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    ENFORCEMENT WORKSHOP ON
    PLANT INSPECTION AND
I   EVALUATION PROCEDURES
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     U.S. ENVIRONMENTAL PROTECTION AGENCY
     OFFICE OF ENFORCEMENT
     OFFICE OF GENERAL ENFORCEMENT
«£    WASHINGTON, D.C. 20460
                                  . 02-00-&o-

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         ENFORCEMENT WORKSHOP ON
     PLANT INSPECTION AND EVALUATION
    COUNTERFLOW INSPECTION PROCEDURES
   FOR PERFORMANCE BASELINE ASSESSMENT
         AND ROUTINE EVALUATION
                   by

            John R. Richards
        PEDCo Environmental, Inc.
          505 South Duke Street
      Durham, North Carolina  27701
         Contract No. 68-01-4147
               PN 3570-2-1
                   for

  U.S. ENVIRONMENTAL PROTECTION AGENCY
DIVISION OF STATIONARY SOURCE ENFORCEMENT
          OFFICE OF ENFORCEMENT
         WASHINGTON, D.C.  20460
              February 1980

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                          CONTENTS

                                                  Page

1.  Counterflow Inspection Procedures for
      Performance Baseline Assessment and
      Routine Evaluation                            1

    1.1  Baseline Assessment                        2

2.  Counterflow Inspection Concepts                 4

3.  Pre-inspection Steps for Regulatory
      Agency Inspectors                             6

    3.1  File Review                                6
    3.2  Inspection Announcement                    7
    3.3  Inspection Equipment                       7
    3.4  Plant Surroundings                         8
    3.5  Plant Entry                                9
    3.6  Pre-inspection Interview                   9

4.  Counterflow Inspection for Routine
      Performance Evaluation                       11

    4.1  Step 1:  Observe the Stack Effluent       11
    4.2  Step 2:  Check the Continuous Monitors    19
    4.3  Step 3:  Measure the Fan Parameters       20
    4.4  Step 4:  Analyze Control Device
           Performance                             26

         4.4.1  Fabric filters                     41
         4.4.2  Wet scrubbers                      42
         4.4.3  Electrostatic precipitators        43

    4.5  Step 5:  Check the Ventilation System     45
    4.6  Step 6:  Evaluate Process Operating
           Conditions                              45

5.  Post-inspection Steps for Regulatory Agency
      Personnel                                    50

    5.1  Plant Interview                           50
    5.2  File Update and Report Preparation        50

6.  Safety Considerations                          51

Appendix A:  (See Working File Handout)
Appendix B:  Sample Inspection Data Sheets         56
                              iii

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                          SECTION 1

      COUNTERFLOW INSPECTION PROCEDURES FOR PERFORMANCE
         BASELINE ASSESSMENT AND ROUTINE EVALUATION
     The Counterflow Inspection Procedure has been developed
by PEDCo Environmental to aid both the source operators and
regulatory agency inspectors to routinely evaluate air pollu-
tion control equipment performance.  The fundamental principal
of the Counterflow Techniques is simply that performance diag-
gnosis is done by comparison of observed operating conditions
with a site-specific baseline operating condition.  It is
recognized that field measurements are sometimes subject to
error or impossible; therefore, diagnosis is based on sets
of trends rather than just one parameter.  Even when some of
the basic data is missing, it is still possible to reach
meaningful and accurate conclusions.
     The purpose of the Counterflow Technique is to rapidly
identify significant changes in performance and the possible
reasons for the changes.  It does not, necessarily, provide
definite evidence of noncompliance nor does it, necessarily
provide a specific list of repairs required.
     Persons utilizing the Counterflow Inspection Technique
should have a technical background—preferably engineering ex-
perience.  As with any work involving equipment, care should
be exercised.  Section 6 provides some minimum guidelines
and should be read and reread regularly.  Formal safety train-
ing is highly recommended for this activity and any field
work involving air pollution control equipment.
     No single technique can satisfy all source characteris-
tics and inspection circumstances.  Inspectors and source
operators should modify these procedures whenever necessary.
                                1

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1.1  BASELINE ASSESSMENT
     Baseline determinations are preferably done soon after
the unit is installed and the shakedown period has been suc-
cessfully completed.  For existing units, an adequate baseline
can be developed during a properly conducted stack test.
The purpose of the baseline assessment is to provide a site-
specific comparison of equipment performance.
     The inspection procedures (and forms) presented in this
report should be used for both the baseline assessment and
the routine evaluation.  There are several additional items,
however, that should be accomplished, namely:
     1.   Request a set of general arrangement drawings of
          the control equipment, ventilation system layout,
          and waste handling system;
     2.   Evaluate the stack test location and procedures to
          ensure the emissions data will be accurate and
          complete;
     3.   Carefully describe all internal conditions (if
          such inspections can be conducted safely).  Photo-
          graphs are extremely valuable and should be taken
          if it is safe to do so and if plant personnel
          permits;
     4.   The sounds of operating components, such as rap-
          pers and solenoids, should be noted so that the
          inspector will be able distinguish developing
          problems;
     5.   Obtain a complete set of process operating condi-
          tions, fan characteristics, and raw material
          characteristics; and
     6.   Obtain Method 9 opacity readings.
Using the opacity observation and the stack test results,
the inspector should evaluate how close the source is operat-
ing to the applicable regulations.  If the margin is small,
the variability is normal; performance may be enough to
result in frequent violations.  If the source is initially
well-below the standard, major changes in operation or
severe deterioration of control equipment is needed to result
                               2

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in noncompliance.  The inspector must always be congnizant
of the compliance margin.  The Counterflow Inspection Proce-
dures are used to evaluate the significance of the changes
since the baseline assessment.

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                          SECTION 2
               COUNTERFLOW INSPECTION CONCEPTS

     Proceeding counter to the gas flow (backward through
the system) should minimize inspection time and reporting
requirements and maximize the amount of useful information
obtained.  More specifically, the information on effluents
and control equipment gained early in the inspection is not
only the easiest to obtain, it can be used later either to
narrow the scope of the inspection or to terminate the
inspection without completing the most time-consuming part
of the evaluation—namely, the process equipment.
     As shown in the list below, the steps start at the
stack, proceed backward through the system, and end with the
process equipment.  For regulatory agency personnel, there
are some additional preinspection and post-inspection steps
required.
     Counterflow Inspection Procedure
          Observe the stack effluent
          Check the continuous monitor(s)
          Measure the fan parameters and evaluate physical
            condition
          Analyze the control equipment performance and
            physical conditions
          Check the ventilation system performance and
            physical condition
          Evaluate process operating conditions
          Check raw materials and/or fuels
     Pre-inspection Steps  (regulatory agency personnel only)
          Review the source files
          Schedule the inspection
          Check the inspection equipment
          Observe the plant surroundings

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     Request entry to the plant
     Interview plant official(s)

Post-inspection Steps (regulatory agency personnel
only)

     Interview plant official(s)
     Update source files
     Prepare report

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                          SECTION 3
                       PRE-INSPECTION

3.1  FILE REVIEW

     A logical starting point for Agency inspectors is to
review the. files concerning the specific plant.  The follow-
ing items should be checked.  Copies of items 1 and 2 should
be obtained for the project files.
     1.   Pending compliance schedules,
     2.   Construction and/or operating permits pertaining
          to source processes,
     3.   Past conditions of noncompliance,
     4.   Frequency of malfunctions reports, and
     5.   History of abnormal operations.
The inspector should also obtain a copy of appropriate plant
layout drawings for use in preparing the audit inspection
report.  If possible, the files should be reviewed before
entry to the plant so that important characteristics will
be more easily remembered.
     The inspector should prepare a concise file containing
basic plant information, process descriptions, flowsheets,
and acceptable operating conditions (Appendix A).   It should
contain the following to facilitate inspections and/or
preparations:
     1.   A chronology of control actions, inspections, and
          complaints concerning each major source in the
          plant;

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     2.   A flowsheet identifying sources, control devices,
          monitors, and other information of interest;
     3.   The most recent permits for each major source, and
     4.   Previous inspection checklists.
Volume IV presents a recommended flow charting technique.
In plants with complex control systems, it may be beneficial
to review the technical literature and/or the complete agency
file.
     Based on reviews of agency and personnel files, the in-
spector should select a time when processes will probably be
operating at representative conditions.  The scheduling of
time to visit plants with batch operations or other irregular
operating schedules (e.g., seasonal)  is especially important.

3.2  INSPECTION ANNOUNCEMENT
     Written instructions from the Agency supervisory person-
nel should be obtained concerning the advance announcement
of inspections.  If it is desirable to announce the inspection
in advance, leads of 1 day to 1 week are generally adequate
to ensure that the necessary plant personnel will be available.
The person contacted should have the authority to release
data and samples and to arrange for access to specific
processes.

3.3  INSPECTION EQUIPMENT
     Necessary tools and safety gear should be carried in a
portable case from source to source:

               Carry at all Times
               Hardhat
               Safety glasses or goggles
               Gloves
               Coveralls
               Safety shoes (steel tipped)
               Ear protectors

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               Tape measure
               Flashlight
               Manometer or differential pressure gauges
               Stopwatch
               pH paper
               Brass rods
               Duct tape
               Pry bar
               Pocket guide of industrial hazards

Other equipment can be left in a central location until needed,

               Carry When Needed

               Pipe wrench
               Respirator with appropriate cartridge
               Velometer
               Pump and filter system
               Bucket
               Combustion gas analyzer
               Thermometers or thermocouples
               Multimeter
               Sample bottles
               Strobe
               Inductance ammeter
              . Tachometer
               Oxygen and combustibles meter
               Self-contained breathing equipment
               Pipe wrench
               Rope

Particularly important is the safety equipment—including the

hard hat, the safety glasses, and the ear protectors.  Remem-
ber, it is the inspector's responsibility to have safety
equipment before entering the plant.  Access to certain
industrial facilities can be rightfully restricted or refused
by plant representatives if designated equipment is not worn.


3.4  PLANT SURROUNDINGS

     Observations of areas surrounding the plant may reveal a

variety of signs of operational practices and pollutant emis-

sions which can aid in the preentry evaluation, including:

     1.   Obvious vegetation damage near the plant,

     2.   Odors downwind of the plant,


                              8

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     3.   Deposits on cars parked closeby,
     4.   Other signs of "dusting" downwind of the plant,
     5.   Fugitive emissions near plant boundaries,
     6.   Conditions around the product and/or waste storage
          piles, and
     7.   Conditions near lagoons and sludge ponds.
Some of the signs may mean that fugitive emission sources
should be added to the inspection agenda.  If odors are a
problem, the weather conditions should be noted for later
inclusion in the inspection report.  Once inside the plant,
olfactory fatigue may (under certain circumstances) reduce the
inspector's ability to detect odors.

3.5  PLANT ENTRY
     Upon arrival at the plant offices, the inspector should
contact a responsible official to gain access to specific
areas.  If requested, the inspector should display an employee
identification card which includes a photograph, and a physical
description including, but not necessarily limited to, height,
color of eyes, and color of hair.  Visitor release forms
generally can be signed as long as they in no way restrict the
scope of the inspection.
     If entry is refused for part or all of a facility within
the scope of the inspection, obtain 1)  reason(s) for refusal of
entry, 2)  plant official's name and title, and 3)  time and date
entry was requested.  Notify supervisory personnel by telephone
immediately.  Under no circumstances should field inspectors
attempt to summarize the potential legal consequences of
refusal of entry.

3.6  PRE-INSPECTION INTERVIEW
     The inspector should plan the initial interview with the
plant manager or other responsible officials prior to the in-
plant inspection.  Some of the points for discussion are:

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     1.   The purpose of the inspection,
     2.   The type of measurements to be made,
     3.   The samples (if any)  to be acquired,
     4.   The systems to be evaluated,
     5.   Changes in plant management that need to be noted in
          the main file,
     6.   Process flowsheets needed to confirm that opera-
          tional conditions in the file still pertain, and
     7.   Operating records required by Standards of Perform-
          ance for New Sources (NSPS) and/or for determinations
          of operating conditions specified in permits.
Applicable regulatory requirements should be reviewed careful-
ly, and their apecific applications to the source in question
should be discussed with appropriate engineering and/or legal
staff.
     Other issues the inspector should be prepared to discuss
include:
     1.   Authority for the inspection,
     2.   Agency organization,
     3.   Scope, timing, and organization of the inspection
          (preferred inspection agenda), and
     4.   Treatment of confidential data.
The inspector should ask plant officials about the operational
status of all processes and pollution control equipment within
the scope of the inspection and about the types and frequencies
of any malfunctions. If equipment is not at or near normal
conditions,  the reasons for deviation should be noted, and the
times when units can be expected to achieve representative
operations should be recorded for use in scheduling follow-up
inspections, if necessary.
                              10

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                          SECTION 4
                   COUNTERFLOW INSPECTION

     The inspector starts the inspection at the gas exhaust
point (or endpoint) of the process and proceeds through the
process flow to the point where raw materials are input. Each
step shown on the flowsheet of Figure 1 should be based on data
from previous steps to derive increasingly precise analyses.
Examples of data received at each step are listed in column 2
of Table 1? the evaluations in column 3 gradually focus on air
pollution control effectiveness as the inspection continues,
due to the expanding data base in column 4.  By the time the
in-plant inspection has ended, a series of ten or fifteen
distinct observations should provide a consistent and logical
assessment of performance conditions.

4.1  STEP 1:  OBSERVE THE STACK EFFLUENT
     The opacity readings  of emission points should be
observed using Method 9 procedures.  PEDCo recognizes that an
agency can, in many cases, develop a legally and technically
sound case solely on the basis of visible emission observa-
tions.  In some cases, however, it is possible that the value
of opacity information will be primarily for diagnosing changes
in system performance.  The following paragraphs describe how
the Counterflow Technique includes this diagnostic requirement.
aOnly staff with currently valid Visible Emission Certificates
 should make these observations.  It should be recognized that
 an agency may choose to initiate enforcement actions directly
 on the basis of these observations.
                              11

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    STEP  6
    INSPECT
    PROCESS
     STEP 5
     INFLUENT GAS
     HANDLING SYSTEM
                                  STEP  1
                               OBSERVE  S.TACK
                                          STEP 4
                                  INSPECT CONTROL DEVICE
                               AND WASTE HANDLING EQUIPMENT
                                                   STEP 3
                                                INSPECT FAN
                              1-A
                              2-A
                        1-B
                        l-B
                                                                              STEP 2
                                                                              INSPECT
                                                                              CONTINUOUS
                                                                              MONITOR
1-C
CMR -
OPACITY
2-C
                              ESP  SCA=350
BOTTOM
 AGII
SILOS
                                                       FI.YASH
                                 FLYASH
                                 SILOS
                                                                    V
                                                                   FLYASH
     Figure 1,
Steps in Counterflow Inspection Technique  for coal-fired utility boilers
controlled by a "cold side" electrostatic  precipitator.

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                           TABLE  1.   COUI1TERFLOW  TECHNIQUE, UTILIZATION OF DATA
     Step
                             Data obtained
                                  Preliminary evaluation
                                          Support data
                                       and steps obtained
1. Stack effluent
Change in opacity reading

Presence of detached plume

Presence and timing of puffs

Colors of emissions
  None
None
2. Continuous monitors
Change in opacity reading
S02 and NO  concentrations
Temperature of gas stream
Intermittent emission spikes
Representativeness of inspec-
tion period (review of
records)
Have emissions Increased to  the  point
of possible noncompllance?
                                                      Has size distribution  of particles
                                                      changed?

                                                      Are there intermittent emission
                                                      problems?
Opacity - step 1
                                       Opacity - step 1
                                       Color - step 1
                                       Puffs - step 1
3. Induced draft fan
Fan static pressure
Fan R.P.M.
Fan motor current
Gas temperature

Fan wheel vibration
Fan housing condition
Fan damper position
Has system pressure drop changed?

Has control system been bypassed?

Is effluent diluted?

Has gas flow rate changed?

Is demister operating satisfactorily?

Has operation changed fan R.P.M.?
                                                                                             None
Inspection stop point
                              Is further inspection necessary?
                                        Opacity  -  step  1
                                        Opacity  -  step  2
                                        Gas  temp - step 2 or  3
                                        Fan  static pressure - step 3
                                        Fan  motor  current - step 3
                                        Fan  R.P.M. -  step 3
4.  Air pollution  control
   device external
   inspection
Static pressure drop

Cleaning system operation

Hopper condition

Liquid flow rate

Liquid temperature

Liquid pH

Electrical  parameters

Rapper operation

Solids/liquids discharge
rate
Has gas flow rate  increased or
decreased substantially?
                                                      Has  mass  loading  increased?
                                                      Has  particle  size distribution changed?
                                                      Are  operating  and maintenance practices
                                                      adequate?
Opacity - steps 1  and  2
Gas temperature -  step 2  or  3
System pressure drop - step  3
Fan motor current  - step  3

Opacity - steps 1  and  2
System pressure drop - step  3

Opacity - steps 1  and  2
Color of plume - step  1
(continue^

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 TABLE  1.   (continued)
       Step
                                Data obtained
                                     Preliminary evaluation
                                              Support data
                                           and steps obtained
Inspection stop point
                              Is  further  Inspection necessary?
                                        Results of  previous  analyses,
                                        plus  comparison  of control device
                                        actual and  baseline  parameters
                                        (diagnostic  score)
5.  Ventilation system
   ductwork (effluent
   delivery)
Hood capture velocities

Static pressures along duct-
work
Gas temperatures
Condition of cleanout traps
Integrity of ductwork
Have gas flow rates changed?
                                                      Are gas streams being diluted?

                                                      Are all sources being operated?
Fan current - step 3
Fan static pressure - step 3
Control equipment static
pressure drop - step 4

Gas temp - steps 2 and 3
6. Process equipment
Production data
Process monitors
Raw material information and
samples
Has production rate Increased?
                                                      Have operating conditions changed?

                                                      Have raw material characteristics
                                                      changed?

                                                      Has particle size distribution of
                                                      effluent changed?

                                                      Can an Internal  Inspection  of  control
                                                      equipment be conducted safely?
Gas flow rate - step 5
Static pressure data - steps 4 and
Solids discharge rates - step 4
Opacity - steps 1 and 2
Fan motor current - step 3
Fan static pressures - step 3
                                                                     Opacity - steps 1 and 2
Inspection stop point
                              Is  an  internal  inspection of air
                              pollution control devices necessary
                              and feasible?
                                        Process operating conditions - step 2
                                        Control device conditions - step 4
7. Air pollution control
   device (external
    inspection^
Clean side deposits

Alignment of electrodes - ESP

Insulator conditions

Fabric condition

Gas distribution plate/vane
conditions

Air inleakage through welds
and holes

Hopper conditions
                                                                                              Confirm preliminary evaluations
                                                                                              - steps 1 through 6

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     In most cases, there is a relationship between the opacity
observed during the inspection and the mass emissions penetra-
ting the control device.  Regardless of the mathematical form
of this relationship, as the opacity increases, the mass
emissions generally increase.  In Figure 2a, Case 1 represents
the most sensitive relationship—a small increase in opacity
indicates a large increase in mass emissions; however, errors
inherent in a small opacity increase can make any conclusions
meaningless in this case.  Case 2 presents "contrary" prob-
lems—above a certain upper opacity level, there is no change
in mass emission rates; thus, at this level, opacity has no
diagnostic value.  The ideal case is the linear relationship of
Case 3; fortuitously, this is generally the prevailing
relationship in most industries.
     Despite the best efforts of regulatory development person-
nel, the mass emission regulations and opacity regulations may
not always agree.  Linear relationships illustrate these possi-
ble disagreements in Figure 2b.  Case 4 represents the intended
situation; that is, any violation of an opacity regulation also
involves a violation of the mass emission regulation.  In
Case 5 there is a substantial opacity violation without a
violation of the mass standard. In other cases (represented by
line segment 6), a violation of mass emission standards might
not be suspected due to decreased sensitivity to opacity.  The
point is:  in certain cases the absolute magnitude of the
observed opacity is most useful when the opacity-mass
relationship is known.
     In the diagnostic phase of the Counterflow approach, the
procedure uses (whenever possible) a change in opacity (ob-
served versus historical) rather than an absolute magnitude of
observed opacity.  Regardless of the opacity-mass relationship,
(or the mathematical form) a change in opacity does indicate a
change in mass emissions.  This information supported by a set
of facts herein provides the conclusions sought in a plant
inspection using the counterflow procedure.

                              15

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                       CASE 2
80
                                            CASE 3    _
   60
I
  20
               1         2         3        ^
               MASS EMISSIONS, ARBITRARY UNITS

          Figure 2a.  Opacity-mass relationships.
                          16

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  Finure  2b.   Opacity and mass emission violations,
                             17

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     The  color of -the effluent  is  another plume characteristic
which should  be observed.  For  fossil  fuel combustion  sources,
the color is  an indirect indication  of operating conditions.
The following list (Table 2) was compiled by EPA's Control
Programs  Development Divisions:

      TABLE 2.  PLUME CHARACTERISTICS AND  COMBUSTION PARAMETERS
     Plume color
     White
     Gray

     Black
     Reddish  brown
     Bluish white
Possible operating  parameters to investigate
Excess combustion air; loss of burner flame in
oil-fired furnace

Inadequate air supply or distribution

Lack of air; clogged or dirty burners or in-
sufficient atomizing pressure, improper oil
preheat; improper size of coal

Excess furnace temperatures or excess air;
burner configuration

High sulfur content in fuel
For other  types of sources, the color may not be as variable  or

may not have  a distinct meaning with  respect to the process or

the control equipment.  Nevertheless,  a  change in the color

indicates  a change in the system.   For example:
          /

     1.    Increased quantities of bluish particulates generally
           indicate increased generation  of very small particles
           (0.1 to 2 microns) which  are difficult to collect in
           most control devices.

     2.    A detached plume indicates  fairly conclusively  that
           particulates are forming  as the vapors are released
           to  the cold ambient air;  detached plumes often  cause
           serious corrosion problems,  since any cold surface  in
           the system is susceptible to acid-mist condensation.

     3.    The frequency and duration  of  "puffs" from the  stack
           are often caused by rapping reentrainment problems  in
           electrostatic precipitators (ESP's)  or by fabric
           leaking/cleaning problems in baghouses.  Cyclic
           process conditions can also lead to puffs.
                               18

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4.2  STEP 2:  CHECK THE CONTINUOUS MONITORS
     After observation of the stack effluent, the next logical
step is to check the continuous monitors downstream from the
control equipment.
     1.   The operation of the purge air blowers should be
          confirmed and the alignment of the source and retro-
          reflection should be checked.
     2.   The actual path length should be compared with the
          value used in the instrument calibration.
     3.   In almost all cases, the zero and full-scale settings
          can be checked and confirmed without taking the
          instrument offline.
     4.   The status of the window inductor light should be
          checked.
     5.   Also, the appearance of the instrument recording
          trace and the changes in recorded values may indicate
          reliability or unreliability of continuous monitor
          data.
Process operating personnel should be able to supply data on
the technique and the frequency of calibrations.
     The continuous opacity monitor (commonly called a trans-
missometer)  indicates intermittent emission spikes caused by
rapping reentrainment (ESP's); pulse flexing of bag seams
(fabric filters); and other problems.   A brief scan of the last
24 hours of chart paper may help to identify these problems and
to describe system performance.
     The transmissometer data should be used to confirm and
clarify the opacity observations in step 1.  Instrument prob-
lems should be suspected when there are substantial differences
between the opacity recorded in step 1 and that indicated on
the monitor.  If the instrument response time and the recorder
chart speed have been set properly, it will be possible to
check for trends in the opacity levels.
     1.   A cyclic pattern suggests variation in process
          operating conditions; and

                               19

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     2.   A continually deteriorating pattern suggests a
          developing control device problem which is likely to
          demand the attentions of the operator and the
          inspector; the deterioration can also suggest a
          gradual drift of the instrument or accumulation of
          dirt on the optical surfaces.
Failure to properly operate and/or maintain an opacity monitor
can constitute a violation of regulations.
     In step 2, the inspector should have:
     1.   Confirmed the visible emissions status with respect
          to opacity regulations,
     2.   Confirmed the installation and operating status with
          respect to continuous monitor regulations, and
     3.   Developed a preliminary idea of the process and the
          control device operating conditions.
As yet, there would not be enough information to evaluate
mass emissions in cases where a reliable opacity-mass emission
correlation has not been identified.
4.3  STEP 3:  MEASURE THE FAN OPERATING PARAMETERS
     Three operating parameters of the induced draft fan are
useful in interpreting control system operations:
     1.   Increase in total static pressure across the fan,
     2.   Electrical current drawn by the fan motor, and
     3.   Revolutions per minute  (R.P.M.'s) of the fan wheel.
Evaluated together these parameters indicate the gas flow rate
and the total system pressure drop.  These changes are impor-
tant in diagnosing control system operating conditions.
     If the fan parameters are not monitored at the plant, the
inspector should use an inductance ammeter, a manometer (or
magnehelic gauge), and a tachometer (or a strobe in cases where
the tachometer cannot be used).  The inspector should request
that static pressure taps be made in the ductwork leading to
and from the induced draft fan.  The inspector should not drill
or cut these holes unless the plant manager approves.  Once

                              20

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taps are available, the static pressures at the fan inlet and
outlet should be measured using the set of magnehelic gauges.
     The fan data can be used to estimate the gas flow at the
time of the inspection.  After correction of all readings to
standard conditions, refer to the appropriate set of charac-
teristic curves to determine SCFM.  Please remember that this
is only an estimate and is subject to errors due to variability
in fan performance, site-specific gas flow factors, and
physical condition of the wheel.  The remainder of this section
concerns means to utilize fan data to diagnose changes since
the previous Counterflow Inspection.  (Note:  in most cases the
baseline data will not be available since fan parameters are
not measured in conventional inspections).
     The type of fan used by most industrial sources with
particulate-laden effluents is the radial blade centrifugal
fan.  Its operating parameters are illustrated in Figure 3;
this curve applies to a New York Blower Company size 332
general induced draft fan with an LS wheel operating at 1460
R.P.M.'s at standard conditions.  As indicated, the static
pressure losses in the control equipment and ductwork (curve.A)
increase proportionally with the square of the flow rate.  The
fan, however, develops less static pressure at higher flow
rates, and thus it has a strong negative slope (curve B).  The
intersection of the system line and the fan pressure drop
curves define the operating point of the system.   At this
point, the gas flow rate is 8,400 SCFM,  and the brake horse-
power (curve C) is approximately 24.5.  Figure 3 should be used
as baseline data in considering:
     1.   The potential effects of gas temperature,
     2.   The changes in system static pressure drop, and
     3.   The changes in fan speed.
Changes in the rotation speed of the fan wheel is possible in
many belt-driven units as shown by the curves in Figure 4.  In
Case 1, an R.P.M. increase leads to a greater gas flow rate and

                              21

-------
   11
.E  10
LU   Q
o:   2
a.
00
                                        CURVE  A

                                        SYSTEM AP
                         7       8      9      10

                        GAS FLOW RATE,  SCFM X 103
             38



             36
             "I
                Q.
                LU

             30 £
                o
                X

             10 UJ
             2o ^
                                                                    26
                                                                    2/t
                                                                    22
11
12
Figure 3.  Operating  characteristics of radial blade centrifugal fan
           (New York  blower size 332 with LS wheel @ 1460
                                    22

-------
   12
0 11
 
-------
higher static pressure.  Increasing the R.P.M. is the course of
action at plants where process gas flow is insufficient; how-
ever, this can dangerously increase tip speed, and it can ad-
versely affect fabric filters or ESP's.  The opposite situation
is illustrated in Case 2.  An R.P.M. decrease (perhaps to save
energy cost) can decrease the flow substantially; this can
reduce the collection efficiency of cyclones and wet scrubbers
since these depend on impaction for particle collection and
since impaction efficiency is directly dependent on gas velo-
city.  Increases in the fan wheel R.P.M. can occur because of
intentional actions of the operator.   (Belt shippage can reduce
R.P.M. without operator's knowledge).
     Other changes in fan operation can occur with or without
the operator's knowledge.  For example, the fan motor current
decreases when the static pressure drop increases; Case 3 in
Figure 5 represents total system pressure drop increases.
Accompanying this Case 3 change should be an increase in the
fan motor current as indicated in Figure 5.  As indicated in
Table 3, this change can be due to a variety of process and
control device operating factors.  Pressure drop decreases can
be caused by (partial list):
     1.   Decreased effluent gas flow rate, and/or
     2.   Operating conditions such as control device short-
          circuiting (open access doors, gaps in ductwork, open
          by-pass dampers),  and
     3.   Decreased scrubber liquor flow.
The cause of the change can be further analyzed by considering
the measured gas temperature at the fan inlet.  A low tempera-
ture suggests either an open access hatch or a serious leak in
the ductwork.
     System diagnoses are based on changes in the three fan
operating parameters.  All three (total static pressure, motor
current, and wheel R.P.M.)  must be measured since all three are
analyzed as a set.   (The Counterflow Procedure does not require

                              24

-------
   s  11 -
UJ

Q-

O


<

1/5
                                      	 	 	I		
                            7       8      9      10
                          GAS FLOW RATE, SCFM x 103
                                                       11
12
Figure 5.
        Fan characteristic curves—effect of system pressure drop
        change.
                                  25

-------
knowledge of fan characteristic curves.)  With these, the
inspector should be able to determine if abnormal conditions
exist and which of the four cases is applicable.
     In addition to analyzing the operation of the fan, the
inspector should observe the physical condition of the fan.  If
it is possible to physically inspect the fan  (be sure it is
locked off), note the presence of:
     1.   Blade abrasion,
     2.   Deposit buildups, and
     3.   Corrosion of the wheel and fan housing.
The first two problems indicate excess emissions of large
particles  (lOy) and demister malfunction.  The third problem
could be due to both the overloading of the demister and excess
emissions of corrosive gases.  The induced draft fan operating
parameters indicate a number of important changes in control
device operating conditions  (Table 3).  The measured parameters
were corrected for the gas temperature at the fan inlet by
using the factors in Table 4.
     At the end of step 3, the inspector should decide whether
or not further on-site efforts are necessary to determine com-
pliance with mass emission standards.  If the fan operating
parameters (static pressure, motor current, and R.P.M.'s) are
+10% and if the gas temperature at the fan inlet is +20 F, it
is unlikely that mass emissions have changed significantly.  In
some cases, the field inspection can be terminated with step 3.
Generally, it is necessary to inspect the control equipment
(step 4)  to confirm the evaluations of steps 1, 2, and 3.

4.4  STEP 4:  ANALYZE CONTROL DEVICE PERFORMANCE
     Based on the previous three steps in the Counterflow
Procedure, the inspector should have a preliminary estimate of
the following:

     1.   Present gas flow rate through the control system and
          changes since last Counterflow Inspection,
                              26

-------
        TABLE 3.   INTERPRETATION OF FAN OPERATING CONDITIONS
                      (RADIAL .BLADE TYPE ONLY)
Case
1
2
3
4
Fan parameters
Calculated
APSD at 70°F
Decreased
Increased
Increased
Decreased
Calculated
Amps at 70 F
Decreased
Increased
Decreased
Increased
Fan wheel
R.P.M.
Decreased
Increased
Unchanged
Unchanged
Possible causes
Operator decreased R.P.M.
Operator increased R.P.M.
a) Filter blinding
b) Filter cleaning problem
c) Hopper overflow
d) Scrubber bed pluggage
e) Decreased gas flow
f) Damper partially closed
a) Baghouse leaks
b) Shortcircuiting
c) Decrease in liquor flow
d) Increase in gas flow
e) Damper partially open
        TABLE 4.  FAN DATA, TEMPERATURE CORRECTION'
Temp
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
Factor
0.91
0.94
0.98
1.92
1.06
1.09
1.13
1.17
1.21
1.25
1.28
1.32
1.36
1.40
1.43
Temp
°F
320
340
360
380
400
420
440
460
480
500
520
540
560
580
600
Factor
1.47
1.51
1.55
1.59
1.62
1.66
1.70
1.74
1.77
1.81
1.85
1.89
1.92
1.96
2.00
Adapted from "Basic Energy/Environment Analysis"
series 67, by C. Heath, August 1978.
NAPA information
                                   27

-------
     2.   Present total system static pressure drop and changes
          since last Counterflow Inspection,
     3.   Changes in particulate emission levels since last
          stack test or Counterflow Inspection,
     4.   Present temperature of the effluent, and
     5.   Presence of cyclic or intermittent emissions.
Results of these five observations should provoke specific
questions to guide the inspection of the control system.
     When inspecting the control device and its auxiliary
equipment, the inspector should proceed in a logical sequence
to obtain the information needed for evaluating the perform-
ance.  Detailed checklists (Appendix B) have been prepared for
wet scrubbers, fabric filters, and ESP's.  The general approach
to all three is to use checklists as the inspector proceeds
from the control room (if applicable)  to the control device.
These checklists are arranged to facilitate the inspection.
The checklists include preliminary diagnostic sections
(Tables 5-7) which are arranged according to commonly encount-
ered problems.
     For example, the ESP diagnostic sheet includes, but is not
limited to:
     1.   Particle resistivity changes,
     2.   Insulator failures,
     3.   Broken discharge wires, and
     4.   Nonuniform gas distributions.
Under the each problem category is a list of readily observed
symptoms and the relative importance of each as indicated by a
rating factor.  If the sum of the factors under any category is
>10, there is a reasonable probability that a problem does
exist; if so, further inspection and/or testing is needed and
should be recommended in the inspection report.
     In most plants, it will be impractical to observe every
item listed in Figures 6-8 or to observe every symptom listed

                              28

-------
                           TABLE  5.   FABRIC FILTERS  COUNTERFLOW INSPECTION DIAGNOSTIC SECTION
         Possible Operating Problems
NJ
Average Ba-seline
 (Specify Value)
  Observed   Locution*
(Specify Value)
Abnormal  Rating
(Check)   (1-10)
Recommended Action
A.
B.
C.
Bag Tears or Pinholes
1. Filter house pressure
drop low (<80X avg.)
2. Opacity high
3. Dag age high (typical avg.)
.4. Some bags inaccessible N/A
5. Design A/C high (>120X avg.)
6. Actual A/C high (>120Z avg.)
7. Wear plate eroded H/A
6. Frequent high excursions

Bag Blinding
1. Filter house pressure
drop high ,<>150j; ftvg.)
2. Opacity low
3. Cleaning frequency high
(cycles/day)
4. Gas temp low (<20°F avg.)
5. Moisture in gas stream N/A
6. Pnrticulnte sticky H/A
7. Air in-leakage (hoppers/ N/A
access doors)
8. Unit not insulated N/A

Bag Bleeding
1. Opacity high
2. Pressure drop gradually
increasing
3. Cleaning frequency high
E
E
E
N/A I
E
E
...'N/A~ I
E or I

E
E
	 E
	 k E
H/A E
H/A E
N/A I
K/A E
E
E
E
(Continued)
	 3
5
5
	 , 2
It
4
3
A
r -
	 7
2
	 5
4
4
4
	 2
	 2
E -
5
2
	 _ 5 ^
Z -
If sum (I) of ratings is > IQ,
perform internal inspection.
Check for deposits on fil-
ter house clean side. Check
inaccessible bags. Use
fluorescent dye technique. '
Check integrity of fabric by ,
attempting to extend rips.
If sum (E) of ratings is >10,
perform internal inspection.
Check dirty side of bags for
coatings (this nay be diffi-
cult to identify in some
.sees) . Check records for
steady rise in filter house
pressure drop. Reschedule
inspection in near future •
If sum (E) of ratings is >10,
attempt to confirm uses oT
fluorescent dye and black
light.
              ^Location:   E is external, and I is internal.

-------
            TABLE 5  (Continued)
OJ
o
Possible Operating Problems Average Baseline
(Specify Value)
D. Cleaning System
1. Filter house pressure drop
high
2. Pulse-jet air header pres-
sure low
3. Solenoids inoperative
4. Reverse air fan inoperative
5. Shaker motor inoperative
6. Bag length long
7. Equipment inaccessible
8. High intensity cleaning
required
E. Hopper
1. Filter house pressure
drop high
2. Solids-removal run in-
termittent
3. Indicator level existent
nnd/or inoperative
4. Heaters nonexistent and/or
inoperative
5. Vibrators nonexistent
nnd/or inoperative
6. 'llopper valves corroded
7. llopper slope <60°
8. Hoppers not insulated
9. Winter
10. Hammer markings on hopper
walls
11. Conveyor inoperative


N/A
N/A
N/A

N/A



N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

Observed Location* Abnormal Rating Recommended Action
(Specify Value) (Check). (1-10)


N/A
N/A
N?A

N/A

•
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
E
E
E or I
•J or I
E or I
E
I
E • ]
E
E
E
E
F.
1
E
E
E
E
E
5 If aura (E) of ratings is '>10,
perform internal inspection
5 and check deposits on dirty
ilde of bags. Check bag ten-
	 10 slon. Reschedule inspection
10 In near future.
10
2
2
2
E •
5 If aura (E) of ratings is >10,
perform Internal inspection
	 3 of hoppers.
	 2
2
2
3
2
7
2
	 2
10
E -
            *Locationi  E is external, and I  la internal.

-------
TABLE  6.   SCRUBBERS  COUNTERFLOW INSPECTION DIAGNOSTIC  SECTION
Poaaible Operating Problems Average Baseline
(Specify Value)
A.
B.
C.
No Liquor Flow
1. Pumps are inoperative N/A
2. Inlet and outlet gas temps N/A
same
3. Opacity high
.4. Scrubber pressure drop low
5. Nozzles plugged N/A

Low Liquor Flow
1. Nozzle operating pressure
(<80X avg.)
2. Gas temp high (10Z above
avg.)
3. Opacity high
4. Reclrculatlon liquor pH
low (<5)
5. Flow rate monitor value low
(<80Z avg.)
6. Scrubber pressure .drop low
(<80Z ovg.)
7. Exit water temp high
(>20Z above avg.)
Gns Flow Rate High
1. Opncity high
2. Outlet RBB stream temp
high (>20°F above avg".)
3. Exit water temp high
Observed Location*
(Specify Value)
Yea, No E
N/A E
E
E
Yea. No I
E
	 E
E
E
E
E
E

E
E
E
Abnormal Rating
(Check) . (1-10)
10
	 10
5
5
	 7
E -
3
	 3
5
	 3
7
3
3
E -
5
5
5
Recomaended Action
If sun (E) of ratings >10,.
request Immediate correction
action, and/or stack teat.
If sura (E) of ratings Is >lu,.
attempt to measure exit water
flow rate to. confirm conclu-'
slons. Request stack test.
If sum (E) of ratings Is > 10,
check process equipment and
production rate.
        (>20°F above avg.)

 *Location:  E is external,  and I  la internal.
(Continued)                         *
                                                       E -

-------
          TABLE 6  (Continued)
to
Feasible Operating Problems Average Baseline
(Specify Value)
D.
E.
F.
Gaa Flow Rate High
1. Opacity high __
2. Temp of outlet gas low
(>20°F below avg.)
3. Temp of exit liquor low
(>20°F below avg.)
4. Scrubber pressure drop low
(<80X avg.)
Bed Plugging
1. Scrubber pressure drop high
(>40X above avg.)
2. Liquor turbidity high N/A
3. Liquor pH high (>B)

Nozzle Erosion
1. Nozzle operating pressure
drop low (<80X avg.)
2'. Opacity high
3. Liquor turbidity high N/A
4. Corrosive liquor N/A
5. Nozzles unchanged in N/A'
6 months
6. Nozzles operable N/A
Observed Location*
(SpeclfyValue)
E
E
E
E

E
N/A ii
E

E
E
H/A E
N/A E
N/A E
N/A 1
Abnormal Rating
(Check) fl-10)
	 ' 5
______ 5
	 	 5
	 . 5
T« —
5
5
5
E -
	 5
3
3.
3
3
10
Recommended Action
If sum (E) of ratings is >10,
check process equipment and
production rate. Request stack
test if problem is serious.
If sum (£) of ratings is >10,
check for bypassing of efTluent
around scrubber. Request
immediate corrective action,!
If sum (E) of ratings is >10,
recommend nozzle replacement .
          *Location:  E is .external, and I  is Internal.
           (Continued)

-------
          TABLE 6  (Continued)
          Possible Operating Problems
to
to
Average Baseline
 (Specify Value)
   Observed    Location*  Abnormal  Rating   Recommended Action
(Specify Value)           (Check)    (1-10)
G.
U.
I.
J.
Demlster
1. No water flow to demlster
2. Gas velocity high (>10 ft.
per second)
3. Fan vibrating 	
tfenturi Throat Adjustment
1. Scrubber pressure drop low
(<80I avg.)
2, Visible evidence of changes N/A
3. Opacity high

ImplnRcraent Plate or Tray Collapse
1. Pressure drop low (<80Z avg.)
2. Opacity high
3. Build-up of liquor in sump N/A

In-lcakaRe of Air
1. Temp of gas stream low
2. Obvious shell corrosion N/A

I
E
	 E
	 E
N/A E
B

E
E
N/A 1
Z
N?A I

5
10
5
E -
	 4
4
4
E •
4
4
	 4
E -
5
5
E -
If earn (E) of ratings is >10,
check for changes in producti'o
rate. Reschedule inspection
in near future in anticipation
of fan unbalance problem.
If sura (E) of ratings is >10,
request corrective action"
immediately or request stack
test.
If sun (E) of ratings is >10,
attempt -internal inspection.
If sum (E) of ratings is >10,
attempt Internal inspection.
          ^Location:  E is external,  and I is Internal.

-------
        TABLE 7.   ELECTROSTATIC PRECIPITATORS COUNTERFLOW  INSPECTION DIAGNOSTIC SECTION
Possible Operating Problems
Average Baseline
 (Specify Value)
  Observed    Location*  Abnormal  Rating
(Specify Value)          (Check)   (1-10)
                                                                                     Recommended Action
I. ELECTRICAL
A. . Particle Resistivity
It Peak voltage low
(down 5-10 kv)
2. Rapping intensity
increased
3. Temp changed (+50°F)
4. 'Spark rate increased
(±50 sparka/min)
5. Opacity high
6. Coal sulfur content
low (<1.0Z)
B. Transformer-Rectifier Set Problems
1. No secondary current N/A
2. No penthouse purge N/A
3. Voltage rero, current N/A
high
4. Opacity high
C. Insulator Failure
1. Peak voltage low
2. Penthouse purge (not N/A
used)
3. Penthouse temp high
(+20°F)
4. Opacity high
5. Cracks visible N/A
E
E
E
E
E
	 E
N/A E
~ N/A E
N/A E
	 E
E
~_ N/A E
E
— r— E
N/A I
5
5
3
5
6
6
E -
10
2
	 10
6
E -
5
	 5
3
6
10
If sum (E) of ratings is >10,
request in-situ resistivity tea
and check sulfur content of
fuel, moisture content of gas,
and temperature of gas.
If sum (E) of ratings is >10,
request repair. ~"
If sum (E) of ratings is >10,
request repair.
   ;Continued)
 •Location!  E is external, and I is internal.
                                                                            E -

-------
            TABLE 7  (Continued)
          Possible Operating Problems
OJ
ui
                          Average Baseline
                           (Specify Value)
   Observed    Location*  Abnormal  Rating   Recommended Action
(Specify Value)           (Check)    (1-10)
D. Broken Dincharfte Wlren
1. Deposits on vires N/A
2. Violent meter flue- . N/A
tuating
3. Hopper level indicator N/A
not used
A. Spark rate high (+50
sparks/min)
5. Opacity high
6. Broken discharge wires N/A
N/A I
N/A K
N/A E
E
E
N/A I
5 If sum (E) of ratings is >tO,
	 10 request repair.
2
5
3
10
E -
II. CAS FLOW
A. Excessive Velocity
1. Flow rate high 	
2. Voltages high, cur-
rents low
3. Opacity high
E
E
E
	 5 If sum '(£)' of ratings is HO,
5 check production and/or genera-
tor rate.
5
                                                N/A
B.   Nonuniforra Distribution

     1.  Flow rate  Increased
     2.  Secondary  currents
        nonparallel
     3.  Hopper levels differ-
        ences on parallel
        branches
     4.  Rappers on distribu-
        tion plates  not used
           ^Location:  E is external, and I is inteiual.
                                                 N/A
                                                                                             E -
      N/A
E or I
                                      2     If sum (E)  of  ratings  is  >10,
                                      5     request velocity traverse.
                                                                                             E -'.
           (Continued)

-------
            TABLE 7  (Continued)
Possible Operating Problems    Average Baseline      Observed    Location*  Abnormal • Rating

                                (Specify Value)    (Specify Value)           (Check)    (1-10)
                                                                                                     Recommended Action-
l/J
en
III. MECHANICAL
A. Rapper Problems
1. Puffs visible
2. Peak voltage changed,
secondary current
constant
3. Spark rate changed
4, Low sulfur coal used
5. Dust sticky
B. Hopper Solids Removals
1. Broken discharge wires
2, Mass loading probably
. increased
3. Nonuniform gas distri-
bution
4. Hoppers not emptied
continuously
S. Level indicators not
used
6. Heaters not used
7. Vibrators not used
8( Hoppers not insulated
9. Corrosion around. out-
let valves
10. Hopper slope <60°
11. Hoppers full or
bridged
N/A



N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

N/A

N/A""
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
7 N/A
E
E
E
E ~
E 	
I
E
E - 	
E
E 	
E
E
E
I
E
I 	
5
5
_ 3
Z 3
5
5
_ 3
5
_ 3
2
	 2
10
E -
If sum (E) of ratings is >10,
request internal inspection by
plant personnel. Request inten
eity measurement, if approprlat
If sum (E) of ratings is >10,
request internal Inspection
and/or changes in operational
practices.
           ^Location!  E ij external,  and  1 in internal.

             (Continued)

-------
          TABLE 7  (Continued)
        Poaaible Operating Problems
                               Average Baseline      Observed    Location*  Abnormal  Rating
                                (Specify Value)   (Specify Value)           (Check)   (1-10)
     Recommended Action
        III. MECHANICAL (continued)
             C.    Collection Plate Warp and Halalignment
1.
2.
3.
A.
Change In air load
Repeated hopper over-
flow
Air in-leakage
Halalignment visible
N/A
N/A
N/A
N/A

N/A
N/A "
N/A
N/A ~

E
E or I
E
I
5 If sum (C) of ratinga la >10.
3 requeat alignment check.
3
10
r ••
CO
-J
IV.   EFFLUENT  CHARACTERISTICS
     A.    Haas Loading Increases

          1. Opacity  high
          2, Inlet  section,  secon-
            dary currents low
          3. Hopper unloading fre-
             quency increases
6     If sum (1)  of  ratings  la >IQ,
5     check production and/or genera-
      tor rate.
                                                                                            I -
        *Locationi  E la external, and I Is Internal.

-------
              NO
                                                       YES - ENTER UNIT
Check pressure drop across
each compartment; also,
check condition of lines
and pressure gauges.

ENTER RESULTS ON LINES Al,
Bl, Cl,  Dl,  and El,  OF
CHECKLIST.
Check cleaning system:
     -Pulse jet pressure
     -Solenoids
     -Reverse air blowers
     -Shakers

ENTER RESULTS IN SECTIONS
B, C, and D OF CHECKLIST.
                        Check condition of bags:
                            ^Bag tears
                            -Bag deterioration
                            -Dropped  bags
                            -Oily bags
                            -Wet bags
                            -Improper bag tension
                            -Deposits on floor

                      ENTER RESULTS IN REPORT.
Check solids removal equip-
ment:
     -Screw conveyor
     -Pneumatic system
     -Heaters
     -Vibrators
ENTER RESULTS IN SECTION E
 OF  CHECKLIST.
            Are
        there  any
     indications of
     nonoptimal per-
       formance?
                      Check clean air chamber for
                      possible  leakage.

                      Check hoppers
                         Incomplete solids removal
                         Corrosion
ENTER UNIT TO CONFIRM
EVALUATIONS.   MAY  NEED
TO RESCHEDULE INSPECTION.
                                                      END INTERNAL  FABRIC FILTER
                                                               INSPECTION.
                       NO - END FABRIC  FILTER  INSPECTION
              Figure  6.   Fabric  filter  inspection  flowsheet.
                                      38

-------
1
««s 	
r
Reschedule inspection
for a time when unit is
operational
i
r
Inspect internal parts:
Nozzle condition
Presensft of corrosion
Presense of erosion
Presence of scaling
i








f
Check integrity of shell
retention grids, and othe:
parts.
,

Check slurry handling
system.





                                               Check pumps on purge,
                                               make-up, and recircula-
                                               tion  lines.

                                               Read  flow meters if avail
                                               able.  Check liquor temp
                                               on  inlets and outlets.

                                              ENTER RESULTS IN  SECTIONS
                                              A AND B.
                                                         I
                                               Check pressure gauges am
                                               differential pressure
                                               monitors across the fol-
                                               lowing:
                                                 Spray nozzles
                                                 Scrubber beds
                                                 Venturi throat
                                                 Demisters
                                              ENTER RESULTS ON CHECK-
                                              I.TST.	
                                              Check sunp and recircu-
                                              lation tanks:
                                                -Liquor temperature
                                                -Liquor pH
                                             :NTER  RESULTS
                                              1ST.	
ON CKECK-
                                              Check inlet conditions:
                                                -Gas temperature
                                                -Presaturator water
                                                 flow rate


                                             ENTER  RESULTS ON CHECKLIST
                  END SCRUBBER INSPECTION
Figure  7.   Scrubber inspection flowsheet.
                           39

-------
   Perform Internal
   Inspection.
             T
                                      NO
 Top  section, check:
     -Rappers
     -Drives
     -Insulators
     -Heaters
     -Blowers
 Electrical Field section,
 check:
     -Alignment
     -Build-up
     -Rappers
     -Drives
     -Insulators
     -Erosion
     -Corrosion
Check:
     -Hopper section
     -Build-up
     -Corrosion
     -Hopper baffles
            T
Check:
     Gas distribution devices
ESP  -Inlet
     -Outlet
     -Ductwork
   •  -Corrosion
     -Erosion
     -Plugging
     -Rapping  systems
            i
End ESP  inspection,  return
for operational  inspection.
                   YES
Identify bus section numbering
  system.
Check for bus sections which
  are not operating.
Check electrical characteris-
  tics of each bus section
  that is operating.
  -Primary voltage
  -Primary current
  -Secondary current
  -Secondary voltage  (if
   measured)
  -Spark rate
Check rapper sequence and
  timing.
Check insulators purge and
  heating system.

ENTER RESULTS IK APPROPRIATE
PLACES ON CHECKLIST.
Check operational  status
  Hopper heaters & vibrators
  Solids removal system

ENTER RESULTS  ON CHECKLIST.
                            ESP IN-
                            SPECTION.
Reschedule  operational  in-
spection.   Recocisiend mainte-
nance work.
                                                   END ESP INSPECTION.
    Figure 8.   Electrostatic precipitator inspection  flowsheet.
                                        40

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in Tables 5-7.  This is why the diagnostic sheets are designed
to reflect combinations of observations.  In the extreme situa-
tion where there are essentially no equipment monitors and
where access to components is restricted, the difficulty and
limitations involved in performance evaluation should be noted
in the inspection report.
     During each stage of the control device evaluation, the
inspector should compare the observed operating conditions with
the baseline values obtained from compliance stack tests or
from manufacturer's specifications.  Deviations from site-
specific baseline values are the best indicators of abnormal
performances.
     The following discussions of control devices do not extend
to standard design methodology and operating procedures.  It is
assumed that the field inspector is familiar with most control
devices and has performed in-plant inspections in the past.
4.4.1  Fabric Filters
     Five major categories of fabric filter operating problems
are listed in the left column of Table 5.  Only one of these—
Bag Tears/Pinholes—causes immediate excess emissions.  The
others strain the fabric to the point that extensive repair
and/or replacement is eventually necessary.
     There are two basic approaches to the inspection of fabric
filters.  With the most common one, the unit is not shutdown
during the inspection.  The field inspector should decide if
the observed performance symptoms call for a follow-up internal
inspection and if a stack test should be recommended.  With the
second approach, the system can be shutdown (or compartments
isolated one-by-one) long enough to perform the internal
inspection.  If the opacity observed in step 1 and/or step 2 is
high and if the internals are accessible, we highly recommend
proceeding along the right-hand path of Figure 6.  Internal
checks are the only truely reliable means for identifying fab-
ric filter problems.  Only if access to the unit is impossible

                              41

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do we suggest the use of the indirect approach illustrated on
the left of Figure 6; in this case, the inspector evaluates
whether a return trip (when the unit is down)  is justified.
     Some of the symptoms on the diagnostic checklists are
design factors.  Fabric filter design is very significant with
respect to long-term performance.  Design deficiencies at any
source should be checked routinely during each inspection.
4.4.2  Wet Scrubbers
     To evaluate the performance of a wet scrubber, the PEDCo
inspector should first confirm that the recirculation pump is
operating.  If there is no water/liquid circulating through the
system, the inspector should recommend a follow-up inspection
when the scrubber will be operational.  If there is circula-
tion, the inspector should proceed along the flow of water
through the system (water flow is generally counter to gas
flow).
     Next, the inspector should confirm that the pumps are on,
and if so, should read the flow meter (if any).   In the line
going to the spray nozzles, low pressure indicates erosion of
the nozzles and likely increases in the water spray droplet
size.  If the line pressure does not change when the flow is
temporarily shut off (the inspector must not adjust valves),
the nozzles are plugged.  Static pressure drop across each
stage should be recorded, if possible, to help in problem
diagnosis.
     To complete the check of the water system,  the inspector
should measure the temperature and the pH of the sump liquor.
It is advisable to take a liquor sample; however, the expense
should not be incurred unless there are reasons  to suspect
operational and/or corrosion problems (chain-of-custody pro-
cedures must be followed). During the inspection, the integ-
rities of the scrubber shell and the component parts should be
rountinely checked.
                              42

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4.4.3  Electrostatic Precipitators
     There are four problems which can affect the performance
of an ESP:
          1.   Electrical,
          2.   Gas flow,
          3.   Mechanical, and
          4.   Effluent.
In each problem category, there are three to five symptoms
which occur with reasonable frequency, but the observed
symptoms do not often indicate a particular problem. Due to the
complexity caused by the interfacing of these problems, it is
important that the inspector use a combination of symptoms in
identifying operational difficulties.
     The checklist (Table 7)  and the flowsheet (Figure 8)  are
logical approaches to the evaluation of an ESP.  Unlike the
comparable charts for fabric filters and wet scrubbers, those
for an ESP include a preliminary flowcharting step for use if
a diagram is not available, so that the electrical data can be
simplified and understood.
     The inspector should begin in the main control room (or
the substation) where much of the electrical data can be ob-
tained.  Performance evaluation should include, but not
necessarily be limited to:
     1.   Power density calculations,
     2.   Evaluation of parallel field secondary currents,
     3.   Evaluation of inlet field secondary currents,
     4.   Spark rate,
     5.   Hopper heater/vibrator operational status,
     6.   Penthouse purge fan operational status,
     7.   Hopper unloading frequency,
     8.   Rapper operational status, and
     9.   Rapper frequency in various locations.
                              43

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We recommend that internal ESP inspections be done only when
the inspector is accompanied by a company representative.  Fur-
thermore, the inspector should always wear a respirator, hard-
hat, and gloves; should fully understand the lockout procedures
used at the plant, and should strictly adhere to safety
procedures due to the many potential hazards.  A precipitator
is essentially a giant capacitor.
     Inside the unit, it is possible to identify many operating
problems which are hard to diagnose otherwise.  Particular
attention should be given to:
     1.   Dust accumulation on turning vanes and distribution
          plates which can indicate and/or cause poor gas
          distribution and low particulate control efficiency;
     2.   Obvious corrosion which suggests in-leakage of air or
          operating below the acid dewpoint;
     3.   A full hopper which causes misalignment of the col-
          lection plates, which in turn can reduce collection
          efficiency;
     4.   Removal of a large number of discharge wires in a bus
          section which can indicate alignment problems and/or
          design deficiences; and
     5.   Inadequate rapping of collection plates, and/or
          discharge wire.
Broken discharge wires can generally be located by checking for
bottle weights hanging below the normal level.
     At the end of step 4, the inspector decides whether or not
the ventilation system and the process, itself, need to be
inspected.  If the operation and maintenance of the control
system appear to be adequate and if there are no indications of
changes in effluent characteristics (e.g., increased gas flow
rates, smaller particle size distribution, higher temperature),
the inspection should be terminated.  Otherwise, the ventila-
tion system (if applicable) and the process operations should
be visited.
                              44

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4.5  STEP 5:  CHECK THE VENTILATION SYSTEM
     To inspect the ventilation system, the inspector checks
the capture velocities of hoods to the extent possible using
the velometer.  Factors which could cause inadequate capture
efficiency include the following problems (partial list):
     1.   Inadequate hood design and location,
     2.   Thermal drafts,
     3.   Cross-drafts in the vicinity of the hood, and
     4.   Leaking of air into hoods and/or ducts within the
          system.
If the ductwork is accessible, the static pressures at various
points should be inspected; furthermore, the physical condi-
tions of ducts should be observed to locate leaks.  Improper
hood locations can account for drops in pollutant mass loading
or for changes in particle size distributions.  Releases of
emissions to roof monitors or as fugitive material should be
checked, especially for movable hoods.

4.6  STEP 6:  EVALUATE PROCESS OPERATING CONDITIONS
     The purpose of the process inspection is to answer ques-
tions and to confirm conclusions reached in earlier steps.
However, if the source is subject to special state/local regu-
lations or -to New Source Performance Standards or to National
Emission Standards for Hazardous Air Pollutants, compliance
with recordkeeping and monitoring requirements should be
checked first, using a DSSE-published series of documents which
includes checklists and associated information.
     The inspector can seek answers to questions which were
derived from steps 1 through 5.  The inspector addresses prob-
lems which could be individually or collectively responsible
for nonoptimal performance, including, but not limited to:
     1.   Has the production rate increased (higher mass
          loading and/or gas flow rate)?
                              45

-------
     2.   Have the raw materials and/or fuels changed to the
          extent that effluent characteristics are different?
     3.   Has the process equipment deteriorated to the extent
          that emissions are affected?
     4.   Have changes in operating conditions resulted in more
          difficult collection problems (particle size
          decreases)?
The process inspector should begin at the control centers where
process monitors are located to look for signs of changes in
operating conditions and to observe current operating/mainte-
nance practices.  At these centers, process operating data are
available; a process flowsheet is generally posted on the con-
trol panel; plant operators are generally nearby; and the
subdued noise level is conducive to technical discussions.
     While in the control room, the inspector should seek out
the process monitors and/or records most pertinent to the
compliance questions.  Example "inspection points" for six
source-types are in Table 2; several generalizations can be
drawn from this table.
     1.   In most cases, the inspector can confirm increased
          production rate by using data available in the
          control room;
     2.   The inspector can confirm raw material changes by
          inspecting records kept either in the control room or
          in the administrative offices;
     3.   The inspector cannot easily confirm process opera-
          tional changes;
     4.   For batch operations, it is necessary to observe the
          equipment since little useful information is
          available in the control room; and
     5.   For other processes, it is possible to identify
          changes in operating conditions, but the significance
          of the changes is hard to determine.
Follow-up questions remaining after the inspection of records
and monitors in the control room can be quite time consuming
due to the cyclic processes and to distances between inspection

                               46

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points at large plants.  The follow-up can be guided by the
items listed in Table 8, but the inspector is encouraged to
develop more extensive lists for specific plants.  The presence
of fugitive emissions should be noted.
                              47

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£>•
00
                                   TABLE 8.   EXAMPLE  INSPECTION  POINTS,  COUNTERFLOW INSPECTION
                                                                     PROCEDURES
                                  Type  of
                               Industry/Source
                       Inspection in  the
                   Office and/or Control Room
         Inspection  of
       Specific  Equipment
                              . !•  Confirm  the Rates of Production and/or Generation
                               Sulfuric
                               acid

                               Aaphalt
Utility or
industrial
boiler

Cement

Refinery
               Check acid production records, and
               observe acid flow rate Indicator.

               N/A
                                             Check megawatt generation and steam
                                             production rates.
N/A
Observe number of  batches  shipped
per hour of plant  operation.

N/A
                                             Check raw material feed  rate records.   N/A

                                             Check throughput records on catalytic   N/A
                                             cracker.
                               2.  Confirm Raw Material Changes
                               Asphalt       N/A
                               Utility or     Check daily records of analyses:
                               Industrial     I ash, US, Btu content,  ash  fusion
                               boiler         temp.

                               Sulfuric       Check records of feed content; high
                               acid          .levels contribute acid mist. .
                                                     Perform lab tests to determine  coal
                                                     gradation and surface moisture
                                                     percentage.

                                                     Take sample for later analyses.
                                                     K/A
Refinery
                                              Checlj: production inventory records.

-------
 TABLE  8  (Continued)
   Typo of             Inspection la the
Industry/Source     Office and/or Control Room
                                                Inspection of
                                              Specific Equipment
3.  Confirm Process Operational Changes
Sulfuric
acid
Secondary
brass and
bronze
Utility or
industrial
boiler
Check catalyst  bed  temp and air flow
rate to catalyst  bed  if 502 monicor
values are high.  Check acid concen-
tration temp and  flow to absorbers.

Check records for percentage of zinc
in alloy and for  pouring temp.
 Check air  preheater exit
 temperatures.
N/A
Check for grease and oil on scrap and
for operational practices such as
maintenance integrity of slag load.
Check hood caption velocity in
furnace area.   Determine if zinc is
added before furnace temp is maximum.

N/A
 4.   Confirm Process Equipment Deteriotation
 Sulfuric
 acid
 Secondary
 brass and
 bronze

 Utility or
 Industrial
 boiler
Observe SO2 concentration monitors;
check for inactive or poisoned
catalyst if S02 is high.


M/A
 Check excess air level by means of
 0-  readings.
Check pressure drop across  mist
eliminator.  If low, check for
shortcircuiting; if high,  check  for
plugging.

Check hoods and ductwork'for
physical damage and caption velocity.
 Check to  see if stoker boiler
 draft above fuel beds has >0.10"
 negative  pressure.
 Refinery
 N/A
                                                      Observe flow rate/

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                          SECTION 5
                       POST-INSPECTION

5.1  PLANT INTERVIEW
     Having evaluated the exhaust system, monitoring equipment,
control systems, and possibly the process itself, the inspector
should meet-with a responsible plant official to:
     1.   Ask follow-up questions as necessary,
     2.   Review inspection notes so that there is general
          agreement on the technical facts, and
     3.   Discuss need for followup inspection or additional
          records.

5.2  FILE UPDATE AND REPORT PREPARATION
     All appropriate file entries should be changed as
necessary.  The conclusions of the inspector, based on
observations and calculations, should be clearly stated in a
concise paragraph in the inspection report which should also
include two sheets—the control device diagnostic checklist and
a coverpage (Table 9)—with the following information:
     -Any change in responsible plant personnel,
     -Requested permit changes or reported process modifica
      tions,
     -Results of Counterflow evaluation,
     -Action requested,
     -Inspector's signature, and
     -Date of inspection.
A copy of both sheets should be kept in the inspector's source
file and in the agency's central file.

                               50

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                          SECTION 6

                    SAFETY CONSIDERATIONS

     The field inspector should take any precautions necessary

to absolutely ensure that the inspection is conducted safely.

All applicable OSHA regulations should be satisfied.  If

there is any question whether all or part of the inspection *

can be -done-safely, that part should be delayed until the
issue is adequately resolved.

     There- are several principles which should be obeyed
during a field inspection, namely:

     1.   Prior to the inspection, the files should be
          reviewed to assess possible hazards.  Consult
          references, such as the Pocket Guide of Industrial
          Hazards and Occupational Diseases, a Guide to
          Their Recognition;

     2.   The inspection should bring all necessary safety
          equipment  (in good working order);

     3.   Safety equipment should be worn whenever necessary
          regardless of the practices of plant personnel;

     4.   The inspector should proceed with the inspection
          at a controlled pace so there is time to fully as-
          sess possible hazards and so foolish accidents do
          not occur;

     5.   Inspectors should not work alone.  If plant person-
          nel are not available or willing to accompany the
          inspector, then the inspector should wait until
          additional help is available from the agency or
          the company;

     6.   Prior to any confined space entry, the inspector
          should read Appendix C, and follow the recommenda-
          tions completely;
                              51

-------
     7.   Physical examinations should be completed annual-
          ly;

     8.   Accidents should be reported to supervisory personnel
          immediately, regardless of the suspected severity
          of the injury;

     9.   Lock-out procedures should be followed completely;

    10.   Entry to electrostatic precipitators should not be
          done until grounding hooks have been used in all
          areas to be inspected;

    11.   Hoppers full of material should never be opened or
          entered by the inspector; and

    12.  ..Jf.ans vibrating severely should be avoided and
          plant personnel should be notified immediately.

     A field inspector cannot afford to under-estimate potential

hazards.  The inspector is inherently exposed on a regular

basis to a wide variety of hazards and does not have the
opportunity to acquaint himself or herself with the details

of each plant.  For these reasons, it is particularly important

that the inspector adhere to the basic principles outlined
above.  It should also be realized that these are simply a
starting point and other precautions will be needed in most

circumstances.
                              52

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     TABLE  9.   CONTROL DEVICE  DIAGNOSTIC CHECKLIST AND COVERPAGE
     INSPECTION
         REPORT
     I.  GENERAL INFORMATION

    A.  Sources Inspected 	
                                         IlKPORT NUMBER
PLANT NAME
PLANT I.D.
                                         SPECIAL ACTION RECOMMENDED (Yes)   (No)
Production Status
    B. Reasons for Inspection (Check Appropriate  Items)
       Routine Inspection 	
       Complaint Investigation
       Stack Testing Observed _
       Special Studies 	
       Other
      Compliance Progress 	
      Permit Review/Renewal
      Tax Certification 	
      Emergency Episode 	
      Equipment Malfunction
    C. Plant Representative Contacted  (Name and  Title)
    D. Inspection Procedures and Conditions

       Prior Notice (Check One) Yes 	  No 	

       Time/Date 	  Duration On-Site

       Type Inspection (Check One)  Counterflow 	

                                 Other 	

       Weather
               Follow-Up
                                                     Wind Direction
    II.  PRE-INSPECTION INTERVIEW

    A. Production Status:  Normal 	
    B. Control Equipment:  Normal 	
    C. Permit/Compliance Schedule Changes Needed:  Yes
    D. Comments
         Abnormal
         Abnormal
                       No
(continued)
                                        53

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TABLE  9.  (continued)
                                            Report Number	

     III.   INSPECTION RESULTS

     A.  General Conclusions

        All Sources  In Compliance with:

         Mass Emission Regulations:          Yes 	 No 	 N/A
         Visible Emission Regulations:       Yes 	 No 	 N/A
         Fuel Quality Regulations:           Yes 	 No 	 N/A
         Continuous Monitoring Regulations:  Yes 	 No 	 N/A
         Sampling/Testing Requirements:      Yes 	 No 	 N/A
         Recordkeeping Requirements:         Yes 	 No 	 N/A
         Permit Stipulations:                Yes 	 No 	 N/A
         Special Orders:                     Yes 	 No 	 N/A

         OStt'Practices:  Good 	 Average 	 Poor 	
         Housekeeping:   Good 	 Average 	 Poor 	
     B.  Specific Conclusions

        Compliance Questionable Due To:

          Changes in Raw Materials and/or Fuels
          Production Rates Increases        	
         Operational Changes in Process 	
         Deterioration of Process Equipment
         Operational Problems in Control 'Equipment (Check Appropriate Items  Below)

         Electrostatic            Fabric              Wet
         Precipitators            Filters  .           Scrubbers
Resistivity
TR Sets
Insulators
Discharge Wires
High Velocity
Gas Distribution
Rappers
Solids Handling
Plate Warpage
Mass Overload
Other
Tears/Pinholes
Blinding
Bleeding
Cleaning System
Hopper Overflow
Corrosion





Low Liquor Flow
Gas Flow Rate Low
Bed Plugging
Nozzle Erosion
Demisters
Throat Adjustment
Tray Collapse
Corrosion

     C.  Samples Taken  (Describe)
     D.  Comments/Recommended Action
                                       Inspector 	 Date

                                       Reviewer  	           Dace
                                           54

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        APPENDIX A



(See Working File Handout)
             55

-------
          APPENDIX B



(Sample Inspection Data Sheets)
               56

-------
                         PEDCO  ENVIRONMENTAL
                            INSPECTION DATA SHEET
A. INSPECTION INFORMATION
   1.   IDENTIFICATION
        Company	
        Plant Name
        Plant I.D.  Number_
        Address
        Control  Device/System Number_
        Process  Served
   2.    PROCEDURES AND  CONDITIONS
        Prior Notice:   Yes	No_
        Time(s)  On-Site	

        Type Inspection	

        Inspectors	
        Plant Representatives
        Information  Claimed Confidential:  Yes       No
                                         57

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B. Visible Emissions                        Inspection  No.
   Observations                             Equipment No. "
                                           Confidential:   Yes	No_
                                           Page  No.	of 	
   1.    STACK CHARACTERISTICS
        Location	
        Height	
        Temperature	
        Exit  Dimensions_
        Orientatfon
        Other  Information
   2.    STACK  EFFLUENT
        Detached Plume:  No	 Yes	Distance_
        Color
       Puffing:  Yes	 No	
       Opacity
   Time       Average Opacity        Observation Point         Sheet No.
  3.   FUGITIVE EMISSIONS
       Control Device:  Yes       No
       Solids Removal System:  Yes	No	
       Process:  Yes	No	
       Continuous	 Intermittent
       Adjacent Deposits:  Yes	No	
                                        58

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Z.  Fan  Data
          Inspection No.
          Equipment No._
          Confidential:
          Page No. 	
                                                          Yes_
                                                           of
             No
       FAN MOTOR
       Manufacturer^
       Model No.
       Rated Horsepower_
       Volts
       Maxifnum!"R":P.M.
       Operating Current:  Panel
         Type
         Maximum Amps	
         Service factor
              Other
       DRIVE
       Direct
       Sheath Reduction
Belt
       Audible Belt Slippage:  Yes_
Other
                   No
       FAN
       Manufacture^
       Model No.
       Fan Vibration	
       Gas Temperature at inlet, °F
       Fan R.P.M.
         Type_
       Fan Static Pressures:  Inlet
                  Outlet
       Differential Static Pressures:
       Fan Housing Condition	
       Dampers	
       Fan Exit
       Measured
   Panel
                                        59

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D. Electrostatic Precipitator
   Data
Inspection No.
Equipment No._
Confidential:
Page No.  	
                                                         Yes_
                                                          of
No
   1.    DESCRIPTIVE  INFORMATION
        Type	
        Manufacturer
        Model  Number
        Plant Inventory  Number_
        Date  Installed
        Number of Chambers
        Number of Fields  in  Series*
        Specific  Collection Area  (FtVlOOO Ft3)_
        Design  Superficial Viscosity  (Ft/Sec)	
        Pulse Energization (Yes/No)	
        LOCATION
        Building/Area_
        Elevation
        LAYOUT  (SKETCH  FIELD LAYOUT AND NUMBER FIELDS, SHOW FANS)
                                     60

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E. Electrostatic  Precipitator
   External  Inspection
Inspection No.
Equipment No._
Confidential:
Page No.	
                Yes
                of
                                                                 No
       HOPPER LAYOUT  (SKETCH TOP VIEW AND NUMBER; SHOW SOLIDS HANDLING
       SYSTEM)
  2.   HOPPER DESCRIPTION
       Vibrators:  Yes	
       Heaters:  Yes
       Insulation:  Yes	
       Level Indicators:  Yes	
       Physical Condition (Characterize),
No_
No_
No_
No
           Type_
       Transport Equipment:  Screws	 Pneumatic
       Transport Equipment Operating:  Yes	
       Characterize Discharge	
                  Other
            No
                                     61

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E.Electrostatic Precipitator
  External Inspection
 Inspection No.
 Equipment No._
 Confidential:
 Page No.	
                                                         Yes
                                                         of
No
  3.   HOPPER VALVES
       Type:  Screw_
       Speed/Cycle Times_
       Blade Type_
Other
  4.   RAPPER LAYOUT (SKETCH TOP VIEW, SHOW DISCHARGE WIRE UNITS AS D,
       COLLECTION PLATE UNITS AS C AND DISTRIBUTION PLATE UNITS AS X).
                                      62

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E. Electrostatic  Precipitator
   External  Inspection
Inspection No.
Equipment No,_
Confidential:
Page No.	
                                                         Yes_
                                                         of
No
   5.    RAPPER  PERFORMANCE  (Continued)
        COLLECTION PLATE  RAPPERS
No.
Ci
C2
C3
Cu
C5
C6
C7
C8
C9
Cio
CM
Cj2
Cl3
Ciu
Cis
Cl6
Cl7
Cl8
Cig
Cao
Time Interval
(Minutes)




















Duration
(Seconds)






•


-





/




Comments




















                                     63

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E. Electrostatic Precipitator
   External Inspection
Inspection No._
Equipment No._
Confidential:
Page No.	
                                                         Yes.
                                                         of
No
  5.   RAPPER PERFORMANCE
       DISCHARGE WIRE RAPPERS
No.
Di
D2
D3
D,,
Ds
D6
D7
D8
D9
Dio
On
Dl2
Dl3
Dm
Dl5
Die
Dl7
Die
Dis
D20
Time Interval
(Minutes)




















Duration
(Seconds)




















Comments




















                                     64

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E.Electrostatic Precipitator
   External  Inspection
  5.
  6.
                                   Inspection  No._
                                   Equipment No._
                                   Confidential:
                                   Page  No.	
                                                         Yes,
                                                         of
No
RAPPER PERFORMANCE (Continued)
DISTRIBUTION PLATE RAPPERS
No.
Xi
X2
X3
x.»
xs
X6
Time Interval
(Minutes)






Duration
(Seconds)






Comments






RAPPER DESCRIPTION
DISCHARGE WIRES
     Type	
            Number
            Manufacturer
            Air Pressure
       COLLECTION PLATES
            Type	
            Number
            Manufacturer _
            Air Pressure _
       DISTRIBUTION PLATES
            Type	
            Number
            Manufacturer
            Air Pressure
                                     65

-------
E. Electrostatic Precipitator
   External  Inspection
                   Inspection No.
                   Equipment No._
                   Confidential:
                   Page No.	
                                                         Yes_
                                                         of
                                No
   7.   TRANSFORMER - RECTIFIER SET LAYOUT  (SKETCH TOP VIEW SHOWING T-R
       SETS ON CHAMBERS AND  FIELDS)
  8.   TRANSFORMER - RECTIFIER SET DESCRIPTION
       Power Control
       Mode Voltage
Yes
No
         Current
                  Spark Rate
No.
T-Ri
T-R2
T-R3
T-R,,
T-R5
T-R6
T-R7
T-Re
T-R9
T-Rio
Plant
No.










Manufacturer










Model
No.










Mi Hi amp
Rating










Type










                                     66

-------
E.Electrostatic Precipitator
  External Inspection
Inspection No.
Equipment No._
Confidential:
Page No.  	
                                                         Yes_
                                                          of
No
  9.   TRANSFORMER - RECTIFIER SET CONDITIONS
No.
T-R-la
T-R-lb
T-R-2a
T-R-2b
T-R-3a
T-R-3b
T-R-4a
T-R-4b
T-R-5a
T-R-5b
T-R-6a
T-R-6b
T-R-7a
T-R-7b
T-R-8a
T-R-8b
T-R-9a
T-R-9b
T-R-lOa
T-R-lOb
Primary
current
(amperes)




















Primary
voltage
(volts)




















Secondary
current
(milliamps)




















Secondary
voltage
(kilovolts)




















Spark
rate
#/mi n




















Control
mode
M-manual
A-automatic




















                                     67

-------
E. Electrostatic Precipitator              Inspection  No.
   External  Inspection                     Equipment No.J
                                           Confidential:   Yes	No_
                                           Page No.	of	
   10.   OPERATING INFORMATION
        Gas  Inlet Temperature,  °F
        Hopper Heater Operational  Indicator Lights  (Identify units not on)
        Penthouse  Heater/Blower  Operational  Indicator Lights  (Identify units
        not on)	
        Comments
   11.   OPACITY MONITORS
        Opacity - Minimum, %
                 Average, %
                 Maximum, %
        Spikes  (Characterize  Frequency, Duration,  Intensity)_
       Calibration  Spikes  (Characterize Levels, Frequency)
        Comments
                                      68

-------
F. Electrostatic Precipitator
  Interal  Inspection
                                   Inspection No.
                                   Equipment No._
                                   Confidential:
                                   Page No.	
                                                         Yes_
                                                         of
No
  1.   PURPOSE
       Reason(s) Necessary_
       SAFETY EVALUATION
       Lockout Procedure Followed'
Plant Employee Performing Lockout,
Grounding Straps Available:  Yes_
Time Period De-energized (Hours)_
Purge Completed:  Yes	
02» %	
Combustibles, %	
Noise
       Other
                                                     No
                                               No
       Inspection Not Conducted Due to Potential  Hazards (  Characterize)
  2,   AREAS INSPECTED (SKETCH TOP VIEW AND INDICATE ENTRY POINTS)
                                      69

-------
F.  Electrostatic  Precipitator               Inspection No.
   Internal  Inspection                      Equipment No. "
                                           Confidential:  Yes	No_
                                           Page	of	
   3.    HATCH  CONDITIONS

        Gaskets
       Corrosion
  4.    PENTHOUSE  CONDITIONS

        Purge Air	
       Heater(s)
        Insulators
       Alignment of Collection Plates_
       Comments
                                      70

-------
F.  Electrostatic Precipitator              Inspection No.
   Internal Inspection                     Equipment No: "
                                           Confidential:  Yes	No_
                                           Page No.	of	
   5.   ELECTRODE CONDITIONS
        DISCHARGE WIRES
             Type	
             Diameter_
             Material
             Spacing and Length_
             Conditions
        COLLECTION PLATES
             Type	
             Material
             Spacing and Length_
             Conditions
             Alignment_
                                       71

-------
F.  Electrostatic Precipitator              Inspection No.
   Internal  Inspection                     Equipment No/
                                           Confidential:   Yes	No_
                                           Page No.	of	
   6.    INTERNAL SUPPORTS
        Describe
        Conditions
   7.    GAS DISTRIBUTION  EQUIPMENT
        Type	
        Condition
   8.    HOPPERS
        Baffle Condition
        Hopper  Condition_
                                      72

-------
G.   Continuous  Monitor Evaluation
     1.    DESCRIPTIVE DATA
          Manufacturer
          Model.
          Type_
          Date Installed
Inspection No.
Equipment No._
                                             Confidential:   Yes	No_
                                             Page No.	of	
          Single or Multiple Breeching (Describe  Sources).
          NSPS Applicable:   Yes_
         No
     2.    TRANSMISSOM'ETER
          LAYOUT (SHOW LOCATION RELATIVE TO FLOW RESTRICTIONS)
                                         73

-------
G. Continuous Monitor Evaluation
Inspection No.
Equipment No._
                                           Confidential:   Yes	No_
                                           Page No.	of	
   2.   TRANSMISSOMETER (Continued)
        Approximate Path Length, (Feet)_
        Mounting (Characterize)	
        Vibration (Characterize)
        Housing (Characterize)
        Purge Air (Condition of Blowers  and Hoses)
        Filters (Characterize Type and Describe Condition)
        Alignment (Window Check)
   3.   CONSOLES
        Breeching/Stack Correlation
        Zero/Span_
        Comments
                                      74

-------
H. Electrostatic Precipitator              Inspection  No.
   Evaluat1on                              Equipment No. "
                                           Confidential:   Yes	No_
                                           Page  No.	of	
   1.    FILES/ADMINISTRATIVE
        Specification Sheets  Available:   Yes	No_
        Prints  Available (Characterize)	
        Supervisor of Unit
        0  and M  Personnel  (Describe  Staff  and Organization)
   2.    RECORDKEEPING
        Type  Records
        Operating  Records  (List  Parameters)
        Diagnostic  Records  (Characterize)
   3.    PROCEDURES
        Spare Parts  Inventory  (Characterize)
       O&M Plan  (Characterize)
       Troubleshooting  (Character!ze)
                                     75

-------
I. Samples                                      Inspection No._
                                               Equipment No.
                                               Confidential:  Yes	No_
                                               Page No.	of	
  1.   Solids
       Sample No.	
       Location Obtained
       Date/Time Obtained_
       Results
  2.   Other Samples
       Sample No.	
       Location Obtained
       Date/Time Obtained_
            Permeability
            Tensile Strength_
            Count
            Weight/Yard2

  3.   Other
                                      76

-------
J. Electrostatic PreclpHator
   Evaluation
                            Inspection  No.
                            Equipment No._
                            Confidential:
                            Page No.	
                                                         Yes.
                                                         of
                                 No
   1.   POWER INPUT
       Collection Plate Area/Field
            Inlet
            Other
       Discharge Wire Length/Field
            Inlet
  Field
   1.
   2.
   3.
   4.
   5.
   6.
   7.
   8.
   9.
  10.
  11.
  12.
  13.
  14.
  15.
            Other
 Secondary
 Currents
(Mi 11iamps)
 Power
 Input
(Watts)
    Current Densities
(Mill lamps/Ft)   Watts/Ft2
                                      77

-------
K. Process                                 Inspection No.
                                           Equipment No.
                                           Conf 1 denti al:   Yes	No_
                                           Page No.	of	
   1.    PROCESS TYPE
        Characterize Source
        Operating Schedule_
   2.    OPERATION
        Product Type During Inspection_
        Production Da-ta During Inspection_
        Raw Materials During Inspection_
        Fuels  During  Inspection_
                                      78

-------
L. Summary
  1.   POWER INPUT
  2.   MECHANICAL
Inspection No.
Equipment No._
                                          Confidential:   Yes	No_
                                          Page	of	._
  3.   SOLIDS REMOVAL
  4.   EFFLUENT QUANTITY/CHARACTERISTICS
  5.   OTHER


6. SHEETS
A. B. C.
D. E. F.
6. H. I.
J. K.
Preparer: Name
Signature
Date
Reviewer: Name
Signature
Date
Copy Received: Initials
Date
                                      79

-------
                         PEDCO ENVIRONMENTAL
                            INSPECTION DATA SHEET
A. INSPECTION INFORMATION
   1.   IDENTIFICATION
        Company	
        Plant Name
        Plant I.D.  Number_
        Address
        Control  Device/System  Number_
        Process  Served
   2.   PROCEDURES AND CONDITIONS
        Prior Notice:   Yes	No_
        Time(s)  On-Site	

        Type Inspection	

        Inspectors	
        Plant Representatives_
        Information  Claimed  Confidential:  Yes       No
                                         80

-------
B. Visible Emissions
   Observations
                  Inspection No.
                  Equipment No._
                  Confidential:
                  Page No.	
                                                          Yes_
                                                          of
                                No
   1.    STACK CHARACTERISTICS
        Location	
        Height   	
        Temperature	
        Exit Dimensions_
        Orientation
        Other Information
   2.    STACK EFFLUENT
        Detached Plume:
        Color
No
Yes
Distance
        Puffing:   Yes	
        Opacity
    Time       Average Opacity
                 No
             Observation Point
                              Sheet No.
   3.    FUGITIVE  EMISSIONS
        Control Device:   Yes
        Solids  Removal  System:
        Process:   Yes	No_
        Continuous
          No
       Yes
        No
        Adjacent Deposits:   Yes
                Intermittent
             No
                                        81

-------
C. Fan Data
          Inspection No.
          Equipment No._
          Confidential:
          Page No.  	
                                                         Yes_
                                                          of
             No
   1.    FAN MOTOR
        Manufacture^
        Model  No.
        Rated Horsepower
        Volts
        Maximum R.P.M.	
        Operating  Current:   Panel
       _ Type
         Maximum Amps	
         Service factor
              Other
   2.    DRIVE
        Direct
        Sheath  Reduction
Belt
        Audible Belt  Slippage:   Yes_
Other
                   No
   3.    FAN
        Manufacture^
        Model  No.
        Fan  Vibration	
        Gas  Temperature  at  inlet, °F_
        Fan  R.P.M.
        Fan  Static  Pressures:   Inlet
         Type
                  Outlet
        Differential  Static  Pressures:
        Fan  Housing Condition	
        Dampers	
        Fan  Exit
       Measured
   Panel
                                        82

-------
D. Fabric Filter Data
Inspection No. 	
Equipment No. 	
Confidential:  Yes	No
Page No. 	of 	
  1.   DESCRIPTIVE INFORMATION
       Fabric Filter Type 	
       Manufacturer 	
       Model No.
       Plant Inventory No.
       Date Installed
  2.   LOCATION
       Building/Area
       Inside
Outside
  3.   LAYOUT (SKETCH FABRIC FILTER, FAN, INLET, SOLIDS REMOVAL, ETC.)
                                     ~l
                                    83

-------
E.Fabric Filter External
  Inspection
    Inspection No.  	
    Equipment No.  	
    Confidential:   Yes
    Page No.  	of
                                                                  No
  1.   SOLIDS REMOVAL
       Valve Type:  Rotary
Flapper
       Valve Speed/Frequency 	
       Transport Equipment:  Screws 	
       Transport Equipment Operating:  Yes 	
       Transport Equipment Discharging Solids:
       Characterize Discharge 	
Other
           Other
                No
          Yes
    No
       Hopper Vibrators:   Yes
       Hopper Insulation:  Yes
       Hopper Level Indicators
          No _
           No
       Hopper Condition
       Disposal Method
  2.   SHELL CONDITIONS
       Insulated:   Yes
             No
       Possible Weld/Seam Gaps, Characterize
                                      84

-------
E. Fabric Filter External                  Inspection No.
   InsPection                              Equipment No. .
                                          Confidential:  Yes	No
                                          Page No. 	of	
  3.   OPERATING CONDITIONS
       Static Pressure on Clean Side, 	 in.  H20
       Static Pressure on Dirty Side, 	 in.  H20
       On-site Monitor, Differential Static .Pressure 	in.  H20
       Tap Conditions 	
       Gas Inlet Temperature	?F

  4.   CLEANING SYSTEMS
       Type	;	
       Frequency 	
       Air Pressure, 	PSIG
       Drier:  Yes 	No 	
       Evidence of Water and/or Oil Problems 	
       Solenoids Inoperative
  5.   PRECLEANERS
       Type 	
       Static Pressures:  Inlet 	Outlet 	in. H20
       Gas Inlet Temperature	°F
                                     85

-------
Fabric Filter Internal                  Inspection No.
Inspection                              Equipment No.  .
                                        Confidential:   Yes	No
                                        Page No.  	of	
1.   PURPOSE
     Reason(s) Necessary
          Inventory Check
          Comprehensive Inspection
          Other
     Safety Evaluation (Describe if applicable)
          Respirator Necessary 	
          Temperature	°F
          02'	%
          Combustibles 	%
          Electrical Grounding 	
          Mechanical Hazards 	
          Noise 	
          Other
   .  Inspection Conducted:   Yes 	 No
     Inspection Not Performed Due to Safety 	
2.   BAG LAYOUT (ATTACH DRAWING)
     No. of bags 	
     Length 	ft
     Diameter	in.
     Material (Characterize)  	
     Attachment(s)
                                   86

-------
R Fabric Filter Internal                  Inspection No.
  Inspection                              Equipment No. .
                                          Confidential:   Yes	No
                                          Page No.  	of	
  3.   HATCH CONDITIONS
       Gaskets
       Corrosion
       Bolts/Ears
       Ease of Access
  4.   LEAK JETS
       Location
       Number
  5.   BAG CONDITIONS
                                      87

-------
F.  Fabric  Filter Internal
   Inspection
Inspection No. 	
Equipment No. 	
Confidential:  Yes
Page No. 	of
                                                                   No
   6.    HOPPERS  AND  BLAST PLATES
   7.    CLEANING  APPARATUS
                                          88

-------
G  Samples                                 Inspection No.
                                           Equipment No.
                                           Confidential:   Yes 	 No
                                           Page No.  	of	
        SOLIDS DEPOSITS
        Sample No.. 	
        Location Obtained _
        Date/Time Obtained
        Results
   2,   FABRIC SAMPLES
        Sample No.  	
        Location Obtained _
        Date/Time Obtained
             Permeability
             Tensile Strength
             Count
             Weight/Yard2

   3.   OTHER
                                         89

-------
H Ventilation System
Inspection No. 	
Equipment No. 	
Confidential:  Yes	No
Page No. 	of	
  1.   DUCTS (SHOW  STATIC PRESSURES  ON LAYOUT.)
                              MILL
  2.   HOOD
       Configuration
       Average  Capture Velocity 	
       Thermal  Drafts (Characterize)
                             ft/mi n
       Cross  Currents (Characterize)
       Estimated Effectiveness
                                     90

-------
I  Process
  1.    PROCESS  TYPE
       Characterize  Source
Inspection No.  	
Equipment No.  	
Confidential:   Yes	No
Page No.  	of	
       Operating  Schedule
  2.    OPERATION
       Product  Type  During  Inspection
       Production  Rate  During  Inspection
       Raw Materials  During  Inspection
       Fuels  During  Inspection
                                       91

-------
                                                                                                                                                            o-
                                                                                                                                                            -$
                                                                                                                                                            o
Possible Operating Problems Average Baseline
(Specify Value)
Observed Location* Abnormal RntJiif, RecommcMidril Art Ion
(Specify Value) (Check) (1-10)
D. Cleaning System
1.
2.
3.
4.
5.
6.
7.
8.
E. Hoj
D 1-
J
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Filter house pressure drop
high
Pulse- iet air header pres-
sure low
Solenoids inoperative
Reverse air fan inoperative
Shaker motor Inoperative
Bag length long
Equipment inaccessible
High intensity cleaning
required
?per
Kilter house pressure
drop high
Solids-removal run In-
termittent
Indicator level existent
and/or inoperative
Heaters nonexistent and/or
inoperative
Vibrators nonexistent
and/or inoperative
Hopper valves corroded
Hopper slope <60°
Hoppers not Insulated
Winter
Hammer markings on hopper
ua 1 1 s
Conveyor inoperative


N/A
N/A
N/A

N/A


N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

	
N/A
N/A
N/A

N/A

N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

E
E
E or I
E or 1
E or 1
E
I
E
E
. E
E
E
E
1
E
E
E
E
E
	 5 If sum (X) of nil lugs is >IO,
perform internal Inspection
5 and rherk deposits on dirty
side of bans. Check bag ten-
10 ston. Reschedule inspection
10 in near future.
10
2
2
2
I =
5 If sum (I) of ratings Is >10,
perform internal inspection
3 of hoppers.
2
2
2
3
2
2
2
2
10
T. =
                                                                                                                                                            fD
                                                                                                                                                            -S
                                                                                                                                                            CU
                                                                                                                                                            rt-
                                                                                                                                               -a  c~>  m
                                                                                                                                               QJ  o   -O
                                                                                                                                              in  3   c
                                                                                                                                                             o
                                                                                                                                                    a.  3
                                                                                                                                                    CD   fD
                                                                                                                                                    3   3   -"•
                                                                                                                                                    rt-  rt-   O
                                                                                                                                                    -••       3
                                                                                                                                                    tu   ~Z.
                                                                                                                                                    — •  O   Z
                                                                                                                                                    ...    O
                                                                                                                                                    tt>
                                                                                                                                               O   (/>
                                                                                                                                               -b
*Location:  E  Is  external,  and I  is  internal.

-------
U)
Possible Operating Problems Average Baseline
(Specify Value)
A.
B.
>
)
C.
Bag Tears or Pinholes
1. Filter house pressure
drop low (<80% avg.)
2. Opacity high
3. Bag age high (typical avg.)
4. Some bags inaccessible N/A
5. Design A/C high (>120X avg.)
6. Actual A/C high (>120% avg.)
7. Wear plate eroded N/A
8. Frequent high excursions
Bag Blinding
1. Filter house pressure
drop high (>150% avg.)
2. Opacity low
3. Cleaning frequency high
(cycles/day)
4. Gas temp low (<20°F avg.)
5. Moisture in gas stream N/A
6. Particulate sticky N/A
7. Air in-leakage (hoppers/ N/A
access doors)
8. Unit not insulated N/A
Bag Bleeding
1. Opacity high
2. Pressure drop gradually
Increasing
3. Cleaning frequency high

Observed Location*
(Specify Value)
E
E
E
N/A I
E
E
N/A I
E or I
E
E
E
E
N/A E
N/A E
N/A I
N/A E
E
E
E

Abnormal Rating
(Check) (1-10)
3
5
5
2
tt
4
3
4
I =
7
2
5
4
4
4
2
2
I =•
5
2
5
I =
Recommended Action
If sum (!') of ratings is > 10
perform internal Inspection.
Check for deposits on fil-
ter house clean side. Check
inaccessible bags. Use
fluorescent dye technique.
Check integrity of fabric by
attempting to extend rips.
If sura (E) of ratings is >10.
perform internal inspection.
Check dirty side of bags for
coatings (this may be diffi-
cult to Identify in some
cases). Check records for
steady rise in filter house
pressure drop. Reschedule
inspection in near future.
If sum (1) of ratings Is >10,
attempt to confirm uses of
fluorescent dye and black
light.
                                                                                                                                                                      CT
                                                                                                                                                                      1

                                                                                                                                                                      o
                                                                                                                                                                       ft)
                                                                                                                                                                       -s
                                                                                                                                                                       <
                                                                                                                                                                       OJ
                                                                                                                                                                       O
                                                                                                                                                                       3
                                                                                                                                                         -o
                                                                                                                                                         OJ
                                                                                                                                                         n>
                                                                                                                                                         o
                                                                                                                                                         -h
o   m  •—<
o  .a   3
3   c   in
-h   -••  -a
—*•  "O   fD
Q.   3   O
(D   ft>   «-h
3   3   -*•
«-h   rt-  O
                                                                                                                                                              n>
             *Locatlon:   E is  external,  and  I  Is Internal.

-------
K  Summary                                 Inspection No.
                                           Equipment No.
                                           Confidential:   Yes	No
                                           Page No.  	of	
        CONTROL SYSTEM PERFORMANCE
        System Air Flow Based on Fan Data 	ACFM
        System Air Flow Based on Pi tot Traverse 	
        System Air Flow Based on Process 	
        Actual Air to Cloth Ratio 	
        Design Air to Cloth Ratio 	
        Fabric Compatibility with Environment 	
   2.   ADDITIONAL COMMENTS
   3.   SHEETS INCLUDED
A.
G.
Preparer:
Reviewer:
B.
H.
Name
Date
Name
Date
C. D. E. F.
I. J. K.
Signature

Signature

   Copies Received 	  Initials 	Date
                                         94

-------
Fabric Filter Supplemental               Inspection No.
Information                             Equipment No. .
                                        Confidential:   Yes  	 No
                                        Page No.  	of	
                                    95

-------
Fabric Filter Supplemental              Inspection No.

Information                             P  .     ^ ,,
                                        Equipment No.
                                        Confidential:  Yes	No


                                        Page No.  	of	
                                    96

-------
                       PEDCO ENVIRONMENTAL
                       WET SCRUBBER INSPECTION DATA, SHEET
LOCATION
DESIGNATION
CLIENT 	
PN
CLAIMED
CONFIDENTIAL  Yes
NO
         DATA SHEET NO.
         DATE
         INSPECTOR(S)  _
         INSPECTION NO.
    DESCRIPTIVE INFORMATION
     Wet Scrubber Type 	
     Manufacturer 	
     Model Number
     Date Installed
     Process/Source Controlled _
     Particulate Characteristics
B.  COMPONENT INFORMATION (Describe if applicable)
     1.  Gas Pretreatment:
         Presaturator 	
         Cyclones 	
         Settling Chamber 	
         Other
         Demister:
         Cyclone _
         Chevron
         Fiberous Mat
         Other
         Pumps:
         Number
         Recirculation 	
          Pump Manufacturer
         Recirculation
          Pump Rated Horsepower
         Recirculation Pump Type

                               97

-------
                                   Inspection No.
                                   Data Sheet No.
                                   Preparer 	
                                   Confidential:   Yes	 No	
B.  COMPONENT INFORMATION (continued)
     4.  Fan/Motor (Specify)
         Fan Manufacturer 	
         Blade Type:   Radial 	
         Drive:   Direct
          Backward
               Belt
Forward
         Damper Position  .
         Motor Manufacturer
         Model No.
         Rated Horsepower 	
         Location:   Forced Draft
                Induced Draft
     5.   Instrumentation (Check if Applicable)
         Differential
         Pressures:
         Temperatures:
Throat
                         Separator
                         Demister
Gas Outlet
Gas Inlet
         pH:
Liquor Inlet
Liquor Outlet
Recirculation
Exit Liquor _
                         Fan Motor Current
                         Other
         Flow Rates:
         Motor Current:
Nozzle Pressure
Recirculation 	
Makeup 	
Purge 	
Fan 	
Pump	
                               98

-------
                                   Inspection No.
                                   Data Sheet No.
                                   Preparer 	
                                   Confidential:  Yes	 No_

B.  COMPONENT INFORMATION (continued)
     6.  Materials of Construction (Specify type and gauge)
         Presaturator 	
         Throat 	
         Scrubber Shell
         Trays/Bed Supports
         Demister
         Fan Housing
                               99

-------
                                   Inspection No.
                                   Data Sheet No.
                                   Preparer 	
                                   Confidential:  Yes   No
C.  DIAGRAM
     1.  Sketch wet scrubber system.  (Show all major compon-
         ents and processes controlled.)
     2.  Sketch wet  scrubber  layout  (each  square  1'  x  I1)
                               100

-------
                               Inspection No.
                               Data Sheet No.
                               Preparer 	
                               Confidential:  Yes
      No
SAMPLE ANALYSIS
 Scrubber Liquor Effluent
      Sample No. ____•	
      Location Obtained 	
      Date/Time Obtained
      Results:
      Suspended Solids 	
      Dissolved Solids 	
      PH 	
      Chloride
 Scrubber Recirculation
      Sample No. 	
      Location Obtained
      Date/Time Obtained
      Results:
      Suspended Solids 	
      Dissolved Solids 	
      PH 	
      Chloride
ppm
ppm

ppm
ppm
ppm

ppm
 Other
                            101

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                               Inspection No.
                               Data Sheet No.
                               Preparer 	
                               Confidential:  Yes
                                                        No
H
CONTROL SYSTEM PERFORMANCE
 Gaseous Flow
   (implied from fan operation)
. Gaseous Flow
   (calculated from pitot traverse)
 Gaseous Flow	
   (implied from process operation)
 Liquor Flow
 L/G Ratio 	
 Bypass ,(% of total gas flow)
 Throat Velocity 	
 Superficial Velocity  (design) 	
                       (effective)
 Visible Emissions  (residual)
ADDITIONAL COMMENTS
                                                    ACFM
                                                    ACFM
                                                    ACFM
                                                    gpm
                                                    FPS
                                                    FPM
                                                    FPM
                Sheets Included:
                                      A
                                      D
                                      G
B
E
H
C
F
                Inspector's Signature
                Date Prepared 	
                Reviewer's Signature
                Date Reviewed •	
                Date Filed
                            102

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                      PEDCO ENVIRONMENTAL
                      MECHANICAL COLLECTOR INSPECTION DATA SHEET
LOCATION
DESIGNATION
CLIENT 	
PN
CLAIMED
CONFIDENTIAL Yes
NO
A.  DESCRIPTIVE INFORMATION
     Mechanical Collector Type
          DATA SHEET NO.
          INSPECTION NO.
          INSPECTOR(S)  _
          DATE
          Cyclone 	
          Cyclone Bank
          Multiclone
      Settling Chamber 	
      Double Vortex Cyclone
      Other (describe)
     Manufacturer
     Model Number
     Date Installed
     Process/Source Controlled
     Particulate Characteristics
B.  COMPONENT INFORMATION
     1.  Cyclone
          Diameter of Body
          Cone Angle 	
                                      ft.
                                      degrees
          Material of Construction
          Gauge of Metal 	
          Number of Cyclones
         Hoppers
          Number
          Slope 	
          Insulation:  Yes
          Heating:   Yes 	
          Vibrators:  Yes
                     No
                    No
                   No
                                103

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                                   Inspection No.
                                   Data Sheet No.
                                   Preparer 	
                                   Confidential:  Yes
                                               No
B.  COMPONENT INFORMATION (continued)
     3.  Solids Removal (Check applicable items and provide
         dimensions)
          Rotary Valves
          Flapper Valves
     4.
          Screw Cpnveyors 	
          Pneumatic Conveyors
          Free Fall
Fan/Motor
 Fan Manufacturer 	
 Model Number 	
 Blade Type:  Radial
 Drive:  Direct
                                   Backward
Forward
                                           Belt
          Motor Manufacturer
          Model Number
          Rated Horsepower
          RPM
          Location:  Forced Draft
                                Induced Draft
    SYSTEM LAYOUT
                               104

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                                   Inspection No.
                                   Data Sheet No.
                                   Preparer 	
                                   Confidential:  Yes
 No
D.  EXTERNAL INSPECTION
     Fan Inlet Static Pressure
     Fan Outlet Static Pressure
     Fan Motor Current
     Fan Rotational Speed 	
     Fan Damper Position 	
     Gas Temperature at Fan Inlet 	
     Fan Vibration (low, moderate, severe)
     Static Pressure at Collector Outlet _
     Static Pressure at Collector Inlet
     On-site Differential Pressure Gauge Reading
     Gas Temperature at Collector Inlet 	
     Rotary Valve Rotational Speed 	
     Flapper Gate Frequency 	
     Hopper Conditions (Check if applicable)
                    Cold 	
                    Dented 	
                    Warped 	
                    Corroded
in. of H-O
in. of H-O
amperes
rpm
in.
in.
in.
o.
of H20
of H2O
of H20
 F
rpm
(f/hr)
                               lOi

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                                   Inspection No.
                                   Data Sheet No.
                                   Preparer 	
                                   Confidential:  Yes	 No_
E.  INTERNAL INSPECTION
     Hoppers (plugged or corroded) 	
     Hopper Baffles Nonexistent  (Characterize potential abra-
     sion)
     Inlet Vanes Plugged/Eroded  (Characterize severity)
     Cones Plugged (location, number)
     Flow Disturbances (Characterize severity)
     Outlet Tube Erosion (Characterize potential bypassing)
     Corrosion (Characterize)
     Scaling (Characterize)
                               106

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                                   Inspection No.
                                   Data Sheet No.
                                   Preparer 	
                                   Confidential:  Yes   No
F.  CONTROL SYSTEM PERFORMANCE
     Air Flow Rate (implied from fan operation) 	 ACFM
     Air Flow Rate (calculated from pi tot tube) 	 ACFM
     Air Flow Rate (implied from process operation) 	 ACFM
     Inlet Velocity 	'_ FPS
     Opacity 	-   %
G.  ADDITIONAL COMMENTS
                         Sheets Included:  A	 B	 C
                                           E    F   G
                         Inspector's Signature
                         Date Prepared 	
                         Reviewer's Signature
                         Date Reviewed 	
                         Date Filed
                               10.7

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 SOURCE NAME
                                                                  SOURCE ID NUMBER
                                                                                                        OBSERVATION
                                                                                                        DATE
                                                                  OBSERVER'S NAME (PRINT)
                                                                  ORGANIZATION
                                                                             CERTIFIED BY
                                          OPERATING MODE
CONTROL EQUIPMENT
                                          OPERATING MODE
DESCRIBE EMISSION POINT
EMISSION POINT HEIGHT
ABOVE GROUND LEVEL
                                   EMISSION POINT HEIGHT
                                   RELATIVE TO OBSERVER
DISTANCE TO
EMISSION POINT
                                   DIRECTION TO
                                   EMISSION POINT
DESCRIBE EMISSIONS
                                   CONTINUOUS Q   FUGITIveJj

                                   INTERMITTENTQ
COLOR OF EMISSIONS
WATER VAPOR PRESENT
                                   IF YES. IS PLUME
                                   ATTACHED        DETACHED
AT WHAT POINT WAS OPACITY
                             DETERMINED
DESCRIBE BACKGROUND
COLOR OF BACKGROUND
                                   SKY CONDITIONS
                                   WIND DIRECTION
AMBIENT TEMPERATURE
                                   RELATIVE HUMIDITY
                                                                                                                READINGS ABOVE
                                                                  AVERAGE OPACITY
                                                                  RANGE OF OPACITY

                                                                  READINGS
 SOURCE LAYOUT SKETCH
                                                                                                              DRAW NORTH
                                                                X
                                                            EMISSION PT.
OBSERVER'S SIGNATURE
                                                                    I HAVE RECEIVED A COPY OF THESE OPACITY OBSERVATIONS

                                                                    SIGNATURE
                                                              108

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