms and/or spectra
1. Since the chromatograms or spectra have been placed in a separate
section, make sure that it Is easy to cross-reference them to the data
sheets.
2.5 SECTION V: Recovery studies
1. Include any previously collected data which pertains to methods and/or
relative error obtained for the sample which is being analyzed.
2.5 SECTION VI; Quantitative analysis by chromatography and/or spectroscopy
data sheets
1„ Make certain that a Chemistry Staff member has checked the
calculations, and signed the data sheets,
'. . 9ata sheets must have the signature or initials of the analyst who
performed the work, and must be dated.
3. Check the Microprocessor tape values against the reported values on the
tabulation of results to be sure that they agree.
-------
Page !2
'{. I SHCIluN VII: Sample chrumdtoijrains and/or- spectr-d
1. lo insure easy cros^-reference, number these so as to correspond with
the appropriate data sheets contained in Section VI.
2.U SfcCTlQNVIIi: Service laboratory chromatograms and/or spectra
1. Make certain that these are dated, identified, and signed.
-------
APPENDIX B
ROTARY KILN AND SECONDARY COMBUSTION CHAMBER
BURNER ASSEMBLIES
-------
oy<-' '»
MULTIFIRE® II and III Gas or Light Oil Burners
Cross Section of Typical MULTIFIRE® Burner
Pilot Air
Burner Block
Gas or
Atomizing
Air Inlet
Pressure Test Connection
Oil Tube Inlet Insert
Strainer \
^' y.v N ~ . ^ I \ » e • ' r~. • , ^ •
IA j?.:- • • X \T* ^ ^ " ^ -v • : ,"\ •7-«:'*i
&£•'v-v'yx "•4s&'*'...'<~?''';-2£^i~~^
Oil Tip/Tube.
Subassembly
Nozzle Body
Burner Block Frame
MULTIFIRE II Burner Nozzle MULTIFIRE III Burner Nozzle
(FRONT VIEW) (FRONT VIEW)
There are minor differences in appearance between the various sizes of MULTIFIRE
Burners. However, the cross section drawing shown here may be considered represen-
tative for understanding the inter-relationship of flow of combustion air, atomiz-
ing air, light oil and gas.
The centering guide used on most MULTIFIRE Burners provides a twist to atomizing
air for oil firing and to the gas for gas firing.
The MULTIFIRE II Burner nozzle provides a twist to the combustion air which creates
a tightly wrapped flame. The MULTIFIRE II Burner may not be overfired.
The MULTtlFIRE.I.I I-Burner'.nozzle does not provide a combustion air twist. It may be
pl ications making use of.available secondary,, .air in the
•• ••- • • •• -., ~ * ••-• ... : . ..:.......-.«---•'<•••'.•
laxor?'
WAXON MtACTKU A MXtCT Of CONTINUOUS IMttOVCMCNt IN ITS ftOOUCT D15ICNS AND CONSKUCTIOM.
If IfSHVfS THC IICHT TO Altfl SP«:*
-------
MULTIFIRE®
Gas or Oil Burners
2", 3" and 4" MULTIFIRE II
Capacities and Specifications
Table 1:
2S" we (14 oti)
NATURAL
2"
680
60
—
25-
M5
—
—
10.0-
9"
2.5-
12:1
•8
•9
- 1 0
3"
1450
140
25"
250
...
—
12.7"
12-
3.5'
11:1
•15
•26
-10
GAS
4"
2825-
420
25"
471
—
—
30.4-
16"
V
7: 1
0
0
-10
#2 OIL
2"
725
98
5.3
.7
25"
113
25"
14
5.5»
9"
3'
7:1
• 14
• 10
-10
3"
14 5O
no
10.4
1.2
25"
250
25"
27
20.0*
12"
4'
9:1
0
•35
-10
4"
29J5
255
20.2
i.a
25"
471
25"
54
I6.0«
16"
6'
11:1
•14
•28
-10
AIR PRESSURE O
FUEL
BURNER SIZE
K8TU/HR
GPH '
02 OIL
COMS. AIR
@> MAX
ATOMIZING
AIR
MAX
MIN
MAX
MIN
APO
SCFM
APO
SCFM
FU£L PRESSURE
AP @ BURNER O
OIA
LOTH
TURNDOWN RATIO
7. CHANGE
MAXIMUY.
CAPACITr
O
CASE
SI
CASE
#2
CASE
«3
32" w< (18 oti)
NATURAL CAS
2"
735
60
32"
122
...
...
n.5"
9"
i.5'
12:1
•19
•It
-10
3"
1600
140
32"
267
15.0"
12"
»3.5'
u:l
•6
•20
-10
4"
5005
420
52"
501
...
34.0"
16"
51
7: 1
0
0
-1C
t»1 OIL
2"
740
125
5.5
.9
32"
122
32"
16
6.1*
9"
5-
6: 1
•4C
•46
-1C
3"
I6OO
200
1 1.4
1 .4
32"
267
J2"
51
24. 0«
12-
4 '
9:1
• 5
•"
-'0
4"
29 5O
295
21.0
2.1
32-
501
J2"
61
18.0"
16"
5'
10: i
.»
•i=
-•-
Capacities shown in Table I
are based on .65 spgr natural
gas (1075 BTU/M-5) and *2
fuel oil (using a separate
oil control valve for each
burner). The oil supply must
be regulated to provide indi-
cated pressure at inlet to the
burner Y-strainer. Oil must
be maintained at 40° F or
higher (50 ssu
cosi tyl .
mininxim vis-
Other gaseous or distillate
fuels such as /» I , *2, JP4,
etc. may be used. V4 oil or
heavier may not be used. Con-
tact Max on for specific recom-
t i ons .
O-iif -
OUif f«
O*a>"
bat*
n«r all terentiai
ew with no teeondar / aif avai'lsclo, 0"-
*on«t p<*fts
«*iy require
feot i*I pressure: Burner 9*1
Body o* r«ot«? E>as*d on liri/i
pressure
C*S£ f| - ririrtt) info still fresn a i r
CASE *2 - firing «cross fre*h «ir stre-ira o* 1,000 fp«« or I-is
PIPING ARRANGEMENTS:
iVULTIFIRE Burners can be shipped in
either of the piping configurations
shown. Unless arrangement "L" is
specified, "0" will be furnished,
and requires use of a flexible con-
nection or street elbow in the atom-
izing air line to avoid scanner in-
terference. «
To achieve minimum capacities
shown: for gas firing, dif-
ferential sir pressure at Tin-
iinuin nxist not exr f-eo .i" we •
for oil firing, air control
valve must be fully closed at
minimum.
MAXIMUM AIR TEMPERATURES
for Seal & Support Housings
Carbon Steel Stainless St_eel
900° F Supply
600° F Return
1500° F Supply
1000° F Return
Table 2:
Assembly Numbers
Basic burner
Burner
with Seal
and Support
Burner with
Seal and
Support and
Dcwflflrlng
Support Ring
DESCRIPTION: •-
Burner
Appro*. Sh. wt. ILbs.l
Replacement Block 4 Frame Asse^oly
with Carbon Steel Seal and Support
with «3IO Stainless Steel Seal
and Support
Approx. Sh. Wt. ILbs.l
fteplaewent "' »« C.S. S t Support
Block/Frame Assy w|th 310 S.S. S * Spt
with Carbon Steel Seal and Support,
Stainless Steel OownHrln^ Ring
with Stainless Steel Seal and Support,
Stainleaa Steel Oownflrlng Rln^
Approx. Sh. Wt. (Lba.)
Seeled, Pressure Type Pilot
Scanner Cooling Tee Set
2"
31528
70
28334
31529
31530
120
28337
28463
32047
32046
I2S
3»
31531
130
28351
31532
31533
200
28460
28464
32049
32050
205
&
JI534
210
2835J
31535
3153(5
310
28461
26465
32051
32052
315
IIS84 •'.V*~
30854
IMPORTANT:
Use only UV flame sensor systems for oil
or.. dual fuel firing.' UV flame sensor
systems are subject to excitation by di-
rect or reflected radiation from spark
Ignltors or other burners. While every
effort has been made in our burner design
to minimize the possibility of spark ex-
citation, each application must be re-
viewed by the user to Insure that the
flame detection system Is not energized
u.nsaf.ely ...by direct or reflected UV radi-
*'-"-"•'-----•-'- jgni tbr.s br.other burners.
. —\-" -u-v; i j.-.si-. .v f urn [shed.;
B£K:;...
-------
MULTIFIRE®
Gas or Oil Burners.
.-<*'' '•:.''« '•
/ 3"dncT4" MULTIFIRE II-
Dimensions
CLEAR FOR Oil TU6f REMOVAL
® SCAl AND SUPPORT
PlAIf THICKNESS
'«" CAS/AIOM.
• - COMB. * I* AIR TEST CONN.
TES! CONN.
ATOM. AIR/CAS CONN.
S)
OIA
(v) on CONN.
u; COMBUSTION
Alt CONN.
,| « > 10
j J |—* I ^-- K SCANNER
CONNECTION
D 4 HOIES
AMD SUPPORT MOUSCMO OlfffNSICNS
BURNER
SIZE
2"
3"
4"
A
9.C
i'..;
B
4.5
5.75
C.7'..
c
14.5
50.
SO.
20.5
SO.
D
5.25
6.25
7.75
E
.69
.69
F
.69
.ec
Burner Dimensions in Inches
G
5.12
6.56
H
5.56
6.58
7.4i
J
4.50
'j.oa
•>.<:.
K
9. CO
i 1.50
L
8.81
i i.K
M°
11.56
DIA.
01".
1 7 . i r
N
7.50
! ' . ':>.
O
7.63
P
'•'*
. . s.
o
.'..44
S
I.CXJ
T
1
'
U
2
'
V
1 ft
w
5.25
t.CC
X
. 19
.19
Y
t.oe
..94
z
11.36
14.26
14.73
mi ng
PIPC THKAOS ON THIS FAOC CONfOlM TO ANSI STANOAIO t).l
-1.28'H
3/4" Scanner
Conn,
4.00"-
3/j" Purge Air Conn.
— 1.69"-
Scanner Cooling Tee Set
MAXOfl MIACIKtl A fOKT Of CONHNUOUi IMFIOVIMINI IN IIS MOOUCI OlSICNi AND CONSHUCIIGN
II IEUIVIS IH( IICHI TO Allll SMCWKAIIONS AT ANT 1IMI WltHOUl f«IOI NOIlCt
MAXON CORPORATION, Muncie, Indiana, U.S.A.
-------
North American |
Mfg. Co.
Cleveland. OH 44 IDS USA 1
OIL ATOMIZERS
Steam or Compressed Air
J
BULLETIN 56.22
5-80 56.23
Series 5622 and 5623 Nozzle Mixing Atomizers produce 30° spray
angles and fairly long flames such as required for steel mill reheat fur-
naces, rotary dryers, and other long combustion chambers. The stainless
steel oil nozzle is concentric in the stainless steel nose, and flush with
it; so steam and oil pressures do not affect each other.
Combustion air must be supplied around the atomizer. To accomplish
this, the atomizers can be supplied as part of Luminous Rame Burners,
Refractory-Lined Burners, or Magna-Flame Burners. By specifying the
proper "L" dimension, a user can adapt the atomizers to existing burners.
For installations where adequate combustion air is provided. North
American can furnish a complete assembly consisting of atomizer,
mounting, mounting plate, and refractory tile as shown below. Special
nozzles to produce wider, shorter flames have been designed — consult
North American.
Cleaning. Strainers are recommended in both the steam and oil lines.
The oil nozzle of any of these atomizers is readily accessible for cleaning
(with steam or a wire) by removal of a pipe plug at the back which opens
a straight passage to the oil nozzle if the customer has piped the unit as
shown dotted for 5622. The quick clean-out feature of Series 5622
permits cleaning of the steam or air passage even during operation, simply
by pushing the oil tube forward against an internal stop, then returning
it to operating position. The outside diameter of the oil nozzle is sized
to efficiently clean the inside of the steam nozzle of any carbon deposits
resulting from shutdowns of steam before oil. The quick disconnect
feature of Series 5623 permits removal of the oil tube, opening a straight
passage to the steam or air nozzle.
The suggested oil valve is a North American Sensitrol (brass, rated
250 psi, 275 F). The oil pressure at the oil valve inlet should be at least
5 to 10 psi (OK to use a Ratiotrol). The steam or compressed air valve
is a Series 1832 Globe Valve (bronze, rated 200 psig).
Although the mountings for these atomizers provide a place for installing
a 4021-14 Pilot Tip, the ability of this pilot to light the oil flame cannot
be guaranteed because of the uncontrolled amount of air induced through
the register.
250
-0-3
25 50 75 100
Stoam or Air Pr«ffur« at Alopiictr in pti
500
25 50 75 100
St«am Pr«s>ur* at Atomit«r in p»i
125
When using compressed air as an atomizing medium, air consumption in scfm is one-third of Ib steam/hr for the same pressure.
Example: An O8 atomizer uses 285 Ib/hr steam with 75 psi steam pressure or 285/3 = 95 scfm air with 75 psi air.
'„ Drtt-4 Holts
MOUNTING for -02 and -01 ATOMIZERS MOUNTING for -0 and -1 ATOMIZERS
t Opening in furnace shell or outer wad must be 54 * larger than tile dimension to allow for mounting plate fillet and draft.
-------
T
NOHTH AMERICAN Mlg. Co.
Cleveland, OH 44105 USA
DIMENSIONS
Bulletin 56.22/23. 5-80
Page 2
Sl.orn Notlle
c 5622-02-A & -02-8
; 5622-01-A & -01-B
| 5622-0-A & -0-8
° 5622-1-A & -1-8
V '/ •>*/ i V ts/ 11/ i7/ i1/ x'/ i1/
/I /, Z/14 I/,4 5/, 1/i J/, 14 4/i I/a
J/ -»/ . V cs/ i ix ^ */ i1/ c V i V
/. 2 /i* 1 /« 5 /, r/J 4 /, 1 /, 5 7,4 1 /,»
X 314 iV, 6s/, l'/* S'/, I1/, S'X lV*
i x, y, 3*4 i5/.
fpt - femal. pipe thread (Anwicart Standard)
mot
6% 17,4 S'/? 17, 67,4
md< pipe thread (American Standard!
1*4
Metric Conversions
275 F s 135 C
1 psi = 0.0703 kg/cm1
1 gph = 0.0631 t/s
1 Ib = 0.4536 kg
1 scfm = 0.000 471 sm'/s
1' = 25.40 mm
3-lpl Pipe Sin
CM Intel
Bock Plot*
St«am NoixU
• A-fpt Pip. Siw
Steam or CompresMd
Air Inlet
CMMonU
Spid«r Unit
Series 5623 Atomizers
•+•
-l" Km. 8" Unl«l
PARTS LIST (S.I screw is a coek.t h.od K-20 x 3/16", IR77S-2020)
Part No. ^ -02-A -02.B -01-A -OI-B
Oil Nozzle
Steam Nozzl
-It
Din-
in
ix-jT-n
en f ions
inches
?.A A. .n?
1 A B
XV V
F
^'/.
G
l'/
J
l1/.
M
IV
1-3289-1
3283-1
3-3289-2
3-3288-2
3-3289-3
3-3233-2
3-3289-4
3-3288-2
Part No. N(^ -0-A
Oil Nozzle V3-3289-S
Steam Nozzle J 3-3287-1
.0-8
3-3239-6
3-3287-2
-1-A
3-3289-7
3-3287-2
.1-8
3-3289-8
3-3287-2
; 5623-01-A & -01-8
f 5623-0-A 4 -0-B
°* 5623-1-A & -I-B
4'/,
4J/,
i'/»
iy,
I1/!
To order, specify: "5622(or 5623)-(code for pipe sizel-detter
for capacity) Atomizer Only with L {specify "L" dimension)."
Example: 5623-02-A V,* Atomizer w/L dimension of 10*
Port No.
5622- 5622. 5622- 5622-
2-A&-B Ol-A&.B O-A&.B 1-A&-B
Part No.
Bod/
Copper Tubing
Globe Valve
Oil Tube
0. T. Packing
Packing Nut
Packing Spring
Packing Seat
Sensitrol
Steam Tube
Stop Collar
3-760-3
3-310-7
1832-02
3-760-2
3-310-7
1832-01
3-724-3
3-310-8
1832-0
3-724-2
3-310-8
1832-1
3-766-2 3-766-2
3-1069-1 3-1069-1
3-767-2 3-767-2
3-773-2 3-773-2
3-1069-2 3-1069-2
3-774-2 3-774-2
*,
3-770-1 3-770-1
I'lll'l
3-770-2
1813-02-C 1813-02-D 1813-01
3-3298-1
3-761-3
3-3298-1
3-761-3
3-772-1
3-761-4
3-769-1
3-770-2
1813-01
3-772-1
3-761-4
Body
Oil Connection
Oil Connection
Locknut
Oil Tube
Retaining Ring
Tru-seal Locknut
-^
5623-
02-A&.B
5623-
01-A&-B
5623.
0-A&.B
5623.
I.A&-B
3-3307-2
3-3233-1
3-3307-1
3-3233-1
3-3232-1
3-3310-2
3-3308-1
3-3309-1
3-3310-1
3-3308-1
3-3309-1
3-3232-1
3-3306-1 3-3306-1 3-3301-1 3-3301-1
IR740-6360 IR740-6360 IR740-5390 IR740-6390
IR790-OUS IR790-0120
Dotted parts olh.r than pip. fittings are for mounting atomizer
inside a burner. To replace these, specify part name, atomizer
series, burner series and size.
Parts not listed for Series S623 Atomizers are the same as for
Series S622 Atomizers.
-------
APPENDIX C
LOCATION OF MOBILE INCINERATOR INDICATING
AND CONTROL DEVICES
-------
rt| »--—-©-
-------
I' I I' I II I II
-------
- II I " I H I 11
-------
Waste Feed Tank
(Trial Burn Only)
------- |