Example Quality Assurance / Quality Control Plan for Continuous Emission Monitor Systems and Continuous Opacity Monitor

Systems (CEMS/COMS)
The following is an example of a Quality Assurance / Quality Control (QA/QC) Plan for Continuous Emissions Monitoring Systems or CEMS This QA/QC Plan meets the minimum re!uirements of the "n#iana State $ule %&' "AC %()(* Stan#ar# +perating Proce#ures an# Chapter &, of the "n#iana Quality Assurance Manual This example QA/QC Plan may -e use# as a gui#e for the construction of your CEMS QA/QC Plan Please .eep in min# that this example plan has the -asic elements that comprise a goo# QA/QC Plan -ut/ it may not co0er all the areas that are specific to your plant1s CEMS 2e sure to incorporate your specific operational .nowle#ge/ experience an# applica-le State an# 3e#eral re!uirements into the QA/QC Plan for your company "f you ha0e any !uestions please call 4arro# 3isher at (%56) &%%(&6&%/ fax at (%56) &%%('7') or e(mail at 8fisher9i#em in go0

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BOLD , UNDERLINED, UPPER CASE ITALICS in this Plan1s text is inten#e# for areas in which company names/ -oiler num-ers or other text can -e inserte# Text which is bold, underlined lower case italics is inten#e# for areas where a##itional text may -e inserte# into the Plan

Continuo u s Emission Monitoring Syste m s (CEMS) Quality Assura n c e /Q u ality Control Plan
for

COMPANY - PLANT

UNIT - MONITOR( S )

DATE

TABLE OF CONTENTS

Section 1.0 Introd uc tio n Section 1.1 Quality Assura n c e and Quality Control (QA / QC) Definition and Function Section 1.2 Quality Assura nc e Policy, Goal, and Objective Section 1.3 Distribution and Docu m e n t Control Section 2.0 Orga niz a tion and Respo n si ble Individu als Section 2.1 Com m u nic a tio n of Inform a tio n, Data and Report s Section 2.2 Emission Data and Emission Report s Section 2.3 QC Data and Report s Section 2.4 QA Audit Data and Report s Section 2.5 QA Results and QA Reports Section 2.6 Emission Data and Emission Report s Section 3.0 Description of Facility and CEMS Section 3.1 Facility Section 3.2 Continuo u s Emission Monitoring Syst e m 3.2.1 Sa m pl e Probe s 3.2.2 Sa m pl e Trans p or t 3.2.3 Analyzers 3.2.3.1 NOx 3.2.3.2 Opacity 3.2.4 Support Hardw ar e 3.2.5 Data Acquisition and Handling Syst e m Section 4.0 Training Section 4.1 Quality Assura n c e Training 4.1.1 Gene r al Training 4.1.1.1 Quality Assura n c e Plan 4.1.1.2 Periodic Refres h e r Training Section 5.0 Quality Control/Quality Assura n c e Activities Section 5.1 Quality Control Activities 5.1.1 Calibration Gas e s 5.1.2 Calibration Check 5.1.3 Syst e m s Audit Section 5.2 Quality ass ur a n c e Activities 5.2.1 Relative Accuracy Test Audit (RATA) 5.2.2 Cylinder Gas Audit (CGA) 5.2.3 Opacity Audit 5.2.4 Perform a n c e Specification Testing Section 5.3 Data Recordin g and Reportin g

TABLE OF CONTENTS

Section 5.4 Preve n tiv e Mainte n a n c e Section 5.5 Repair Progra m Section 5.6 Spar e Parts Invent ory Section 5.7 Activity Matrix Section 6.0 Docu m e n t a t i o n and Report s Section 6.1 DAHS Section 6.2 Emission Measur e m e n t Data Proce s sin g Section 6.3 DAHS Report s Section 6.4 Mainte n a n c e Record Section 6.5 Audit Report s Section 6.6 CGA Gas Certification Section 7.0 Quality Assura n c e Proce d u r e s Section 7.1 Introd uc tio n Section 7.2 RATA Proce d u r e s 7.2.1 Prelimin ary Activities 7.2.2 Detaile d Proce d u r e s 7.2.3 Data Reduction and Analysis 7.2.4 Relative Accuracy Calculation s 7.2.5 Report Prep ar a tio n Section 7.3 Proce d u r e s for CGA 7.3.1 Introd uc tio n 7.3.2 Cylinder Gas Audit 7.3.3 Data Reduction and Analysis 7.3.4 Reporting Section 8.0 QC Proce d u r e s Section 8.1 Introd uc tio n Section 8.2 Daily Calibration Check Section 8.3 Weekly Syste m s Audit Section 8.4 Quart e rly Syst e m s Audit Section 9.0 Routine Preve n tiv e Mainte n a n c e Section 10.0 Correc tive Action and Require d Notifications Section 10.1 Sugg e s t e d Correctiv e Action Section 10.2 Require d Notification s Section 11.0 Refer e n c e s Section 12.0 Attach m e n t s

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Page No.: 1 of 3 1. 0 INTRODUCTION

A Quality Assura n c e (QA) Plan is the basis for ass e s si n g and maint ai ning of the qual ity of continu o u s emission monitoring dat a. This QA Plan has bee n prep a r e d for the COMPANY oper a t o r s of Continuo u s Emission Monitoring Syst e m s (CEMS) at the PLANT NAME in CITY OR COUNTY , Indian a. Thes e CEMS are use d for me a s u r e m e n t of efflue n t pollution conc e n t r a tio n s from boiler(s) No. BOILER NUMBER OR DESIGNATION and stack opacity from boilers num b e r( s) BOILER NUMBER OR DESIGNATION . In th e Plan , lis t th e CEMS co v e r e d b y th e Plan . For ex a m p l e : The following CEMS hav e bee n inst alled and certified at PLANT NAME: CEM NOx CO 2 BRAND- MODEL SERIAL NUMBER SPAN LOCATION TECO 42 42D- 1234 5- 269 1000 pp m Unit # 1- Stack A Milton Roy 3300 N1 E0392 4 20% Unit # 1- Stack A

Thes e CEMS were installe d to com ply with the specific require m e n t s of the OPERATING PERMIT, STATE RULE, FEDERAL REGULATION , AGREED ORDER, ETC . Thes e CEMS also provid e proc e s s dat a to aid in the oper a tio n and the maint e n a n c e of the pollution control equip m e n t require d at this facility. This quality assur a n c e plan was dev elo p e d from guide lines develo p e d by Indian a Depar t m e n t of Environ m e n t a l Mana g e m e n t , Office of Air Quality (IDEM - OAQ) and the U. S Environ m e n t a l Protec tion Agency. All docu m e n t s used in the dev elop m e n t of this quality ass ur a n c e plan are liste d in Section 10, Refere n c e s .

1. 1 QUALITY ASSURANCE AND QUALITY CONTROL (QA / QC) DEFINITION AND FUNCTION Quality Assura n c e and Quality Control are two inde p e n d e n t and interr el a t e d functions . First, Quality Assura n c e will be define d as a syst e m of gen e r al progr a m m a t i c activities imple m e n t e d to ens ur e Quality Control is perfor min g ade q u a t e l y. Where a s , Quality Control is define d as a series of specific activities perfor m e d to provide a reprod u cible quality prod uc t. Cons e q u e n tl y, quality ass ur a n c e serve s as a quality control for the quality control function.. QA Plans consist of prim arily two function s: (1) the QA function which is the ass e s s m e n t of the quality of the dat a (accur a c y and precision) and, (2) the QC functions which are the activities that maint ai n or improv e dat a quality. Thes e two functions com bin e d form a control loop. For inst a n c e ,

when accur a c y or precision (a QA function) is unacc e p t a b l e , QC functions mus t incre a s e until the quality of the dat a is acce p t a bl e .

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Quality Assura n c e involves me e ti n g progr a m m a t i c require m e n t s but on occasion require s the imple m e n t a t i o n of ext er n al checks on dat a quality. Thes e ext er n al checks may includ e inde p e n d e n t syst e m audits, third party sa m pl e and analysis for accur a c y and precision, com p a ris o n to know calibra tion sta n d a r d s or interla b o r a t o r y audits. Conver s ely, Quality Control functions are usu ally a series of frequ e n t (daily, weekly, mont hly) routin e intern al checks, such as syst e m insp ec tio n s, periodic calibra tion s , and routin e maint e n a n c e . A compl e t e Quality Assura nc e Plan enco m p a s s e s both QA and QC function s and strives to identify which function is addr e s s e d by a specific activity.

1. 2

QUALITY ASSURANCE POLICY, GOAL, AND OBJECTIVE

It is COMPAN Y NAME'S policy to efficiently oper a t e and maint ai n its facilities and CEMS in accord a n c e with good oper a tin g practice s and all applica ble local, stat e and feder al environ m e n t a l regul ation s . COMPAN Y NAME is com mit t e d to collecting all nec e s s a r y dat a to de m o n s t r a t e that its oper a tio n s are in com plianc e with its oper a tin g per mit. The COMPAN Y NAME is also com mit t e d to ens urin g tha t all environ m e n t a l control syst e m s are oper a tin g within acce p t a bl e limits. The goal of this QA progr a m is to provide emis sion dat a of known and acce p t a bl e quality and in sufficient qua n tity to de m o n s t r a t e com plia nc e with the following air pollution emission and monitoring regula tio n s: List th e ap p li c a b l e re g u l a t i o n s , for ex a m p l e : 40 CFR 60, SUBPART Db INDIANA OPERATING PERMIT NO. XXXXX 40 CFR 60, APPENDIX F 40 CFR 60 APPENDIX B

32 6 IAC 3- 1. 1 - 4 COMPAN Y NAME recog niz e s that the reliability and acc e p t a bility of CEMS dat a is directly dep e n d e n t on satisfact ory com ple tion of all activities stipulat e d in a well- define d QA plan. Accordingly, the objective of this QA Plan is to define thos e activities nece s s a r y to guar a n t e e that CEMS dat a quality is maint ain e d at acc e p t a bl e levels. The Plan also provid e s the fram e w o rk for carrying out QA activities by addr e s sin g item s such as docu m e n t a ti o n, training, correctiv e actions, and prev e n tiv e maint e n a n c e activities.

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This Plan addr e s s e s oth er nec e s s a r y supp ort servic es and activities, such as ma n u al met h o d s sourc e testing, dat a reduc tion, missing dat a routin e s , inven t o ry control and report prep a r a tio n and sub mitt al, all of which are requir e d to maint ain dat a qual ity. It should be not e d that som e QA/QC activities may not be discus s e d in as gre a t det ail as oth er more critical activities. Activities not fully discus s e d may include, but are not limite d to, dev elo p m e n t of instru m e n t maint e n a n c e ma n u al s (usu ally provide d by the man uf a c t u r e r ), procur e m e n t proc e d u r e s , and plant oper a tion proc e d u r e s . Thes e proc e d u r e s are refer e n c e d is this QA Plan and may be upd a t e d as the CEM progr a m dev elo p s throu g h oper a tio n al exp e rie n c e .

1. 3

DISTRIBUTION AND DOCUMENT CONTROL

This QA Plan will be review e d ann u ally and any chan g e s and revisions will be forward e d to all appro p ri a t e parties . In the eve n t a major revision to the QA Plan is require d, eac h copy will be reissu e d to all appro pri a t e pers o n s . All revisions to the Plan will be clearly mark e d on each pag e with a revision nu m b e r and revision dat e. When modification s to the QA Plan beco m e nece s s a r y , TITLE is respo n sibl e for ens urin g that curre n t revisions are includ e d in the QA Plan, and that distribution of the revis e d Plan is mad e to all appro p ri a t e partie s.

A copy of this QA Plan will be sent to the Indian a Depar t m e n t of Environ m e n t a l Manag e m e n t Office of Air Quality (IDEM - OAQ) for their review and com m e n t . All futur e chan g e s or revisions to the Plan will also be forward e d to IDEM - OAQ.

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2. 0

ORGANIZATION AND RESPON SIBLE INDIVIDUALS

Pro v i d e a lis ti n g or flo w ch a r t of th e indi vi d u a l s an d / o r th e i r titl e s in th e co m p a n y / p l a n t re s p o n s i b l e for CEMS an d CEMS- rel a t e d op e r a t i o n s . Inclu d e du t i e s an d re s p o n s i b i l i t i e s su c h as ba s i c pla n t op e r a t i o n s , CEMS op e r a t i o n an d m ai n t e n a n c e , pr o c u r e m e n t , QA/QC, da t a an d re p o r t re v i e w , tr ai n i n g an d su p e r v i s o r y fun c t i o n s .

2. 1

COMMUNICATION OF INFORMATION, DATA AND REPORTS

For a QA plan to be function prop e rly, provisions mus t be mad e for the effective com m u nic a tio n of the results from QA/QC activities to all affect e d partie s. Clear chan n el s of com m u nic a tio n and respo n sibility mus t exist within the respo n sibl e dep a r t m e n t and throu g h o u t the Plant. Emissions dat a and emission s report s are crucial parts whe n det e r mi nin g

the oper a tio n al stat u s of a CEMS syst e m . This Plan also provid e s for the com m u nic a tio n of QA and QC inform a tio n and the nece s s a r y mec h a ni s m s for trigg erin g correctiv e actions bas e d on the cont e n t s of the QA/QC report s.

2. 2

EMISSION DATA AND EMISSION REPORTS

TITLE is respo n sible for the prep a r a tio n and distribution of all emission report s. Therefor e, CEMs dat a must flow throu g h this position to ens ur e the accur a t e and com pl e t e pre p a r a tio n of quart e rly report s. TITLE is respo n sibl e for verifying tha t the dat a are reduc e d , validat e d , and report e d prop e rly. Addition ally, as an inde p e n d e n t QA/QC check, TITLE will decid e if the emission dat a is following an acc e p t a bl e tren d as bas e d on docu m e n t e d boiler and control equip m e n t oper a tin g record s. This review of emission dat a is used to identify periods of unus u al oper a tion, which may be indicativ e of CEM oper a ti n g proble m s .

2. 3

QC DATA AND REPORTS

There are ma n y type s of QC checks perfor m e d routin ely. With resp e c t to the num e r o u s type s and the various levels of string e n c y involved in the s e test s it is impra ctic al to discus s every possible direction of inform a tio n flow or exch a n g e .

Section No.: 2 Revision No.: 0 Date: Se p t e m b e r 10 , 19 9 7 Page No.: 2 of 3 Howev er, an exa m pl e of a QC inform a tio n exch a n g e would be the daily zero/s p a n calibration check. The CEMS auto m a tic ally switch e s to sa m pling known gas conc e n t r a ti o n s once every 24 hours and the s e value s are logg e d to a com p u t e r dat a acquisition and han dling syst e m (DAHS). On a daily basis, TITLE would review the me a s u r e d value s comp a r e d to the known conc e n t r a tio n s to det e r mi n e if the QC check is within per mis sible limits. If value s are outsid e limits, the TITLE would proce e d to the instru m e n t to compl e t e a visual insp ec tio n checklist. Norm ally, it the value s are confirm e d to be outsid e the oper a ti n g limits a recalibr a tio n of the instru m e n t is nec e s s a r y . After recalibr a tion, the visual checklist, the daily calibra tion report and a description of corrective action would be sub mitt e d to the

TITLE for review. If any unus u al conditions continu e to be obs erv e d , the TITLE will initiat e a maint e n a n c e requ e s t to det e r mi n e and rep air the obs erv e d proble m . Upon com ple tion of the maint e n a n c e rep air requ e s t , a det ailed description of the proble m and its resolution will be ent er e d in the maint e n a n c e log records and report e d to the TITLE for any furth e r postmaint e n a n c e QA/QC actions. After the review of the s e report s is com pl e t e d , each report will be place d in a per m a n e n t file for later docu m e n t a t i o n and use in report sub mitt al.

2. 4

QA AUDIT DATA AND REPORTS

Quality ass ur a n c e audits includ e quart e rly Cylinder Gas Audits (CGA) , annu al Relative Accuracy Test Audits (RATA) and quart e rly opacity Calibration Error (CE) audits. Thes e audits are perfor m e d in accord a n c e with sta n d a r d proc e d u r e s and are use d to det er mi n e CEM accur a c y on a periodic basis. The actu al perfor m a n c e of an audit may be conduc t e d by a contr a c t o r or by TITLE . Regar dle s s of whom actu ally conduc t s the audit, TITLE is respo n sible for the com pl e t e n e s s and the correct n e s s of the final audit report. This report det ails a com p a ris o n betw e e n results and comp a r a bl e CEM dat a and consists of all raw dat a as well as final results.

2. 5

QA RESULTS AND QA REPORTS

TITLE is respo n sible for com pilation, pre p a r a tio n and distribution of QA results and report s to all appro pria t e grou p s. TITLE is also resp o n si ble for prep a r a tio n of the final QA report and its sub mit t al to the Indian a Depa rt m e n t of Environ m e n t a l Mana g e m e n t Office of Air Quality (IDEM OAQ).

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2. 6

EMISSION DATA AND EMISSION REPORTS

In com plia nc e with our oper a ti n g per mit requir e m e n t s , all emission dat a is availa ble for review, eith er as a com p u t e riz e d dat a bas e or print e d emission logs, and maint ain e d in a file for 24 mont h s . All quart e rly complia nc e report s will be sub mit t e d to the IDEM - OAQ within 30 days of the end of the quart e r as define d in the oper a tio n per mit.

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10 , 19 9 7 Page No.: 1 of 3

3. 0 3. 1

DESCRIPTION OF FACILITY AND CEMS FACILITY

Pro v i d e a bri e f d e s c r i p t i o n an d a dia g r a m of th e pla n t / b o i l e r ( s ) an d s t a c k s rel a t e d to th e CEMS, for ex a m p l e : BOILER NUMBER OR DESIGNATION is a Folster Whe ele r 200,0 0 0 poun d s of ste a m per hour circulating fluidized bed, firing Indian a bitu mino u s coal. Dry limes t o n e injection into the furnac e are a is use d to control sulfur dioxide emission s. [DIAGRAM ]

3. 2

CONTINUOUS EMISSION MONITORING SYSTEM

Pro v i d e a g e n e r a l d e s c r i p t i o n an d dia g r a m of th e CEMS, for ex a m p l e : The specific CEMS em ploy e d her e is bas e d on an extra c tiv e sa m pl e acquisition syst e m using a dilution prob e for moist ur e , gas e s and particula t e control. Major comp o n e n t group s of this syst e m include: sa m pl e prob e , sa m pl e tran s p o r t , sa m pl e analyz er s , suppor t hardw a r e , and dat a acquisition handling syst e m (se e figure). Effluent com p o n e n t s monitor e d and me a s u r e d include LIST THE MEASURED GASES AND/OR FLOW S . Opacity is me a s u r e d using stack moun t e d in-situ devic es . [DIAGRAM ]

Section No.: 3 Revision No.: 0 Date: Se p t e m b e r 10 , 19 9 7 Page No.: 2 of 3 3. 2 . 1 Sa m p l e Prob e s

De s c r i b e th e sa m p l e pr o b e , its co n s t r u c t i o n m a t e r i a l s , co m p o n e n t s , flo w ra t e s , dilu t i o n ra ti o , e t c . , for ex a m p l e : Each prob e consists of a 12- inch tip moun t e d on an ext e n sio n to position the tip at the sa m pl e extr ac tio n point. The sa m pl e point is a repr e s e n t a ti v e location within the efflue n t stre a m . Cont ain e d within the prob e are: - a cours e ste el me s h particula t e filter, - a fine quartz wool particula t e filter, - a sonic orifice and, - an air pow er e d sa m pl e educ a t o r. The filters, cours e and fine particula t e , are design e d to prev e n t pluggin g of the sonic flow critical orifice. To minimize maint e n a n c e require m e n t s on the s e filters, a high vacuu m (min. 15 inche s of Hg), low flow (1 to 5 cubic feet per day) is utilized to reduc e the total am o u n t of particulat e being expos e d to the filters. This efflue n t sa m pl e is draw n throu g h the filters using the air educ a t o r. A dilution ratio of 1:250 is achiev e d throu g h the use of a restrict e d flow (sonic) orifice. 3. 2 . 2 Sa m p l e Tran s p o r t for ex a m p l e :

De s c r i b e th e sa m p l e tr a n s p o r t s y s t e m ,

The sa m pl e umbic al trans p o r t is a multiple line unit use d to conn e c t the prob e , analyz er and calibration gas delivery syst e m . The umbilical cord consist s of a polyet h yl e n e line for dilution air, a Teflon line for the dilut e d sa m pl e, a Teflon line for calibra tion gas e s , and a polyet h yl e n e line for monitoring vacuu m at the sonic orifice. This tube bundle is wrapp e d in a Mylar R (thin plastic liner) and enclos e d in a PVC (he a vy plastic) jacket for prot e c tio n. 3. 2 . 3 Analy z e r s

De s c r i b e th e an al y z e r s , for ex a m p l e :

After tran s p o r t to the instru m e n t location, the dilute d sa m pl e is distribut e d to the an alyz er s for det e r mi n a ti o n of the various polluta n t conc e n t r a tio n s . The dilut e d sa m pl e flows into a ma n ifold at a rat e of 5 to 7 liters per minut e (lpm). Each analyze r use s approxi m a t e ly 0.5 to 1.0 lpm. The exc e s s sa m pl e is exh a u s t e d to an at m o s p h e r e dum p ma nifold.

Section No.: 3 Revision No.: 0 Date: Se p t e m b e r 10 , 19 9 7 Page No.: 3 of 3 3. 2 . 3 . 1 Nitro g e n Oxid e s (NOx)

De s c r i b e e a c h ty p e of an al y z e r (e. g . , . SO 2 , NOx, CO 2 .O p a c i t y ) , for ex a m p l e : ( DISCLAIMER) The CEMS/COM S m o n i t o r i n g e q u i p m e n t us e d to illu s t r a t e thi s ex a m p l e ar e no t to b e con s t r u e s as e n d o r s e m e n t of th e par t i c u l a r pr o d u c t or m a n u f a c t u r e r ) A Therm o Environ m e n t a l (TECO) Model 42 an alyz er is used to monitor and me a s u r e Oxides of Nitrog e n (NOx) emission s. This analyz er is a part of an dilution extr a c tio n analysis syst e m , and receiv e s an effluen t sa m pl e that has be e n dilute d in a ratio of 1:250 with clean dry air. This analyz er me a s u r e s NOx conc e n t r a ti o n s by reac tin g nitric oxide (NO) with ozon e (O 3 ) to form nitrog e n dioxide (NO 2 ). This che mic al reaction produc e s a sm all am o u n t of light that is directly propor tion al to the am o u n t of NO pres e n t in the sa m pl e. To me a s u r e NO 2 conc e n t r a tio n s , the sam pl e pass e s throu g h a conve rt e r unit which tran sfor m s any NO 2 pres e n t to NO. The sa m pl e is the n introd uc e d to the reaction cha m b e r wher e it com bin e s with O 3 . A photo m ul tiplier tub e det e c t s this light produc e d by the che mic al reaction of O 3 with NO 2 and an outpu t signal is sent to the dat a syst e m . 3. 2 . 3 . 2 Opa ci t y

De s c r i b e th e op a c i t y m o n i t o r , for ex a m p l e : The COMS monitoring syst e m consist s of an opacity monitor (tran s c eiv e r and retror eflect or), control unit and a DAHS collection syst e m . All comp o n e n t s listed mak e up the COMS syst e m and are certified in conc ert with each oth er thus providing a CERTIFIED SYSTEM. An exa m pl e of an

opacity monitor which might be used are the Durag Model 281 units (in -situ) which are locat e d on the individu al s tacks (as det er mi n e d by the regula t o ry or per mit conditions ). The me a s u r e m e n t of a stack opacity is acco m plish e d by passin g a bea m of visible light acros s the stack (throu g h the efflue n t) and reflecting it back thus me a s u ri n g the perc e n t absorb a n c e caus e d by the particula t e mat t e r in the effluen t. This an alyz er use s a double- pas s me a s u r e m e n t techniq u e that allows easi er zero and spa n calibra tion checks. 3. 2 . 4 Su p p o r t Hard w a r e De s c r i b e th e ap p li c a b l e s y s t e m s th a t su p p o r t th e op e r a t i o n of th e CEMS . 3. 2 . 4 . 1 3. 2 . 4 . 2 3. 2 . 4 . 3 Air Filt er/ Dr y e r Pro gr a m m a b l e Tim er Diluti o n /C ali br a t i o n Contr ol

Section No.: 4 Revision No.: 0 Date: Se p t e m b e r 10 , 19 9 7 Page No.: 1 of 1 3. 2 . 5 Dat a Acq ui s i t i o n an d Han dlin g Sy s t e m (DAHS)

De s c r i b e th e DAHS, for ex a m p l e : The CEMs DAHS is an auto m a t e d syst e m that record s both pollut a n t and dilue nt dat a for subs e q u e n t calculation s and report prep a r a ti o n. DATA gen e r a t e d by the syst e m includ e not only the sa m pl e dat a but monitor oper a tio n al dat a such as alar m stat u s , calibra tion dat a, and routin e emission report s. Table xx lists the pollut a n t/ dilu e n t dat a record e d by the DAHS. Listed in Table xx are the value s calculat e d by the DAHS. 4. 0 4. 1 TRAINING QUALITY ASSURANCE TRAINING

Training is an ess e n ti al ele m e n t of a succe s sful QA/QC progra m . It provid e s the basic knowled g e require d to acco m plis h a proce d u r e correctly. Training also provide s the und e r s t a n di n g of a given task or proce d u r e , ther e b y en a bling the individu al involve d to mak e an inform e d and effective

decision. Training is a fra m e w o rk abou t which require d activities are tau g h t in a consist e n t ma n n e r . 4. 1 . 1 Gen e r a l Trainin g

Gene r al training is viewe d as providing an initial found a tio n. It is not inte n d e d much to deliver det ailed or specific knowled g e but to provide an gen e r al und e r s t a n di n g of the over all syst e m and progr a m goals. This training is com m o n to all individu als directly involve d in the CEM progr a m . Gene r al training is training provide d by Co m p a n y Na m e which is specific to this facilitys oper a tion and consid e r e d beyon d any monitor vendor supplied training. This training is pres e n t e d in the following sections. 4. 1 . 1 . 1 Qualit y As s u r a n c e Plan

All em ploy e e s directly involve d in the CEMS progr a m mus t have acce s s to this QA/QC Plan. All employ e e s mus t at a minim u m beco m e familiar with this Plan and review appro p ri a t e SOPs. 4. 1 . 1 . 2 Sp e c i a l an d Refr e s h e r Traini n g

Special and refre s h e r training is nece s s a r y to maint ain curre n t levels of monitoring com p e t e n c y . All new hires are require d to att e n d QA plan training progr a m s offer periodically. Addition ally all CEMS senior staff will receiv e refres h e r training on SOP chan g e s , oper a tin g par a m e t e r s , or as QA/QC chan g e s are ma d e .

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Quality Assura n c e audits are perfor m e d on CEMS in order to verify the precision and accur a c y of the dat a . QA audits also serv e to confirm oper a tio n al and maint e n a n c e proce d u r e s are being prop e rly imple m e n t e d . 5. 1 . 1 Rela ti v e Acc ur a c y Te s t Audit (RATA)

A RATA as describ e d in EPAs, 40 CFR 60 Appen dix B, is a test design e d to ass e s s the accur a cy of the CEMS monitors relative to the appro p ri a t e EPA refer e n c e met h o d tes ts . Its prim ary use is in det e r mi nin g efflue n t conc e n t r a tio n s . RATAs are cond uc t e d in accord a n c e with Perfor m a n c e Specification 2 for SO 2 and NOx, and Perform a n c e Specification 3 for CO 2 . Should the me a s u r e d inaccur a c y exce e d + 20% of the refer e n c e met h o d (perc e n t expr e s s e d as the sum of the me a n differe nc e s plus the 95% confide n c e interv al), corrective action is imm e di a t ely take n by the staff respo n sibl e for CEM maint e n a n c e and rep air. Norm ally a recalibr a tion is appro pri a t e followe d by a rea u dit of the OUT OF CONTROL (failed) monitor. This reau dit is conduc t e d to de m o n s t r a t e that the monitor is no longe r OUT OF CONTROL and also reaffirms the effective n e s s of the training progr a m on incre a s e d QC proce d u r e s . In order in ens ur e the accur a c y of the Refere n c e Metho d analysis being perfor m e d during a RATA, EPA audit sa m pl e s should be analyz e d by both the Refer e n c e Method and the CEM. Thes e blind audit perfor m a n c e sa m pl e s are availa ble throu g h IDEM. 5. 1 . 2 Cylin d e r Gas Audit (CGA)

CGA's is a quart e rly audit test employ e d to show monitor linearity. The test consist s of triplicat e non cons e c u tiv e injections of thre e (3) certified protoc ol 1 gas e s covering zero (0), 20 to 30% and 50 to 60% of spa n for each analyz er. The CGA is design e d to ass e s s calibra tion error, resp o n s e time, and the effect of the sa m pl e handling syst e m on repr e s e n t a t i v e n e s s . A CGA is perfor m e d by individu ally injecting thre e known gas e s at the prob e so that the entire sa m pling train will be use d to dilut e and trans p o r t the gas to the analyze r. A total of thre e non- cons e c u tiv e rea ding s are take n for eac h upsc ale gas conc e n t r a tio n. The individu al gas e s are inject e d singly and the monitor oper a t e d in the calibra tion mod e . Once a sta bl e reading is obt ain e d , the respo n s e time s (minim u m 95% of known conc e n t r a tio n) and CEMS instru m e n t resp o n s e s are record e d .

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Opacity monitor audits shall be don e accordin g to EPAs 40 CFR 60 Appen dix B Perfor m a n c e Specification 1. Thre e sep a r a t e and certified neutr al density filters are use d to challen g e the oper a tion of the opacity monitors. A total of fiftee n (15) non- cons e c u tiv e reading s are take n, five for each filter. 5. 1 . 4 Perf or m a n c e Sp e c i fi c a t i o n Tes ti n g (PST)

First a QA audit using Perform a n c e Specification Testing guideline s is perfor m e d to est a blish initial acc e p t a bility of the CEMS. It is perfor m e d in accord a n c e with EPAs 40 CFR 60 Appen dix B, (PST 1, 2, 3). Require d Appen dix B Refer e n c e Method testing is conduc t e d by a com p e t e n t , profes sion al testing contr ac t or, in accord a n c e with approv e d EPA proc e d u r e s Should the PST not produc e acce p t a bl e results, correctiv e action is take n and the PST is rep e a t e d . Full docu m e n t a t i o n of all correc tive actions perfor m e d is require d. 5. 2 QUALITY CONTROL ACTIVITIES

Quality control activities are design e d and perfor m e d to ens ur e tha t monitor oper a tion s and maint e n a n c e are ade q u a t e and appro pri a t e . Application of the s e activities rang e s from syst e m inst allation to dat a handling and reportin g proce d u r e s . Quality control activities rely upon a qualified and well- traine d staff. Initial installation of any monitoring syst e m is carrie d out in strict accord a n c e with proc e d u r e s est a blish e d by the vend or. Thes e proce d u r e s also includ e d initial start- up, debu g gi n g , and inspe ction of the syst e m s to ens ur e prop er oper a tio n. A compl e t e set of oper a tion al and maint e n a n c e ma n u al s for all comp o n e n t s of the syst e m is maint ain e d by the TITLE OF RESPO N SIBLE PERSO N . Thes e ma n u al s provid e com pl e t e description s of the syst e m including the ory, installation, oper a tio n, troubl e shootin g, rep air and gen e r al maint e n a n c e . 5. 2 . 1 Calibr a ti o n Gas e s

The calibra tion of all gas e o u s emission monitors is acco m plish e d throu g h the use of known conc e n t r a tio n zero and spa n gas e s of the applica bl e gas species . Thes e gas e s are requir e d to be protocol 1 gas e s , certified to within + 2 ppm of the listed conc e n t r a tio n. Opacity calibra tion checks use an intern al filter syst e m which is factory

calibra t e d . Extern al zero is perfor m e d eith er during actu al or stimula t e d clear stack conditions. Alignm e n t checks betw e e n the trans c eiv e r and retror eflec t or are perfor m e d during any ext er n al zero adjust m e n t or any routin e maint e n a n c e . Section No.: 5 Revision No.: 0 Date: Se p t e m b e r 10 , 19 9 7 Page No.: 3 of 6 5. 2 . 2 Calibr a ti o n Che c k

Dyna mic calibration checks are perfor m e d by challen gin g the monitors once every 24 hours with a calibra tion gas of a known conc e n t r a tio n. A progr a m m a b l e timer auto m a t ic ally initiat e s the precision check. This syst e m can be man u ally calibrat e d at the oper a t o r s beh e s t . During the calibra tion check, the value s rea d by the analyz er are sent to the DAHS, which auto m a t ic ally com p a r e s the value to the certified value s of the gas cylinder s. Should any individu al zero drift or spa n drift exce e d two (2) tim e s the applica bl e sta n d a r d or any rea din g exc e e din g four (4) time s the applica bl e sta n d a r d , the DAHS initiat e s an instru m e n t "OUT OF CONTROL" alar m. During the calibra tion checks of the opacity monitors, the dat a syst e m verifies the prop e r compl e tio n of the calibration cycle. Should any individu al zero drift exce e d 2% of the instru m e n t spa n, or any calibration drift exce e d s 2% of the instru m e n t span, an alar m condition is indicat e d and correc tiv e action s as per the writte n QC SOPs are initiat e d . 5. 2 . 3 Sy s t e m s Audit

A syst e m s audit involve s a gen e r al inspe c tio n of the monitoring syst e m . Walk- throu g h audits are use d to provid e quick ass e s s m e n t of the availability of dat a, gen e r al effectiv e n e s s of oper a tion and maint e n a n c e , and com ple t e n e s s of recordk e e pi n g proce d u r e s . Syst e m s audit involve s the following are a s : Administr a tiv e - maint e n a n c e logs: com ple t e d in a timely and det ailed ma n n e r by aut h oriz e d perso n n e l - recordk e e pi n g: com ple t e n e s s , availability - verification: correct spa n value s ent e r e d into the dat a syst e m Technic al

- print er: oper a tion al, legible print, rea din g s consist e n t with the proc e s s conditions - dat a syst e m : shelt er cabine t s clean, are a s maint ain e d - monitor enclos ur e : clean, all oper a tio n al syst e m s , i.e., hea tin g & cooling - spa n gas cylinder s: with certification dat e s , in the correct conc e n t r a tio n rang e , abov e the 250 psi minim u m pres s u r e s - sa m pling/ a n aly sis: sa m pl e flows, vacuu m s , and pres s u r e s within applica ble rang e s - opacity monitor: align m e n t v e rifica tion, purg e air blowers oper a tio n al

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5. 3

DATA RECORDING AND REPORTING

Data collect e d as part of the auditing of the CEMS falls into two cat e g o ri e s: (1) Routin e dat a from the nor m al oper a tion of the CEMS (See Section 6.3); and (2) Data gen e r a t e d as a function of the audit. The TITLE checks and prep a r e s both audit and routin e emission dat a into a sum m a r y report. 5. 4 PREVENTIVE MAINTENANCE

The prev e n tiv e maint e n a n c e progr a m for the CEMS is bas e d on the vendor' s reco m m e n d e d proc e d u r e s . Addition al proce d u r e s may be includ e d as exp e ri e n c e dictat e s . Thes e proc e d u r e s may be modified to be more specific for the inst allation. Preve n tiv e maint e n a n c e is sche d ul e d and perfor m e d in a timely man n e r by the TITLE .

5. 5

REPAIR PROGRAM The CEMS rep air progr a m shall be maint ai n e d by TITLE OF

RESPO N SIBLE PERSON ( S ). Syst e m faults are monitor e d by both TITLE (tech nicia n level) and TITLE (sup er visory level). In the eve n t of a syst e m proble m , the TITLE will be notified directly and in writing. A nota tion of the proble m is place d in the shift log book. 5. 6 SPARE PARTS INVENTORY

TITLE maint ai n s a spar e part s invent o ry ad e q u a t e to me e t the nor m al oper a ti n g require m e n t s . Emerg e n c y parts are availa ble throu g h the vendor on a next day basis. TITLE has the over all respo n si bility for maint ai nin g the ade q u a c y of the spar e parts invent ory. The curre n t inven t ory is bas e d on the vend or' s reco m m e n d e d list for 90% dat a availability, and is modified on an as- require d basis. 5. 7 ACTIVITY MATRIX

An activity matrix sum m a rizing the various routin e QA/QC activities is pres e n t e d in the table on pag e s 5 and 6. Daily activities will include checks of daily zero and spa n value s and obs erv a tio n of routin e dat a from the norm al oper a tion of the CEMS.

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Activity/ QA Checks 1. Calibration Gas Pressure 2. Sample Gas Pressure/Vacuum 3. Sample Gas Pressure/FlowsAnaly er !. "#$ Analy er %esiccant &. 'eplace Filters Weekly X X X Monthly Quarterly Annually

X X

Analy ers (. 'eplace Filters/ Scrubbers Air System ). 'eplace/Clean Filters-Probe *. +emperature Control Analy er ,nclosure -. AC Filter Cleane. 1/. Clean 0nterior o1 ,nclosure/ Analy er 11. 2ea3 C4ec3 Gas Connections 12. Clean %isc %ri5e 6ea. 13. Printer 7aintenance 1!. System Au.it X X X

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Activity/ QA Checks 1&. Clean #ptical Sur1aces 1(. C4ec3 Air 6oses 1). Clean/'eplace Filters 1*. C4ec3/A.8ust Ali9nment X X Weekly Monthly Quarterly Annually

Acti5ity/ :A Au.it 1. CGA 2. #pacity Au.it 3. 'A+A X X X

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6. 0

DOCUMENTATION AND REPORTS

The docu m e n t a t i o n of QA/QC dat a and inform a tio n syst e m is an inte gr al part of this QA Plan. This section describ e s report s and oth er record s that provid e ade q u a t e docu m e n t a t i o n of QA/QC activities. The two prim a ry me a n s of docu m e n t a ti o n us ed are:

(1) Data Acquisition and Handling Syst e m (DAHS) (2) Manu ally pre p a r e d QA/QC forms, logs and report s The following subs e c tio n s describ e the DAHS and its uses in QA/QC docu m e n t a ti o n, and pres e n t s exa m pl e s of DAHS-gen e r a t e d routine dat a report s. During QA audits, the DAHS will be oper a t e d to collect dat a in a norm al fashion, but will print all insta n t a n e o u s engin e e rin g units for a real time hard copy of tes t e d value s. The DAHS it also serv e s the following subs e c tio n s : is use d not only to docu m e n t QA/QC dat a and inform a tio n, but as the CEMs dat a acquisition and proce s sin g syst e m . Each of type s of docu m e n t a t i o n are describ e d in subs e q u e n t hourly report s, daily report s, alar m report s, quart e rly report s.

Writte n QA/QC report s are nec e s s a r y to provide suppor tin g docu m e n t a ti o n of the continu e d oper a tio n of the CEM in an acc e p t a bl e ma n n e r . Report s are used to notify individu als of proble m s relat e d to oper a tio n of the CEMS. Compilation of the s e report s is inten d e d to assist in identifying the nee d for prev e n tiv e maint e n a n c e , oper a tion al proce d u r al cha n g e s , training upd a t e s , or surplus inven t ory action. 6. 1 DAHS De s c r i b e of th e Da t a Han dli n g an d Ac q u i s i t i o n Sy s t e m . Pro v i d e a si m p l i fi e d blo c k dia g r a m of th e DAHS sh o w i n g th e flo w of infor m a t i o n an d pr o c e s s si g n a l s . [DIAGRAM ]

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6. 2

EMISSION MEASUREMENT DATA PROCESSING

De s c r i b e th e si g n a l pr o c e s s i n g b y th e DAHS. Pro v i d e ex a m p l e s of th e vari o u s re p o r t s th a t th e DAHS g e n e r a t e s . 6. 3 6. 3 . 1 6. 3 . 2 6. 3 . 3 6. 3 . 4 6. 4 DAHS REPORTS Curre n t (Hourly ) Rep or t s Daily Rep or t s Alarm Rep or t s Quart e rl y Rep or t s MAINTENANCE RECORD

This record is maint ain e d throu g h TITLE. The TITLE ent er s description s of routin e prev e n tiv e and maint e n a n c e actions perfor m e d on the monitoring syst e m com po n e n t s . Thes e entrie s are kept in maint e n a n c e files or site log books. This record also docu m e n t s the us e of spar e part s, and its periodic review by the maint e n a n c e dep a r t m e n t provid e s inform a tio n to the spar e part s invent ory.

6. 5

AUDIT REPORTS

Each audit proc e d u r e discus s e d in section 5 of this Plan is docu m e n t e d in a report. All supp ortin g dat a are kept on file by TITLE . Thes e audits serv e as verification of the accur a c y of emission s dat a in the quart e rly report.

6. 6

CGA GAS CERTIFICATION

Manufact ur e r/ dist rib u t or s of all Protocol 1 spa n gas e s und e r this QA Plan mus t provide a gas conc e n t r a tio n certificat e for each cylinde r of gas supplied. TITLE is respo n si ble for maint aining a file of the s e certifications, including the dat e of prod uc tion, certified value, and cylinder serial num b e r .

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7. 0 7. 1

QUALITY ASSURANCE PROCEDURES INTRODUCTION

The purpos e of thes e proce d u r e s is to ens ur e the CEMS syst e m provid e s accur a t e and reliable dat a. Thes e proc e d u r e s comp a r e the pollut a n t / dilue n t value s obt ain e d from the CEMS to value s obt ain e d by EPA Refer e n c e Method or approv e d altern a tiv e testin g met h o d . The res ults of the s e test s provide verification of the continu e d comp a r a bility of the CEM dat a to, dat a collect e d by and com p a r e d to, outsid e refer e n c e s . The proc e d u r e s for the s e test s are publish e d in EPA 40 CFR 60, Appen dix A, B and F [OR OTHER APPLICABLE RULES OR REGULATION S ] . 7. 2 7. 2 . 1 RATA PROCEDURES Preli mi n a r y Activiti e s

Prior to the actu al RATA tes tin g proce d u r e s ther e are testing prer e q ui sit e s require d by IDEM. Thes e activities include notification to IDEM, informing the m of the inte nt to tes t. This is done by sub mitt al of the test protoc ol form. Verifications are ma d e tha t the boiler to test e d will not be und e r g oin g sche d ul e d maint e n a n c e and that no oth er condition exists which would preclud e testing the boiler emission s und er repr e s e n t a tiv e oper a tin g conditions . Verify the availability of all pers o n n el require d to perfor m testing. Verify that all sche d ul e d maint e n a n c e on the CEMS has be e n perfor m e d . Verify that the test location conditions are ade q u a t e for testin g, and tha t nec e s s a r y supp ort service s are available. Review Refer e n c e Method s tha t will be used in EPAs 40 CFR 60 Appen dix A and B proc e d u r e s .

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7. 2 . 2

RATA Tes ti n g De t a il e d Proc e d u r e s

Thes e proce d u r e s are to be conduc t e d befor e, during and after RATA testin g. Verify that the CEM oper a tin g conditions are norm al by conduc tin g a syst e m s audit.

Notify TITLE OF RESPO N SIBLE PERSO N of testin g and requ e s t notification should any condition arise that would result in less tha n a 50% sta ble load during the testing. Proce e d to the test location and verify the following for the stack testing crew. 1. Safe acce s s 2. Electrical power 110 volts @ 30 am p 3. Safety belts, if requir e d 4. Hoist equip m e n t 5. Small work spac e for proce s sin g sa m pl e s Verify availa bility of plant or pollution control equip m e n t oper a tin g dat a requir e d for the report. Upon com pl e tion of the testing, notify the TITLE that testing has bee n compl e t e d . Obtain copies of CEM report s covering the test period. Perform the post test calibra tion, docu m e n t the results of the calibra tion. Docu m e n t results from CEM and Refer e n c e Method analysis of blind audit sa m pl e s .

7. 2 . 3

Dat a Red u c t i o n an d Analy s i s

The results of the ma n u al Refer e n c e Method s , as part of the RATA, are calculat e d accordin g to proc e d u r e s includ e d in EPAs 40 CFR 60, Appen dix A. Each test run is calculat e d individu ally, and the s e results are used with the concurr e n t CEM dat a to calculat e relative accur a c y.

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7. 2 . 4

Rela ti v e Acc ur a c y Calc ul a ti o n s

The calculation proc e d u r e for relative accur a c y is as found in Perform a n c e Specification 2. In this proce d u r e , the res ults of the Refer e n c e Method tes tin g in units of the sta n d a r d are comp a r e d to the CEM dat a. For each test run, com p u t e the differe n c e betw e e n the Refer e n c e Method results and the corre s p o n di n g CEM results with the following equ a tio n: Diff = CEM Results - Refer e n c e Method Results Relative Accuracy = (d + |cc|) / Refere n c e Method x 100 7. 2 . 5 Rep or t Pre p a r a t i o n

A report of the results of each RATA is prep a r e d for inclusion in the curre n t Quart e rly Emis sion Report. The RATA report follows the following outline. I. Introduc tio n - briefly describ e the audit and purpo s e II. Results -give the dat e of the audit & a brief description of the results - if correc tiv e action was require d, describ e

- pres e n t the res ults of rep e a t audits, if requir e d III. Suppor tin g Dat a - includ e RATA sum m a r y report

7. 3 7. 3 . 1

PROCEDURES FOR CGA Intro d u c t i o n

During a CGA, the CEMs is challeng e d dyna mic ally throu g h the sa m pling and the analysis sys te m s . Zero, low, and mid- rang e audit gas e s are introdu c e d in lieu of the norm al calibra tion gas e s . The DAHS calibra tion report is use d in stre s sin g calibra tion error.

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The nor m al conc e n t r a ti o n s of low and mid- rang e audit gas e s use d at each monitoring location are show n in table xx. Audit dat a and obs erv a tio n s , including conc e n t r a tio n s of gas e s actu ally use d during the audit, are record e d on the CGA audit she e t (Form xx). Beside s this SOP, the following docu m e n t s are refer e n c e mat e ri als which, as nec e s s a r y , should be review e d befor e perfor min g the CGA: DAHS Oper a tion and Mainte n a n c e Manu al 40 CFR Part 60, Appen dix F 7. 3 . 2 Cylin d e r Gas Audit

For each syst e m to be audit e d , record on the dat a she e t s the appro pri a t e audit cylind er serial num b e r s , certified gas conc e n t r a tio n s and the dat e s of analysis. The following step s s hould be perfor m e d : 1. Notify the appro pri a t e staff that the audit is rea dy to begin and to disre g a r d the CEM calibra tion alar m s .

2. Initiat e a Zero and Span check of the CEMS by ma n u ally switching gas e s on. Upon com pl e tio n, discon n e c t the "routin e oper a tion" calibra tion gas and conn e c t the appro p ri a t e audit gas cylinder s. 3. Verify the audit cylinder conc e n t r a tio n value s as listed on the audit dat a she e t , and initiat e a calibra tion. 4. Repe a t with all conc e n t r a ti o n s - zero, low and mid values , for thre e non cons e c u tiv e runs. 5. The value s for the comp u t e r are ent e r e d on the CGA Audit Data Form. 6. Disconn e c t the audit cylinder s and recon n e c t the routin e oper a tion cylind er s. 7. Verify that the syst e m has bee n retur n e d to norm al oper a tion (alar m conditions). 8. Advise the appro pri a t e staff that the audit is com pl e t e . Record compl e tion in the CEM log.

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1. Obtain CGA Audit Dat a Form and ent e r dat a from the DAHS calibra tion report. 2. Calculat e the perc e n t differe n c e (% diff) for each value as follows: % diff = (aver a g e rea din g - known conc e n t r a tio n) / known conc e n t r a ti o n x 100 3. Verify that the % diff does not exce e d dat a point. 15% ( or applica bl e limit) for any

4. Add any rem a r k s relating to the audit on the dat a she e t . If any audit value exc e e d s the acce p t a bl e limits, initiat e imm e di a t e appro pri a t e correc tion actions, as specified in the QA Plan. Upon com ple tion of the nec e s s a r y corrective actions, the CGA mus t be rep e a t e d . The results of the original audit, correc tive actions, and any rep e a t audits are report e d .

7. 3 . 4

Rep or ti n g

A report of the results from each CGA is prep a r e d for inclusion in the curre n t Quart e rly Emission Report. The CGA report should use the following outline: I. Introduc tio n - briefly describ e the audit and purpo s e II. Results - give the dat e of the audit & a brief description of the results - describ e any com m e n t s from obs erv a tio n that may have affect the results - pres e n t the res ults of rep e a t audits, if requir e d III. Suppor tin g Dat a -includ e the CGA Audit Data, Calibration Report and any othe r suppor tin g dat a ( i.e., vend or' s gas cylinder certification report s).

Section No.: 8 Revision No.: 0 Date: Se p t e m b e r 10 , 19 9 7 Page No.: 1 of 2 8. 0 8. 1 QC PROCEDURES INTRODUCTION

Quality control checks may be define d as all thos e checks perfor m e d on a

routin e basis such as syst e m insp ec tio n s, periodic calibra tion s and routin e maint e n a n c e . The proce d u r e discus s e d her e are pres e n t e d as docu m e n t e d writt e n proc e d u r e s . Other proce d u r e s will be inher e n t in the use of emission dat a for boiler oper a tio n s .

8. 2

DAILY CALIBRATION CHECK

Each CEMS is auto m a ti c ally challeng e d to a know stan d a r d once each 24 hour period. The DAHS calculat e s the perc e n t differe n c e from ent er e d known value s. The TITLE OF RESPO N SIBLE PERS ON will be respo n sibl e for verifying monitor respo n s e to be within specification s of 40 CFR 60, Appen dix F at a minimu m . Recalibra tion of the CEM will be perfor m e d if drift is indicat e d .

8. 3

WEEKLY SYSTEMS AUDIT

A weekly syst e m s audit will be perfor m e d and record e d in a boun d logbook. A syst e m s audit may be perfor m e d at any time if oper a ti n g proble m s are obs erv e d during routin e checks of emission dat a on daily zero/s p a n checks. This audit is a gen e r al appr ais al of the CEMS oper a ti n g par a m e t e r s . The following checks will be record e d during the syst e m s audit and may be revis e d as oper a tin g exp e rie n c e dictat e s . 1. Obtain multida y calibration report for previous 7 days for all CEMS. Check for tren d s in drift. 2. Verify that the correc t span value s are ent e r e d into the com p u t e r . 3. Insect the instru m e n t cabin e t for gen e r al cleanline s s and te m p e r a t u r e within limits of 68 to 86 degr e e s F. Check air conditioning filter for clea nline s s . 4. Check tha t the gas cylinder pres s u r e s are abov e 250 psi. 5. Exa min e opacity re mo t e pan el, not e any alar m s display e d and tha t rea din g s are consist e n t with monitor oper a tion.

Section No.: 8 Revision No.: 0 Date: Se p t e m b e r 10 , 19 9 7

Page No.: 2 of 2

6. Check dilution air pres s u r e and corre s p o n di n g prob e vacuu m for any chan g e s . 7. Verify that scrub b e r s in the air syst e m are acce p t a bl e and indicating silica gel is blue. Verify that reg e n e r a t iv e dryer and absor b e r units are cycling every 30 secon d s . 8. Check NOx analyz er desicc a n t . 9. Check NOx analyz er sa m pl e vacuu m . 10. Check SO2 analyz er sa m pl e vacu u m , sa m pl e flow and lamp voltag e . 11. Check CO2 sa m pl e flow. 12. Re- calibrat e monitors if nec e s s a r y . 8. 4 QUARTERLY SYSTEMS AUDIT

Administr a tiv e 1. Check maint e n a n c e logs for tim ely and com pl e t e rep airs.

Technic al (includ e all checks ass oci at e d with weekly syst e m s audit) 1. Printer oper a tion al and legible, rea din g s consist e n t with proc e s s conditions . 2. Compu t e r dat a table clean and are a is maint ai n e d . 3. Monitor enclos ur e clean and are a well maint ain e d . 4. Purge air blowers for opacity oper a tio n al and align m e n t of opacity monitor is correct.

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9. 0

ROUTINE PREVENTIVE MAINTENANCE

All maint e n a n c e of the CEMS can be classified into one of two are a s : Routine prev e n tiv e maint e n a n c e : A regularly sche d ul e d set of activities design e d to prev e n t proble m s before they occur. Non- routine prev e n tiv e maint e n a n c e : A set of activities is also design e d to prev e n t proble m s , but the nee d for it canno t be pre dict e d , so it is done on an as- nee d e d basis. For exa m pl e , if sa m pl e vacuu m on the NOx analyz er drops from its norm al rea din g, the pum p, gau g e or sa m pl e capillarie s should be replac e d or clea n e d . This would be consid e r e d non- routine prev e n tiv e maint e n a n c e . Non- routin e prev e n tiv e maint e n a n c e is not discus s e d in the QA/QC man u al bec a u s e it is neith e r practic al nor nec e s s a r y to dev elop writt e n proc e d u r e s for it.

The routin e prev e n tiv e maint e n a n c e require d for the CEMS is listed in Table 9- 1. The TITLE OF THE RESPON SIBLE PERSO N is ultim a t ely respo n si ble for since all routin e prev e n tiv e maint e n a n c e is com pl e t e d on sche d ul e.

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TABLE 9- 1 RECOMMENDED ROUTINE PREVENTIVE MAINTENANCE Opa ci t y Quart e rl y 1. Clean blower pre- filter 2. Replac e blow er filter ele m e n t 3. Check optic align m e n t 4. Clean optics, set window check value S e m i - Ann u a l 1. Check ext er n al zero whe n boiler is off line 2. Scale syst e m (electro nic ally) SO2 Quart e rl y 1. Chang e Teflon inlet filter NOx We e k l y 1. Check drierite canist e r & chan g e if exp e n d e d Quart e rl y 1. Replac e Teflon inlet filter Air Sy s t e m Quart e rl y 1. Replac e reg e n t scrub b e r s Ann u a l 1. Replac e particulat e filters Prob e s Quart e rl y 1. Check conn e c tion s for leaks

2. Clean coars e scre e n and quartz wool plug Com p u t e r Sy s t e m (DAHS) We e k l y 1. Back- up the fixed disk

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10 . 0

CORRECTIVE ACTION AND REQUIRED NOTIFICATIONS

When e v e r the CEMS is found to be "out- of- control" the dat a gen e r a t e d from the syst e m canno t be use d to show complia nc e with per mit limits or dat a capt ur e requir e m e n t s . Correc tive action must be perfor m e d as soon as possible after det e r mi nin g that the CEMS is not oper a tin g within 40 CFR 60 , Ap p e n d i x F. Correc tive action is define d as the resolution of proble m s tha t occur on a non- routin e basis. 10 . 1 SUGGESTED CORRECTIVE ACTION Refer e n c e s to specific troubl e s h o o tin g proc e d u r e s are listed in Table 10- 1. 10 . 2 REQUIRED NOTIFICATIONS

Imm e di a t ely after learning the CEMS is non oper a tio n al, the following individu als mus t be notified: TITLE OF THE RESPON SIBLE PERSO N

TITLE OF THE RESPON SIBLE PERSO N

TITLE OF THE RESPON SIBLE PERSO N

List th e s p e c i fi c re s p o n s i b i l i t i e s for e a c h p e r s o n .

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TABLE 10- 1 REFERENCES TO TROUBLE-SHOOTING/CORRECTIVE ACTION List th e ap p r o p r i a t e ref e r e n c e s to th e an al y z e r , pr o b e , DAHS, e t c . m a n u a l s wh e r e tr o u b l e s h o o t i n g pr o c e d u r e s ar e s p e c i f i e d .

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11 . 0

REFERENCES

List all ref e r e n c e s us e d to co m p i l e thi s QA Plan .

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12 . ATTACHMENTS Inclu d e an y p e r t i n e n t infor m a t i o n su c h as: 1. Op e r a t i n g Per m i t 2. Ap pli c a b l e CFRs or por t i o n s of th e CFR. 3. Ap pli c a b l e an al y z e r , pr o b e , DAHS, e t c . m a n u a l s or por t i o n s of th e m a n u a l s 4. Ap pli c a b l e St a t e Rul e s or por t i o n s of th e Rul e s 5. Exa m p l e s of au d i t an d cali b r a t i o n for m s 6. Exa m p l e s of op e r a t i o n an d m ai n t e n a n c e log s

7. Exa m p l e s of re p o r t i n g for m s 8. Exa m p l e DAHS prin t o u t s