SAMPLE QAQC PLAN 

(DISCLAIMER: THIS SAMPLE QAQC PLAN IS A MODIFIED VERSION OF AN ACTUAL DOCUMENT 

SUBMITTED TO AND APPROVED BY SCAQMD. THE NAMES OF THE COMPANIES, MANUFACTURERS, 

PRODUC-RE- AND PERSONS HAVE BEEN ALTERED AND/OR DELETED FROM THE ORIGINAL 

DOCUMENT. THE APPEARANCE OF ANY PRODUCT, MODEL IDENTIFICATION OR SERVICES IN THIS 

SAMPLE QAQC PLAN DOES NOT CONSTITUE ENDORSEMENT OF SUCH PRODUCT OR SERVICES BY 

CONTINUOUS EMISSIONS MONITORING SYSTEM 

QUALITY ASSURANCEjQUALITY CONTROL PLAN 

PREPARED BY: 

John Doe Environmental Services 

December 1, 1998 

FOR 

INDUSTRY INTERNATIONAL INC. 

LOS ANGELES FACILITY 
INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions ~onitorin~.~~stem 

Quality Assurance/Quality Control Plan 

Section No. Distribution 

Date: 0 1 -Dec-99 

Page No.: 2 of 67 

Revision No. 0 

Revision Date: 0 1 -Dec-99 

Distribution Table 

Delivered To: Number of Copies 

Industry International, Los Angeles Facility 

Industry International, Corporate Office 

Industry International, Regional Office 

SCAQMD 

Approved by: 

Ronald Emil, Ph.D. 

Vice-President and General Manager 

Industry International Inc., Los Angeles Facility 
INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions ~onitorin~~~~stem 

Quality AssuranceIQuality Control Plan 

Section No. Table of Contents 

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TABLE OF CONTENTS . 

DESCRIPTION PAGE NO. 

COVERSHEET . 1 

TABLE OF CONTENTS . 2 

1.0 INTRODUCTION . . 6 

1.1 Program Goals . . 6 

1.2 Organizational Chart . 6 

2.0 INSTALLATION . . 6 

.- 

3.0 CEMS GENERAL DESCRIPTION 7 

3.1 General Description . 7 

3.2 Analyzers Supplied . 7 

3.3 Calibration Gases Required . . 8 

3.4 PLC Control System . . 8 

3.5 Shelter Equipment Controls . 9 

4.0 ANALYZER SPECIFICATIONS (See Appendix B) . . 10 

4.1 Raymond Model 70R (02) Oxygen Analyzer, Range 0- 10% . 10 

4.2 Raymond Model 12 1 B (NOINOX) Nitric Oxidemitrogen Dioxide 

Analyzer, Range 0-5Oppm . . 10 

4.3 Raymond Model 890 Sulfix Dioxide (SO2) Analyzers, Ranges 

0-250 ppm and 0-5OOppm . . 11 

4.4 Rach Series 20 Oxygen (02) Wet Analyzers, Ranges 

0-10%and0-25% . . 11 

4.5 RachFlo Series 30 Stack Flow Analyzer Systems, Ranges 

0-5,839 sch and 0-1 71,429 scfm . . 12 

4.6 4R Scientific's SulfixDetectTM Model 6200 Total Sulfur 

Analyzer, Range 0-200 ppmv . 13 

4.7 Rach Cal 50 Series Calorimeter, 

Ranges 900-1 400 btulscf High Heating Value 

and 0.6-1.0 Specific Gravity . . 14 
- INDUSTRY INTERNATIONAL INC. 

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Section No. Table of Contents 

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TABLE OF CONTENTS 

(Continued) 

DESCRIPTION 

5.0 SAMPLE HANDLING SYSTEM . 5.1 Probe Design and Heated Sample Line Design . 5.2 Heated Sample Line . 5.3 Filtering and Conditioning . 5.4 Flow Measurement Devices . 5.5 Leak Checking . . . 

5.6 Interlocks 

6.0 DESRIPTION OF SYSTEM CALIBRATION . 6.1 Remote Calibration . 6.1.1 Automatic Remote Calibration 

as.. 6.1.2 Manual Remote Calibration . 6.2 Local Calibration (Sample Bypass Testing) . 

7.0 DESCRIPTION OF SYSTEM OPERATION PROCEDURES . 7.1 Scheduled Calibration Procedures . 7.1.1 Automatic Calibration. 

7.2 Procedure for Measurement Correction 

7.3 Procedure for Determination of Out-of-Control Conditions. . 7.4 Corrective Action Procedures to Correct Out-of-Control 

Conditions 

7.5 Documentation of System Operations 

8.0 PREVENTATIVE MAINTENANCE PROCEDURES . 8.1 Daily Maintenance . 8.1.1 Instruction for Completing Form Q (See Appendix B) 

9.0 DATA ACQUISITION SYSTEM . 9.1 Equipment Descriptions . 9.1.1 Raymond Programmable Logic Controller PLC 5/20 

9.1.2 Raymond Operator Interface Module . 9.1.3 Raymond 45-IFE Analog Input Modules . 9.1.4 Raymond 45-OFE Analog Output Modules . 

PAGE NO. 
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LOS ANGELES, CA 

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TABLE OF CONTENTS 

(Continued) 

DESCRIPTION PAGE NO. 

9.1.5 Raymond 45-IBD Digital Input Modules . 9.1.6 Raymond 45-OW 16 Digital Output Modules. 

9.1.7 Infoconcentrator PLC . 9.1.8 DCNX System 

9.2 Calculations Performed in the PLC Control System (CEMS PLC) 

9.2.1 Zero and Span Calibration Error Calculation. 

9.2.2 Automatic Correction Calculation . 9.3 Calculations Performed in the DCNX 

9.3.1 Determination of Emission Rate . 9.3.2 Determination of Fuel Gas Flow Rate 

- 9.4 Missing Data Procedures . 

10.0 QUALITY ASSURANCE . . 35 

10.1 Data Validation Criteria . 35 

10.2 Data Reduction Criteria . 36 

11.0 SCHEDULE OF ACTIVITIES . ' . 36 

1 1.1 Frequency of System Calibration . . 36 

1 1.1.1 Daily Calibration . . 36 

1 1.2 Frequency of Preventive Maintenance . 37 

1 1.3 Schedule of System Audi-RE- ., 37 

1 1.3.1 Relative Accuracy Test Audit. . 37 

12.0 SYSTEM AUDIT PROCEDURES. . 38 

12.1 Relative Accuracy Test Audit. 38 

12.1.1 Relative Accuracy Test Audit for 

Emission Rate Measuremen-RE- 3 8 

12.1.2 Relative Accuracy Test Requirement for Stack Gas 

Volumetric Flow Measurement System . 38 

12.1.3 Bias Test . 39 
. . INDUSTRY INTERNATIONAL INC. 

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TABLE OF CONTENTS 

(Continued) 

DESCRIPTION PAGE NO. 

12.2 Cylinder Gas Audit . . 39 

12.3 Record Keeping . . 39 

APPENDICES: 

Appendix A - System Configuration . . 40 

Appendix B - Daily~Weekly Operational Check Form . 43 

Appendix C - Routine Maintenance Operations . 45 

Appendix D - Recommended Spare Par-RE- Inventory . 48 

Appendix E - Diagnostic Tes-RE- . 60 
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I .- LOS ANGELES, CA 

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- 1.0 INTRODUCTION 

INDUSTRY INTERNATIONAL INC.'s Los Angeles Facility is required to demonstrate 

compliance with the Regional Clean Air Incentives Market (RECLAIM). This program 

was established by the South Coast Air Quality Management District's (SCAQMD) 

Regulation XX, which was adopted on October 15, 1993, and air pollution emission 

regulations as listed in the Code of Federal Regulations (CFR), Title 40, Part 60, February 

21, 1991. To ensure all aspec-RE- of compliance, INDUSTRY INTERNATIONAL INC. 

has developed and implemented this Quality AssuranceIQuality Control Program 

(QAIQC). 

This program will outline two very important aspec-RE-. The first aspect is the 

assessment of the quality of data collected by estimating precision, reliability, accuracy 

and timeliness. The second aspect is the control and improvement of the quality of the 

Continuous Emission Monitoring Systems (CEMS) data by implementing quality control 

policies and defining necessary corrective actions. This document will also dictate the 

(- measures to be taken when data quality has deteriorated. 

1.1 Program Goals 

1. To provide 100% data capture when heaters are active. 

2. To achieve a 95% confidence coefficient for all collected data. 

3. Track calibration drift to eliminate out of control periods. 

4. To provide steps in determining instrument performance. 

1.2 Organizational Chart 

Day to day operations and maintenance will be provided by maintenance personnel. Data 

assessment and reporting will be done by the environmental department manager who 

will assess the effectiveness of this manual and initiate change when warranted. 

- 2.0 INSTALLATION 

The monitoring systems are located such that the air contaminant and diluent gas 

concentration measuremen-RE- are representative of the stack emissions of the individual 

processes. The location selection follows the general guidelines as specified in 40 CFR 

60, Appendix B, Performance Specification 2, Section 3, and SCAQMD guidelines. 
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- 3.0 CEMS GENERAL DESCRIPTION 

3.1 General Discussion 

The Continuous Emissions Monitoring Systems (CEMS) provided has been designed to 

extract a gaseous sample from Facility exhaust stacks. The CEMS systems continuously 

measure all parameters necessary to directly determine mass emissions of RECLAIM 

pollutan-RE- such as Oxides of Nitrogen (NOx) and Oxides of Sulfur (SOx). This system 

is also designed to meet all performance standards for CEMS set forth in the RECLAIM 

Protocols for Reporting and Recording the accumulated data. The Data Acquisition 

System collec-RE- all of the accumulated data from each of the CEMS systems and 

calculates the NOx, SOx and stack flow. NOx is calculated fiom nitrogen oxides and 

oxygen concentrations, SO, is calculated from total sulfur in the fuel gas, and stack flow 

is calculated fiom the fuel gas flow, heat content and Fd factor per Rule 20 1 1. 

3.2 Analyzers SuppIied 

Each of the CEMS systems is supplied with an 0, Dry Analyzer and a NOx Analyzer. A 

couple of them have been equipped with O2 Wet, SO2 and Stack Flow Analyzers. The 

analyzer span ranges selected are based on the expected concentrations of pollutan-REproduced by each source. Refer to the CEMS Unit Specifications Table 3.2.1 for the list 

of analyzers supplied for each CEMS unit. The following is a summary of analyzers 

supplied for the CEMS systems: 

a. Raymond Model 70R - Oxygen (0,) Dry Analyzers, 

Ranges 0-1 0% and 0-25% 

b. Raymond Model 12 1B - Nitric Oxide / Nitrogen Dioxide (NO/NOx) Analyzers, 

Ranges 0-25 ppm, 0-50 ppm, 0-100 pprn and 0-250 pprn 

c. Raymond Model 890 - Sulfur Dioxide (SO2) Analyzers, 

Ranges 0-250 ppm, 0-500 pprn and 0-2000 ppm. 

d. Rach Series 2000 - Oxygen (02) Wet Analyzers, 

Ranges 0- 10% and 0-25% 

e. RachFlo Series 3000 - Stack Flow Analyzer Systems, 

Ranges 0-2,223,000 scfm and 0-1 71,429 sch 

f. 4R Scientific's Sulfur Model 1000 - Total Sulfur Analyzer, 

Range 0-200 pprn 

g. Rach Cal 50 Series Calorimeter, 

Range 900-1400 btulscf High Heating Value and 0.6-1.0 Specific Gravity 
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3.3 - calibration Gases Required 

EPA Protocol 1 gases shall be used to calibrate analyzers. When EPA Protocol 1 gases 

are not available because National Institute for Standards and Testing (NIST) does not 

produce Standard Reference Materials (SRM's) for these gases at the appropriate 

concentration, EPA Protocol 2 may be used to certify calibration gas standards. In the 

case where no SRM's are available, the facility shall submit a gas calibration protocol for 

approval, which specifies the steps to be taken for analyzing the concentration and 

stability of calibration gases. 

All calibration gases used during certification tes-RE- and quality assurance and quality 

control activities shall be certified according to the latest protocol approved by the 

SCAQMD. 

The calibration gas concentrations are selected based on a minimum of 80 percent of the 

analyzer span range. Refer to the CEMS Unit Specifications Table 3.2.1 for the list of 

analyzer span ranges supplied in each CEMS unit. Calibration gases required for the 

CEMS system are summarized as follows: 

a. N, zero gas to calibrate the low-level span range of all analyzers 

b. O,/CO span gas mixture to calibrate the high-level span range of the 02 and CO 

analyzers (CO analyzers are for INDUSTRY INTERNATIONAL INC.'s use only.) 

c. NOx span gas to calibrate the high-level span range of the NOx analyzers 

d. SO, span gas to calibrate the high-level span range of the SO, analyzers 

e. Multi-componant sulfur span gas to calibrate the high-level span range of the Total 

Sulfur analyzer 

f. Ethylenemethane (C, H6 / CH,) span gas mixture to calibrate the high-level span 

range of the BTU analyzer 

3.4 PLC Control System 

The Programmable Logic Controller (PLC) system automatically calibrates the analyzers 

once each day. The calibration is performed by introducing zero and span calibration 

gases into the sample system. This is accomplished by applying calibration gas at the 

sample probe and allowing the sample pump to pull the calibration gas through the heated 

sample line as if it were an actual sample. The PLC control system computes and applies 

a correction factor to the raw analyzer inpu-RE- by calculating the ratio of the expected 

gas versus the difference between the actual measured gas and the zero drift factor. 

The major tasks of the PLC control system provided are as follows: 

a. Performs 1 -minute rolling averages and 15-minute block averages for each of the 

analyzers. 
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b. Performs calibration to correct the following: 

1) raw analog input signals from each analyzer in order to apply the corrected 

analog output signals to each analyzer 

2) 1-minute rolling averages for each analyzer 

3) 15-minute averages for each analyzer 

c. Provides measurement correction and invalidation. 

d. Collec-RE- and stores the calibration data for up to 10-days, the 1-minute rolling 

averages for 1 -hour, and 15-minute averages for up to 10-days. In some cases, the 

15-minute averages are stored for only 7 or 8 days due to the PLC's memory 

capacity limitations. 

e. Provides dry contact outpu-RE- for system alarms. 

f. In some cases, initiate a sample pump shutdown when chiller failure or moisture 

in sample is detected. 

f. Provides analog outpu-RE- to strip chart recorder for recording all raw and 

corrected analyzer data. 

g. Monitors calibration error alarms and system malfunction alarms. 

h. Repor-RE- system status, calibration data and analyzer data to the Data 

Acquisition System via the InfoConcentrator PLC. 

3.5 Shelter Environment Controls 

Each of the CEMS shelters have been provided with environmental controls such as an 

air conditioning system, pressuring blower, temperature control alarm and pressure purge 

system. The air conditioning system runs continuously to cool down all instrumen-REand equipment in the shelter at about 70 OF. The pressuring blower provides continuous 

air flow in the shelter independent of the air conditioning system. The temperature alarm 

is designed to alarm when the shelter temperature exceeds about 85 OF, which is within 

the manufacturers temperature requiremen-RE- for the instrumen-RE- and equipment in 

the CEMS shelter. The pressure purge system is used for declassifying purposes. 
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- 4.0 ANALYZER SPECIFICATIONS (See Appendix A - System Configuration) 

The selected analyzers meet or exceed the performance requiremen-RE- set forth in 

RECLAIM Protocol SCAQMD Rules 201 1 and 20 12, and minimum specifications as 

presented in SCAQMD Reference Method 100.1, , and 40 CFR 60, Appendix B, 

Performance Specification 2, Section 4. Instrument specifications will also be consistent 

with requiremen-RE- in EPA Reference Methods 3A, 6C, 7E, or 10, as applicable for 

method of detection, sensitivity, noise, precision, linearity, and interference. 

Detailed system information can be found in the specific technical manuals or in the 

system documentation provided by each analyzer manufacturer. 

4.1 Raymond Model 70R (03 Oxygen Dry Analyzers, 

Ranges 0-10% and 0-25% 

The Raymond Model 70R Oxygen Dry Analyzer provides continuous readout of the 

oxygen content of a flowing gas sample. The determination is based on measurement of 

the magnetic susceptibility of the sample gas. Oxygen is strongly paramagnetic while 

most other common gases are weakly diamagnetic. 

The instrument provides direct readout of 0 to 10% or 25% oxygen concentration on a 

fiont panel digital display. In addition, a field-selectable voltage output of 0 to +5V is 

provided as standard. An isolated current output of 0 to 20 ma or 4 to 20 ma is obtainable 

through plug-in of an optional circuit board. Current and voltage outpu-RE- may be 

utilized simultaneously if desired. An alarm option is also available by way of a relay 

assembly that moun-RE- at the rear of the case with a cable that plugs into the Control 

Board. Customer connections are available on this assembly. 

The. basic electronic circuitry is incorporated into two master boards designated the 

Control Board assembly and the Power Supply Board assembly. The Control Board has 

receptacles that accept optional plug-in current output board and alarm features. 

4.2 Raymond Model 121B (NO/NOx) Nitric Oxide / Nitrogen Dioxide Analyzers, Ranges 

0-25 ppm, 0-50 ppm, 0-100 ppm and 0-250 ppm 

The Raymond Model 121B NO/NOx Analyzer continuously analyzes a flowing gas 

sample performing one of two switch selectable determinations: 

1. Nitric Oxide (NO); or 

2. Combined nitric oxide (NO) and nitrogen dioxide (NOz) designated NOx. By 

definition [NOx] = [NO] + WO2]. 
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The analyzer utilizes the Chemiluminescent method of detection in the nitric oxide 

determination, sample NO is quantitatively converted into NO2 by gas-phase oxidation 

with molecular ozone produced within the analyzer from air or oxygen supplied by an 

external cylinder. A characteristic of this reaction is elevation of approximately 10% of 

the NO2 molecules to an electronically excited state, followed by immediate reversion to 

the non-excited state accompanied by the emission of photons. 

The emitted photons impinge on a photo-multiplier detector generating a low-level DC 

current. The current is amplified to drive a front panel meter and an accessory 

potentiometric recorder if desired. 

4.3 Raymond Model 890 Sulfur Dioxide (SO,) Analyzers, 

Ranges 0-250 ppm, 0-500 and 0-2000 ppm 

The Raymond Model 890 Sulfur Dioxide (SO,) Analyzer provides continuous 

measurement of sulfur dioxide content of a flowing gas sample. This analyzer utilizes an 

ultraviolet source which emi-RE- a pulsed (80Hz) beam of energy. This energy is split by 

a beam splitter, each beam being directed to pairs of detectors before and after the sample 

cell. 

This analyzer uses a spectrally selective mirror to isolate the sample and reference 

spectral passbands for the detectors. They reflect energy below a wavelength region and 

transmit the remaining, higher wavelengths, all with much lower energy loss than the 

more commonly used bandpass interference filters. 

Four detectors are used in this system, two before the sample cell and two after . These 

four detectors measure SO, concentration and correct for NO, interference and UV lamp 

fluctuations. The difference between detector determinations is the SO, concentration. 

The sample is introduced to the sample cell and the component of interest absorbs 

ultraviolet energy in proportion to the concentration of the gas. The difference between 

the signals of the detectors located at both ends of the sample cell determines the 

concentration of SO, in the sample. Additionally, the adjacent (non-SO,-absorbing) 

reference wavelengths are used as a baseline for measurement and correction of sample 

interference componen-RE-, particularly NO,. 

4.4 Rach Series 2000 Oxygen (02) Wet Analyzers, 

Ranges 0-10% and 0-25% 

The Rach Series 2000 Oxygen Wet Analyzer provides continuous measurement of 

oxygen content of a flowing gas sample. This analyzer consis-RE- of an oxygen sensing 

cell, aspirator assembly, control unit and temperature system. 
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i - Quality Assurance/Quality Control Plan 

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A sample is drawn from the process stream by means of an air-operated aspirator and is 

immediately returned to the process. A portion of this gas rises past the oxygen sensing 

cell and returns to the primary loop. All sample wetted par-RE- are heated to maintain 

the sample above the dewpoint of the gas. 

The working element of the oxygen gas sensor is a closed-end tube made of a ceramic 

oxide, Zirconium Oxide. When the sensing cell is hot, it becomes a conductor of 

electricity because of the mobility of the oxygen ions in i-RE- crystal structure. Thus, a 

voltage is produced that is logarithmically proportional to the ratio of the oxygen 

concentration of the gas on the reference side of the cell (usually ambient air) and the 

oxygen concentration of the sample. The percent oxygen value will appear on the 

microprocessor control unit display. The sensing cell is a partial pressure device and 

responds directly to changes in sample partial pressure. 

When the two electrode coatings are in contact with gases (at the same nominal pressure) 

that have different levels of oxygen concentration (or different partial pressures), a 

voltage is produced that is dependent upon their ratio. If the oxygen gas is known (the 

reference gas is normally air at 20.9% 03, the oxygen of the other then is indicated 

directly by the voltage fiom the cell. 

4.5 RachFlo Series 3000 Stack Flow Analyzer Systems, 

Ranges 0-2,223,000 scfm and 0-171,429 scfm 

The RachFlo Series 3000 Stack Flow Analyzer provides continuous, accurate, and 

reliable volumetric flow monitoring for stacks of any size and configuration. RachFlo's 

flow monitoring system consis-RE- of in-stack flow measurement equipment (STACKprobes), auto-purge system and flow monitoring instrumentation. 

The RachFlo STACK-probe is used to accurately monitor the average flow and 

temperature of the stack emissions based on differential pressure (Pitot-Fechheirner) 

method for measuring airflow. Each STACK-probe consis-RE- of two separate round 

tube self-averaging manifolds; one to measure the stack total pressure, and the other to 

measure stack static pressure. Flow rate monitoring is performed by sensing individual 

flow componen-RE- at multiple poin-RE- (traversing) across one or more diameters for 

circular stacks or along multiple parallel traverses for rectangular stacks, and averaging 

the obtained values. Similarly, average stack temperature is measured using a 

thermocouple probe with multiple temperature sensing elemen-RE- spaced along the 

probe length. 

The RachFlo AUTO-purge system required for differential pressure flow monitoring 

systems is a back purging means to insure that the in-stack flow monitor probe has i-REpressure sensing por-RE- and averaging manifold maintained fiee of particulate or 

condensation. This system sequentially operates a combination of valves to periodically 
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i -- Quality Assurance/Quality Control Plan 

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and automatically back purge the sensing lines and the STACK-probes with high 

volurne/high pressure compressed air for a short duration, while simultaneously locking 

in the transmitter output and isolating the transmitter fiom over-pressurization. 

The RachFlo Series 3000 flow monitoring instrumentation is the means to amplify, 

linearize, and scale the differential pressure flow signals received fiom the in-stack 

probes to generate a continuous output signal representing the volumetric flow in SCFM 

(wet basis) being discharged into the atmosphere. The Flowmeter is an ultra-low 

differential pressure transmitter with built-in signal conditioning, square-root extractor, 

scaling multiplier, auto-calibration circuitry and circuitry for temperature and pressure 

correction of ACFM to SCFM. An integral LED digital display provides local readout of 

stack SCFM and temperature. 

4.6 4R Scientific's Sulfur Model 1000 Total Sulfur Analyzer, 

Range 0-200 ppmv 

4R Scientific's SulfurDetectTM precision series of analyzer provide on-line analytical 

measurement of hydrogen sulfide (H2S) concentrations. 

The ~ach~hem~ technology provides H2S-specific, interference-fiee, detection and 

measurement. Hydrogen sulfide detection and concentration analysis by the use of 

RachChemTM are based on chemical factors and physical constan-RE-, which confirm the 

unique analytical precision of the technology. 

4R Scientific's SulfurDetectTM H2S monitor utilizes a single optical sensor and light 

source to detect and measure the rate of lead sulfide formation. The single optical sensor 

used in SulfurDetectTM series functions as both a reference and measurement optical 

sensor. At the beginning of each measurement cycle the tape advances to a new or 

unexposed portion of the tape. Instantly, as the tape stops, the optical sensor value is fed 

into a circuit driving a preamplifier into an AD converter, and the resultant voltage level 

is stored in the microprocessor memory section. A new optical sensor reading is 

compared to the stored information. 

At this point, the microprocessor determines the level of H2S by comparing the two 

readings, and displays the result on the digital display in engineering uni-RE- as selected 

at the time of order, such as PPM by volume, weight or grains11 00 standard cubic feet or 

mole %. Simultaneously, the second reading is stored in the memory for later comparison 

to a third reading. The cycle is repeated on an average of every second, until the tape is 

too dark for further accurate readings and the complete cycle star-RE- again. 

Effectively, a new zero or reference point is selected with each reading after the initial 

period. Temperature drift is virtually eliminated, as it is confined to a time span of less 

than 1 0-seconds. 
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As the H,S level is displayed, it is used to actuate any alarms, if the level is above the 

alarm set point, and drive the optional 4-20mA loop and chart recorder. 

Rach Cal50 Series Calorimeter, 

Ranges 900-1400 btulscf High Heating Value and 0.6-1.0 Specific Gravity 

The Rach Cal 50 Series Calorimeter is a high-speed (6 to 8 seconds response) instrument. 

The variations in the rate of heat released from a continuously burning gas are fed back 

via a thermal expansion element to a flapper-nozzle control system, which adjust the flow 

of cooling air to the air orifice and subsequently the burning chamber. The varying flow 

of air is used to control the temperature of the combustion product. Thus, the air flow 

varies according to the heat released by the gas. Measuring the air flow would provide a 

direct measurement of the heat value of the burning gas. 

The pressure across the air orifice is measured by a differential pressure transducer. The 

pressure differential across the air orifice is an indication of a change in flow rate of the 

air. This is proportional to the measured heat value within the calibrated range of the 

Calorimeter. Utilizing the constant volume positive displacement metering pump allows 

the Calorimeter to measure the Calorific Value instead of Wobbe Index. Thus, the 

calorimeter would measure, with a calculated offset, the gross calorific value. The 

calorific value, measured in BTUISCF, is defined as: 

Calorific Value = Heat Energy 

Unit Volume at standard pressure and temperature 30" Hg @ 60°F = BTUISCF 760rnrn 

Hg, 0°C for ~cal/~m~. 

As stated, calorific value, the heat value at standard conditions is expressed as the Gross 

Heating Value, which is the theoretical heat value of the sample gas at standard 

conditions. 

The Calorimeter uses a programmable low pressure transmitter for accurate differential 

pressure measurement. The micro-processor based transmitter monitors the differential 

pressure across the air orifice supplying a continudus 4-20mAdc output signal, which is 

proportional to the heat value. 
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(- Quality AssuranceIQuality Control Plan 

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SAMPLE HANDLING SYSTEM 

.The gas sample extraction and conditioning equipment (probe, filter, pump, conditioner, 

connective plumbing, etc.) associated with each monitoring system will meet or exceed 

minimum specifications as described in SCAQMD Reference Method 100.1 and 

RECLAIM guidelines. 

The function of the sample handling system is to extract a gaseous sample continuously 

fiom the point of measurement of the flue gas stream, condition and cool the sample to 

below the dew point, and deliver a dry sample to the analyzers. A heated sample line is 

used between the point of measurement and the sample conditioning cabinet to keep the 

gaseous stream above the 40°F dew point. A temperature controller holds the heated 

sample line temperature to between 275°F and 350°F. 

5.1 ,- Probe Design and Sample Line Design 

The probe is constructed of a 3/4-inch stainless steel horizontal element filter with a 

maximum temperature rating of 400°F. The heated sample line contains two heated-and 

hvo unheated Teflon tubes. The heated tubes accommodate the sample 'gas and 

calibration gas, while the unheated tubes are not used. The sample gas, calibration gas 

and air blowback flow are controlled by two solenoid valves. During normal operations, 

both solenoid valves are in the "off" position, which allows the sample gas from the stack 

to go through the probe and sample line and down to the analyzers. During blowback and 

remote calibration, both solenoid valves are in the "on" position, which allows air to be 

blown back into the probe, filter and sample lines, as well as, allow calibration gas to pass 

through the probe and sample line and down to the analyzers. 

5.2 Heated Sample Line 

The heated sample line temperatures are controlled using individual temperature 

'controllers, panel items TC1 and TC2, respectively. In both cases, a two (2) wire 

temperature element is used to sense the temperature. 208 VAC power is applied as 

necessary to the heating element to control the sensed temperature of the set point value 

which should be 275350°F. 

5.3 Filtering and Conditioning 

The.sample handling system contains a single stage AD1 @IA-VAL 193 10T) sample 

pump. This system is located on the wall of the analyzer shelter. The sample is 

introduced into the Universal Analyzer, Inc. (Model 1050) single channel sample cooler 

where the outlet sample dew point is 41°F (5°C). The water that is dropped out during 
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this stage is collected in a built-in reservoir. The reservoir is drained continuously by a 

4R Peristalic pump. 

Once the sample gas has passed through the sample pump, it is pushed into the sample 

dryer assembly. Before the sample leaves the sample dryer assembly, it passes through a 

moisture monitor which detec-RE- if any moisture is left in the sample gas indicating 

improper dryer operation. If moisture is detected, an alarm is generated and the sample 

pump is automatically shutdown to protect the analyzers. 

5.4 Flow Measurement Devices 

Once the sample gas has passed through the sample dryer assembly, the sample gas is 

directed to the instrument panel IP which is mounted on the cabinet. Sample pressure is 

indicated on a pressure gage. Sample pressure is also monitored using pressure switch 

VPS. An alarm contact is activated if the sample pressure drops below the normal value. 

The pressure gage normally reads between 4 to 6 PSIG. The sample gas flow is split by 

using two needle valves with flow indication. The two valves are piped in parallel. The 

valve labeled "BY-PASS FLOW" direct the sample gas to an ambient vent. The valve 

labeled "SAMPLE FLOW" direct the sample gas to the analyzers. The two valves must 

be adjusted together to set up the correct flow to the analyzers which is approximately 50- 

500 cclmin at 10 PSIG maximum for the Oxygen analyzer and 2000 cclmin for the NOx 

analyzer. 

The Oxygen analyzer receives the sample via gas flow through the 0, analyzer solenoid 

valve. The 0, analyzer output a linear 0 to +5 VDC signal proportional to the oxygen 

content in the sample gas. This output is wired to the PLC and strip recorder. The 

analyzer also has a vent which direct the measured sample gas to atmosphere. Refer to 

the Model 70R instruction book number 01 5-74821 3-5 for detailed information 

concerning the operation of the oxygen analyzer. 

The NOx analyzer receives it's sample via gas flow through the NOx analyzer solenoid 

valve. The NOx analyzer output a linear 0 to +5 VDC signal proportional to the NOx 

content in the sample gas. This output is wired to the PLC and strip recorder. This 

analyzer also has a vent which direct the measured sample gas to atmosphere. Refer to 

the Model 121B instruction book number 01 5-556383-U. 

It is important to note that each of the above described solenoids is a normally closed 

valve which are held open, energized under normal operating conditions. This sample 

conditioning system contains interlocks which will close the solenoid . valve 

automatically, to protect the analyzers, if the proper operating conditions are not met. 

These interlocks will be described in Section 5.6 below. 

5.5 Leak Checking 
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Leaks in the sample lines can be checked by manually performing a remote and local 

calibration (sample bypass testing), and comparing the raw input signals going into the 

analyzers. The analyzer input measuremen-RE- resulting fiom local calibration should 

match the values resulting fiom remote calibration. A mismatch in measuremen-RE- may 

indicate a leak in the sample lines. A second test method is to reduce the gas pressure on 

the Zero calibration gas bottle to less than 5 psig and observe the O2 reading during a 

remote manual zero gas calibration. Because the gas pressure is low, the sample pump 

will increase suction and if there are any leaks in the sample system, air will be drawn 

into the sample system and you will see an increase in the O2 reading. This increased 

reading is due to a leak in the sample system. 

5.6 'Interlocks 

Several safety interlocks have been provided with this system to protect the analyzers 

fiom being damaged. The goal is to keep the analyzers fiom being subjected to moisture. 

Below is a list of interlocks which, if not satisfied, will automatically shut down the 

sample pump. 

a. Chiller Failure 

b. High Moisture Content in Sample 

A chiller failure alarm indicates a high moisture content in the samples resulting fiom the 

chiller malfunction. When this alarm condition occurs, alarm messages shall be indicated 

on the PLC operator interface display. The alarm messages will clear only when the 

problem indicated on the alarm messages are fixed. 
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DESCRIPTION OF SYSTEM CALIBRATION 

calibration gases are used to calibrate the analyzers. The CEM systems supplied offers 

several options for applying calibration gas to the analyzers. Calibration gas can be 

injected "automatically" or "manually" in remote mode, or "manually" in local mode. Per 

40 CFR Part 60, zero and span gases must be applied once every TWENTY FOUR 

HOURS to calibrate analyzers. The following discussion will describe the various 

methods for calibration. 

6.1 Remote Calibration b 

Remote calibration is the method most often used for this application. Remote injection 

means that the calibration gas is introduced to the sampling system by injecting the gas at 

the sample probe. The calibration gas is then drawn into the sample conditioning system 

the same as a normal sample as described above. This allows the whole system to be 

exposed to the calibration gas which will show any malfunctions such as leaks. 

Remote calibration operation can be initiated manually or automatically. It is important 

to note that automatic and manual initiation of calibration is accommodated throughathe 

PLC operator interface. 

6.1.1 Automatic Remote Calibration 

Automatic remote calibration can be initiated automatically at a preset time once 

daily or instantaneously by operator command on the PLC operator interface. 

Initiating automatic calibration at a preset time is the most common calibration 

method used. Initiating automatic calibration instantaneously is required only 

after performing manual calibration. 

Zero and span calibration gases for each analyzer are automatically applied. The 

automatic calibration determines the numbers used in the calculation of the 

corrected analog values, 1-minute and 15-minute values. The readings are taken 

at the time the appropriate cycle is complete. All automatic calibration data, such 

as date and time of calibration, zero and span calibration gas values (expected 

values), actual readings and deviation values, are stored in the PLC data files and 

are retained for 10-days. This data stored shall be transferred to the 

Infoconcentrator for the DCNX system to access. 
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6.1.2 Manual Remote Calibration 

Manual remote calibration can be initiated at the PLC operator interface. This 

calibration method allows the operator to inject any zero or span calibration gas to 

all analyzers in the CEMS system. 

For example, if O2 span gas is selected for injection, the PLC processor will 

operate the following solenoid valves (SOV) to allow the calibration gas to flow 

up to the sample probe via a second tube in the heated sample line: local/remote 

SOV is switched to remote position, the O2 span calibration gas SOV is opened, 

the bubbler SOV is closed, and the sample probe blowback SOV is energized. The 

test gas is then drawn down the sample tube of the heated sample line and into the 

CEMS analyzers. With the sample probe blowback SOV energized, instrument 

air is blown back through the sample probe back flushing it with air to clean and 

clear it. This blowback occurs during the calibration period. 

Applying other calibration gases to the system result in the same operation except 

that different set of solenoid valves open. 

6.2 Manual Local Calibration 

Applying calibration gases locally is an option which can only be accomplished manually. 

It is used for sample line leak checking or analyzer maintenance. Zero and span 

calibration gas injection can be locally controlled by the PLC operator interface. It is 

important to note that when calibration gas in injected locally, it is directed only to the 

selected analyzer as opposed to all analyzers during a remote operation. 

For example, if O2 span gas is selected, the PLC processor will operate the following 

solenoid valves (SOV): locallremote remains in local position, the O2 analyzer SOV is 

opened, and the bubbler SOV is closed. The sample probe solenoid will remain deenergized, thus cutting off the sample, and the span calibration gas is transported directly 

to the analyzer. The needle valve just ahead of the analyzer is used to adjust the test gas 

flow. 

Applying other calibration gases locally to the individual analyzers will result in the same 

operation as described above, except that different solenoid valves open for the other 

calibration gas selections. 
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DESCRIPTION OF SYSTEM OPERATION PROCEDURES 

This section will describe procedures developed to meet RECLAIM Protocol SCAQMD 

Rules 201 1 and 2012, Appendix A. 

Scheduled Calibration Procedures 

7.1.1 Automatic Calibration 

Initiate the automatic calibration automatically once a day at a preset start time or 

manually by operator command via PLC operator interface. The auto-calibration 

shall be initiated instantaneously only after a manual calibration in order for the 

PLC processor to adjust the calibration factors to the newly calibrated analyzer 

output. Once the automatic calibration is initiated, the processor will hold the last 

transmitted sample gas data and will automatically begin the following calibration 

sequence. 

Note that for the entire duration of the auto-calibration sequence, the bubbler 

solenoid is closed and the probe solenoid valves are energized. Each calibration 

gas is applied to the analyzers for 3-minutes, with the exception of the 0, Wet and 

Stack Flow analyzers. Thus, the total duration for the auto-calibration sequence is 

dependent on the number of calibration gases to be applied. 

1. Zero gas is the first gas to be applied to all analyzers via the sample probe 

and sample line. After 3-minutes, all solenoid valves are reset and the zero 

calibration errors are calculated. 

2. O,/CO Span gas is applied to the 0, Dry and CO analyzers via the sample 

probe and sample line. After 3-minutes, all solenoid valves are reset and 

the 02 and CO span calibration errors are calculated. (The CO analyzer is 

for INDUSTRY INTERNATIONAL INC.'s use only.) 

3. NOx Span gas is applied to NOx analyzer via the sample probe and sample 

line. After 3-minutes, all solenoid valves are reset and the NOx span 

calibration errors are calculated. 

4. This step is for INDUSTRY INTERNATIONAL INC.'s use only. PreSCR NOx Span gas is applied to the Pre-SCR NOx analyzer via the 

sample probe and sample line. After 3-minutes, all solenoid valves are 

reset and the Pre-SCR NOx span calibration error are calculated. 
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5. For CEMS systems with SO, analyzer, the SO, Span gas is applied to SO, 

analyzer via the sample probe and sample line. After 3-minutes, all 

solenoid valves are reset and the SO, span calibration errors are 

calculated. 

6. For CEMS systems with 0, Wet analyzer, the PLC processor initiates the 

0, Wet analyzer calibration by triggering a digital output signal to the 

analyzer. Prior to calibration, the time duration values for zero and span 

calibration should be programmed into the analyzer control unit. The time 

duration values should also be entered into the PLC operator interface for 

the purpose of monitoring calibration data. Once the 0, Wet analyzer 

calibration sequence is completed, the 0, Wet zero and span calibration 

errors are calculated. 

7. For CEMS systems with Stack Flow analyzer, the PLC processor initiates 

the Stack Flow analyzer calibration by triggering a digital output signal to 

the analyzer. The analyzer will hold the last transmitted flow value for 60- 

seconds before beginning zero calibration. Zero calibration will occur for 

60-seconds. There's a 30-seconds delay prior to the start of Span 

calibration. Span calibration will occur for 60-seconds prior to resuming 

the normal sample flow. At the completion of Stack Flow analyzer 

calibration sequence, the Stack Flow zero and span calibration errors are 

calculated. 

7.2 Procedure for Measurement Correction 

Measured analyzer signals are corrected when excess analyzer drift is detected. 

Calibration errors for each span gas and zero gas are calculated and compared to the 

calibration limit after an automatic calibration. Whenever the calibration limit are 

exceeded, the raw analog input signals, the 1-minute and 15-rolling averages are 

corrected based on the calculated correction factor and zero drift factor. These limits are 

as listed below: 

NOx Zero Limit - 2.0% of span 

NOx Spa Limit - 2.5% of span 

SO, Zero Limit - 2.0% of span 

SO, Span Limit - 2.5% of span 

0, Zero Limit - - 0.5% 0, 

0, Span Limit - - 0.5% 0, 

- 7.3 Procedure for Determination of Out of Control Conditions 

An out-of-control period occurs when, 
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the calibration error of an 0, analyzer exceeds 1 percent 02, 

or when the calibration error of a NOx or SO, analyzer exceeds 5 percent based upon 

the span range value. 

The out-of-control period. begins with the hour of completion of the failed calibration 

error test and ends with the hour of completion of following an effective re-calibration. 

Measured signals are invalidated when the calibration errors exceed the "Out of Range" 

or "Out of Control" limit Calibration errors or analyzer drift for each span gas and zero 

gas are calculated and compared to the "Out of Range" and "Out of Control" limit after an 

automatic calibration. If any of the NOx, SOxor 0, zero or span calibration errors exceed 

the "Out of Control" limit listed below, then the measurement will be flagged as invalid 

data. 

NOx Zero or Span Out of Control Limit = 5.0% of span 

SO, Zero or Span Out of Control Limit = 5.0% of span 0, Zero or 

Span Out of Control Limit = 1 .O% 0, 

The NOx measurement will also be flagged as invalid data if the measured sample gas 

concentration (analyzer raw reading)does not fall within the "Out of Range" Limit of .Ol - 

95% of span. 

For the SO, analyzer or fuel gas sulfur content analyzer, the same "Out of Range" limiRE- apply. 

7.4 Corrective Action Procedures to Correct Out of Control Conditions 

Out-of-Control conditions occur when calibration fails due to CEMS system malfunction. 

The CEMS PLC is designed to monitor different par-RE- of the system, in order to 

determine the source of failure quickly and efficiently. The system malfunctions when 

the following occurs: 

a. sample pump failure 

b. chiller failure 

c. probe temperature is high or low 

d. sample line temperature is low 

e. analyzer failure 

When any of the above malfunctions occur, the CEMS PLC system will trigger an alarm 

which will be stored in the PLC and displayed on CEMS annunciator panel. The 

maintenance personnel will investigate and correct system malfunctions as soon as they 

occur. The analyzers will then be re-calibrated using the manual remote calibration 

procedure. Adjust the calibration, at a minimum, whenever the daily calibration error 

exceeds the limit of the applicable performance specification for the 0, monitor and NOx 
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NOx monitor. Re-calibration, following an adjustment or repair, will demonstrate that 

the corrective actions taken were effective. 

Whenever the failed calibration, corrective action and effective re-calibration occur 

within the same hour the hour is not out-of control if 2 or more valid 15-minute readings 

are obtained during that hour. 

7.5 Documentation of System Operations 

INDUSTRY INTERNATIONAL INC. will record and store raw and corrected 

concentrations in par-RE- per million (ppm) and percent (%) on a strip chart recorder. 

A chronological file shall be maintained and retained for a minimum of three years, 

which includes: 

a. All strip chart recordings. 

b. All valid averages. 

c. Data and resul-RE- for all performance tes-RE- and re-calibrations. 

d. A record of any repairs, adjustmen-RE- or maintenance to the monitoring 

system; of which a system log book will be maintained. 

The following information will be reported electronically by a Remote Transmitting Unit 

(RTU) to the agency on a daily basis: 

a. The previous day's NOx emissions, in pounds, for each Major NOx 

RECLAIM device with status codes. 

b. The previous day's SOX emissions, in pounds, for each Major SOX 

RECLAIM device with status codes. INDUSTRY INTERNATIONAL INC. 
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PREVENTIVE MAINTENANCE PROCEDURES 

Preventive maintenance requirement are described in the instruction and operation 

manual. Due to the method and complexity of these analyzers, daily, bi-weekly and 

monthly maintenance routines are required to maintain equipment operation. Sample 

system bias testing shall also be performed on an "as needed" basis to insure relative 

accuracy of the CEMS system. 

The following preventive maintenance procedures shall be implemented to minimize 

CEMS breakdown. 

8.1 Daily Maintenance 

Daily maintenance will be performed to maintain continuous uninterrupted operation of 

the system. Abnormal findings will be reported immediately to the appropriate 

maintenance authority. This will assure minimum downtime and accurate data recovery. 

The daily calibration log generated by the data acquisition system will be used by the 

Instrument Department to track the operation of the system, as well as, assess the 

calibration drift of the daily zero and span checks. This data will also be utilized by 

management to determine the success of the QNQC manual and direct appropriate 

changes as required. 

8.1.1 Instruction for Completing Form Q (See Appendix B) 

The Instrument Department will be responsible for verifying all data printed 

during each day shift. A daily system verification form will also be completed. 

The majority of this form requires only a check mark indicating that the specific 

operating parameter was verified. Any problems found should be reported 

immediately. 

Step Procedure 

A. At Analyzers 

1. Proceed to enclosure of first set of analyzers 

2. Check and record flow meter settings 

3. Check and record system back pressure 

4. Check condensate removal system for operation and clean drains 

5. Record condenser temperature 

6. Check and record probe and line temperatures 

7. Check calibration cylinder pressure readings. Replace if below 200 

PSI 
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8. Initial check list and proceed to next enclosure 

B. At Recorders 

1. Examine strip chart recorder operation - printing legibly and 

operating normally 

2. Check if ink and paper are sufficient to operate for the next 24 hours 

3. Review the last automatic calibration data 

4. Log actual readings of zero and span, and calculate the zero and span 

calibration error (drift). 

5. Compare the calculated calibration error (drift) to the "Out of Range" 

and "Out of Control" limits. If the calibration error exceeds the limit, 

report to the supervisor; take corrective action and log problem; 

corrective action taken, and period of invalid data 
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- 9.0 DATA ACQUISITION SYSTEM 

9.1 Equipment Descriptions 

9.1.1 Raymond Programmable Logic Controller PLC 5/20 

The Raymond Programmable Logic Controller PLC 5/20 is a complete PLC 

control or CEMS PLC system which collect and stores data, performs 

computations, automatically correct- and invalidates data, performs control 

sequences, and communicates to a DCNX system via the Infoconcentrator. The 

PLC for this project has been programmed to perform all of the above functions. 

The PLC utilizes PLC5 Logistics software in order to run the CEMS PLC 

program. The following discussion will cover the specifics of this project. 

Reference the Raymond PLC 5/20 User's Manual for general information about 

the PLC. 

.- 9.1.2 Raymond Operator Interface Module 

The Raymond operator interface module provides the capability for operators to 

input data and retrieve data fiom the PLC. It also functions as a message display. 

The operator interface has the following features: 

a. Displays calibration and analyzer data. 

b. Allows the operator to input zero and span calibration gas data (expected 

values). 

c. Allows the operator to set the time for initiating automatic calibration. 

d. Allows the operator to initiated the automatic calibration sequence manually 

after performing a manual calibration. 

e. Allows the operator to initiate the remote or local manual calibration. 

f. Allows the operator to set the time duration for zero and span calibration for 

the 0, Wet analyzer, if applicable. 

g. Allows the operator to initiate the 0, Wet and Stack Flow analyzer calibration 

sequence. 

9.1.3 Raymond 45-IFE Analog Input Modules 

The analyzers deliver 0 to +5 Volt signals. The analog input channels are 

configured for -5V to +5V in order to detect zero drift below zero vol-RE-. 
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A raw signal from each of the analog input channels is read by the PLC processor 

once every 10-seconds from which the 1-minute and 15-minute averages are 

computed and stored. 

Each CEMS PLC system has been provided with an analog input card containing 

eight (8) input channels. The input channel designations varies with each CEMS 

system. 

The first three channels, assigned to NOx, CO and O2 analyzers, are typical for all 

CEMS PLC systems, except in Uni-RE- 41-MG-1 and 88. In Unit 41-MG-1, 

channel 2 is assigned to a SOX (Lo) analyzer. In Unit 88, the first three channels 

are assigned to calorimeter for higher heating value, calorimeter for specific 

gravity and total sulfur analyzer. 

The fourth channel is typically a spare, but in the case of Uni-RE- 30-LG-301, 

56-LG-1,2 58-LG-1, the fourth channel is assigned to a Pre-SCR NOx analyzer 

(INDUSTRY INTERNATIONAL INC.'s use). In Uni-RE- 41 -MG- 1 and 6 1 -MG1, this channel is assigned to a SOX analyzer. 

Channels 5 through 8 are typically assigned to the field devices, and these A1 

.channel designations varies with each CEMS system. In Uni-RE- 41-MG-1 and 

6 1 -MG-1 , channel 7 is assigned to the Stack Flow analyzer. 

9.1.4 Raymond 45-OFE Analog Output Modules 

The analog output channels are configured for 4-20mA. These channels provide 

the strip chart recorder with corrected analyzer data. These corrected data are 

derived from the raw analog input signals automatically corrected based on the 

correction factor calculated after an automatic calibration. These corrected values 

are stored in the PLC data files, and sent out to the strip recorder via the analog 

output card and Data Acquisition System via the Infoconcentrator. 

The first three A0 channels typically registers NOx, CO and O2 corrected data, 

except in Uni-RE- 41-MG-1 and 88. In Unit 41-MG-1, channel 2 output the 

corrected SOX (Lo) concentration value. In Unit 88, the first three channels are 

assigned to calorimeter for higher heating value, calorimeter for specific gravity 

and total sulfur analyzer. 

The fourth A0 channel is typically a spare, but in the case of Unit 30-LG-301 and 

56-LG-1,2, the fourth channel output the corrected Pre-SCR NOx concentration 

value (INDUSTRY INTERNATIONAL INC.'s use). In Unit 41 -MG-1 and 61 - 

MG-1 , this channel is assigned to the corrected SOX concentration value. 
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9.1.5 Raymond 45-IBD Digital Input Modules 

Each CEMS PLC system is provided with one 16-channel digital input card. This 

DI card utilizes several status input for CEMS and shelter system alarm status. 

The DI channel designations in each CEMS system varies, but have typical digital 

input descriptions as listed below. 

In Maintenance Alarm 

CEMS Pump Failure Alarm 

Pre-SCR Pump Failure Alarm (For INDUSTRY 

INTERNATIONAL INC.'s Use only) 

CEMS Chiller Failure Alarm (moisture) 

Pre-SCR Chiller Failure Alarm (moisture) (For INDUSTRY 

INTERNATIONAL INC.'s Use only) 

Pre-SCR Probe HighiLow Temperature Alarm (For INDUSTRY 

INTERNATIONAL INC.'s Use only) 

CEMS Probe High/Low Temperature Alarm 

Pre-SCR Sample Line Low Temperature Alarm (For INDUSTRY 

INTERNATIONAL INC.'s Use only) 

CEMS Sample Line Low Temperature Alarm 

CEMS Shelter Power Failure Alarm 

CEMS Shelter Pressure Purge Failure Alarm 

CEMS Shelter Temperature Control Alarm 

H2S High Alarm 

H2S High-High Alarm 

H2S Reset Button to reset H2S alarm horn 

Low Instrument Air / Low Calibration Gas Alarm 

9.1.6 Raymond 45-0 W 16 Digital Output Modules 

Each CEMS PLC system is provided with two to three 16-channel digital output 

cards. These DO card utilizes several status output for alarm status annunciator 

panel indication, calibration and blowback system control. The DO channel 

designations in each CEMS system varies, but have typical digital output 

descriptions as listed below. 

The Digital Output Module #I operates all solenoid valves. 

DO #1 - 0, Analyzer Solenoid 

DO #2 - CO Analyzer Solenoid Valve 

DO #3 - NOx Analyzer Solenoid Valve 

DO#4 - Spare 

DO#5 - Spare 
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DO#6 - Spare 

DO #7 - LocalIRemote Solenoid Valve 

DO #8 - O,/CO Span Calibration Gas Solenoid Valve 

DO #9 - NOx Calibration Gas Solenoid Valve 

DO#10 - Spare 

DO #11 - Zero Calibration Gas Solenoid Valve 

DO #12 - Spare 

DO # 13 - Bubbler Solenoid Valve 

DO #14 - Probe Blowback~Calibration Solenoid Valve 

DO #15 - Probe Blowback Solenoid Valve 

DO #16 - Sample Pump Shutdown Solenoid Valve 

The Digital Output Module #2 transmi-RE- the CEMS and shelter system alarms 

to the H,S alarm devices and annunciator panel. 

DO #1 - H,S Alarm Horn 

DO #2 - H,S Alarm Beacon 

DO #3 - "Maintenance Mode Selected" alarm light 

DO #4 - "Automatic Calibration in Progress" alarm light 

DO #5 - "Manual Calibration in Progress" alarm light 

DO #6 - "Low Air Supply Pressure" alarm light 

DO #7 - "Calibration Gas Pressure Low" alarm light 

DO #8 . - "Sample Pump Failure" alarm light 

DO #9 - "Sample Chiller Malfunction" alarm light 

DO #10 - "Sample Line Temperature Low" alarm light 

DO #11 - "Probe Temperature Low" alarm light 

DO #12 - Spare 

DO#13 - Spare 

DO #14 - "Shelter Power Supply Failure" alarm light 

DO #15 - "Shelter Purge Failure" alarm light 

DO #16 - "Shelter Temperature Control Failure" alarm light 

The Digital Output Module #3 transmit the calibration failure alarms to the 

annunciator panel. 

DO # 1 - "H,S High" alarm light 

DO #2 - Spare 

DO #3 - "0, Analyzer Calibration Failure" alarm light 

DO #4 - "CO Analyzer Calibration Failure" alarm light 

DO #5 - "NOx Analyzer Calibration Failure" alarm light 

DO #6 - Spare 

DO #7 - Spare 

DO #8 - "0, Analyzer Out-of-Control" alarm light 

DO #9 - "NO, Analyzer Out-of-Control" alarm light 

DO#10 - Spare 

DO #11 - Spare 
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Page No.: 3 1 of 66 

Revision No. 0 

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DO#12 - Spare 

DO #13 - "NOx Analyzer Out-of-Range" alarm light 

. DO#14 - Spare 

DO #15 - "PLC Trouble" alarm light 

DO #16 - Spare 

9.1.7 InfoConcentrator PLC 

The InfoConcentrator is an Raymond PLC 5/40 which utilizes ICOM PLC5 

Ladder Logistics software to run the InfoConcentrator PLC program. The 

InfoConcentrator serves as a "mail box" for all the CEMS PLC within the data 

highway network. The InfoConcentrator is responsible for reading and storing all 

CEMS system status, calibration data, 1-minute rolling and 15-minute block 

averages from each of the CEMS PLC's. It will also pick appropriate data from 

each CEMS and move them into a contiguous file allowing specific data to the 

accessed by the PLC Gateway, which interfaces between the PLC network and the 

DCNX RTU network. 

9.1.8 DCNX System 

The DCrVX system accesses the InfoConcentrator for each of the CEMS PLC 

data file through the PLC Gateway. The PLC data file contains information such 

as system status, calibration data; 1-minute rolling averages and 15-minute 

averages. 

The DCNX performs the following functions: 

a. Reads the system status from each CEMS, and determines if the last 15- 

minute data is valid. This will include monitoring the communications to 

each CEMS PLC to ensure that the data is being updated. 

b. Calculates the corrected fuel gas flowrate to the heater based on the 

differential pressure, pressure, temperature and specific gravity. 

c. Calculates the stack flowrate from the corrected fuel gas flowrate, the gas 

Btu and Fd factor. 

d. Calculates the SO, emissions from the fuel gas sulfur content and the fuel 

gas flow rate. 

e. Calculates the following for every 15-minute period: 

1) average stack volumetric flowrate on a dry basis 

2) average fuel gas flowrate in scfh 
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SectionNo. 9 

Date: 01-Dec-98 

Page No.: 32 of 67 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

3) average NO, emissions rate from the calculated stack flow and NOx 

analyzer readings 

4) average calculated SO, emissions rate from the total sulfur analyzer 

reading and fuel gas flow rate 

f. Calculates the following for each hour based on the valid 15-minute data . readings and calculations: 

1) hourly average NO, ppm dry readings 

2) hourly average O2 percentage 

3) hourly average stack flowrate 

4) hourly average fuel gas flowrate 

5) hourly average SO, emissions based on total sulfur and fuel gas flow 

rate 

6) hourly average NO, emissions 

g. Calculates the following each day: 

1) total mass emissions of SO, from the sum of all valid hourly readings 

plus the sum of all substituted hourly readings. 

2) total mass emissions of NOx from the sum of all valid hourly readings 

plus the sum of all substituted hourly readings. 

3) substitutes data based on Rule 201 1 for SO, and Rule 2012 for NO,. 

h. Each hour determines if the data for the hour is valid. This will normally 

require four 15-minute average data point, although an hour may be 

considered valid, per Rules 201 1 and 2012, during periods of 

calibrationlmaintenance 

i. Calculates, on a daily basis, the rolling percentage of the operating hours of 

the equipment that each NO,, SO, and stack flowrate measurement was 

available for the previous 365 days. 

j. Records, on a daily basis, the percent annual NO, monitor availability, SO, 

and stack flowmeter availability fiom the valid hours as a percentage of stack 

operating hours over the previous 365 days. 

k. For each hour, when valid data is not available, substitutes data based on the 

historical percentage availability and the appropriate historicallfuture data as 

detailed in the applicable rule. 

1. Records the actual Fd factor for the Facility fuel gas used in the calculations. 
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Section No. 9 

Date: 0 1 -Dec-98 

Page No.: 33 of 67 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

m. Transmit total NOx and SOx emissions and CEMS status codes to SCAQMD 

daily per Rules 201 1 and 201 2. 

Calculations Performed in the PLC Control System (CEMS PLC) 

Two specific calculations are performed within the CEMS PLC system. These 

calculations are performed once at the end of each automatic calibration. The resul-REare stored m the CEMS PLC storage data file and read by the Infoconcentrator for 

DCNX system access. The calculations are listed below. 

9.2.1 Zero and Span Calibration Error Calculation 

The following formula is used to determine the zero calibration error and span 

calibration error for each analyzer. 

Where:CE = Percentage calibration error 

R = Expected value of zero or span calibration gas introduced 

into the monitoring system 

A = Actual zero or span calibration gas reading during 

calibration 

S = Span range of the analyzer 

9.2.2 Automatic Correction Calculation 

The automatic correction calculation is only applied whenever the calibration 

error exceeds the calibration limit outlined in paragraph 7.2 of this QAIQC 

document. The following formulas are used to determine the corrected analyzer 

input, and the corrected 1 -minute and 15-minute average values for each analyzer. 

Zero Drift Factor = Zdf = Az - Rz 

Correction Factor = Cf = Rs 

(AS - Zdf) 

Corrected Value = [Uncorrected value - Zdfl x Cf 

Where:Az = Actual zero reading during calibration 

Rz = Expected value of zero calibration gas 
INDUSTRY INTERNATIONAL INC. 

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Section No. 9 

Date: 0 1 -Dec-98 

Page No.: 34 of 67 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

As = Actual span reading during calibration 

Rs = Calibration gas span 

9.3 Calculations Performed in the DCNX 

9.3.1 Determination of Emission Rate 

9.3.1.1 Calculates the mass emissions of SO, using fuel gas flow rate and 

sulfur content 

Assumption: 15-minute calculation will be summed for hourly reading. 

Equation: e = s x q x 1.662 x 1 o-~ 

Where:e = emissions of sulfur oxide in lbh 

s = sulfur content of fuel gas in ppmv 

q = fuel gas flow rate in dscfh 

9.3.1.2 Calculates the mass emissions of NO, using heat input rate and 

oxygen concentration 

Assumptions: 

a. 15-minute calculation will be summed for hourly reading. 

b. No enriched oxygen is used 

c. No non-fuel sources of C02 are present 

d. Oxygen content of the stack gas is less than 19 percent. 

e. One type of fuel is used 

f. Fd is a constant 

Equation: e = a x [20.9/(20.9 - b)] x 1.195 x 10-7 x [Fd x q x V] 

Where:e = emissions of nitrogen oxides in lbh 

a = stack gas concentration of nitrogen oxides on a dry 

basis in ppmv 

b = stack gas concentrations of oxygen on a dry basis in 

percent 

q = fuel flow rate, see calculation (e) below 

V = higher heating value of the fuel 

Fd = dry F factor for type of fuel, the ratio of the dry gas 

volume of the product of combustion to the heat content 

of the fuel in dscf per MMBTU 
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i " Quality Assurance/Quality Control Plan 

Section No. 9 

Date: 0 1 -Dec-98 

Page No.: 35 of 66 

Revision No. 0 

Revision Date: 01-Dec-98 

9.3.2 Determination of Fuel Gas Flow Rate 

9.3.2.1 The equation for calculation of the uncorrected volumetric flow rate at the 

orifice sizing conditions is as follows: 

Q,, (uncorrected) = K, 

where, 

Q,,. (uncorrected) = Volumetric flow rate in standard cubic feet per 

hour at the orifice sizing base conditions. 

- KF - A constant representing a flow meter factor derived at the 

orifice sizing base conditions. 

- hw - The differential pressure measured in inches of water 

column across the orifice plate. 

9.3.2.2 The equation for calculation of the volumetric flow rate, corrected to 

flowing conditions, is as follows: 

h 

a, (corrected) = [dpm] P, + 14.7 T, + 460 * esClh (uncorrected) 

where, 

QscF (corrected) = Volumetric flow rate in standard cubic feet per 

hour corrected to flowing conditions. 

QscF (uncorrected) = Volumetric flow rate in standard cubic feet per 

hour at the orifice sizing base conditions. 

pf = Pressure in pounds per square inch gauge at flowing 

conditions. 

Pb + 14.7 = Pa = Pressure in pounds per square inch absolute 

used for orifice sizing calculations. 

pb - - Pressure in pounds per square inch gauge used for orifice 

sizing calculations. 

Tf - - Temperature in degrees Fahrenheit at flowing conditions. 
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Section No. 9 

Date: 0 1-Dec-98 

Page No.: 36 of 66 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

Tb - - Temperature in degrees Fahrenheit used for orifice sizing 

calculation. 

Gf - - Specific gravity measured at flowing conditions. 

Gb - - Specific gravity used for orifice sizing calculation. 

9.4 Missing Data Procedures 

For each equipment, whenever a valid hour of NOx and/or SO, pollution concentration 

data has not been obtained or recorded, the DCNX system shall substitute data using the 

following procedure. 

1. Calculate, on a daily basis, the percent data availability from the NOx and/or SOx 

pollutant concentration monitoring analyzers or the fuel gas sulfur content 

monitoring analyzer according to the procedure below. 

a. Calculate, on a daily basis, a rolling percentage of the operating hours of 

each equipment that each concentration monitoring system was available 

for the previous 90 days. 

b. - Calculate and record, on a daily basis, the percent annual concentration 

monitor availability by taking the total operating hours for which the 

monitor provided quality-assured data during the previous 365 days and 

dividing this by the total operating hours of the equipment during the 

previous 365 days, then multiplying the result by 100. 

2. Whenever the data from the pollutant concentration monitor has been available 

and recorded for 95 percent or more of the total operating hours of the equipment 

during the previous 365 days, calculate the substitute data for each hour according 

to the following procedures. 

a. For a missing data period less than or equal to 24 hours, substitute data 

shall be calculated using the 1N Procedure in Attachment A of Rules 201 1 

and 2012. 

b. For a missing data period greater than 24 hours, substitute data shall be 

calculated using the maximum hourly concentration recorded by the 

concentration monitor for the previous 30 days. 

3. Whenever data from the coneentration monitor has been available for 90 days or 

more but less than 95 percent of the total operating hours or the equipment 
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Section No. 9 

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Revision No. 0 

Revision Date: 0 1-Dec-98 

during the previous 365 days, calculate the substitute data for each hour according 

to the following procedures. 

a. For a missing data period less than or equal to 3 hours, substitute data shall 

be calculated using the average of the recorded concentration for the hour 

immediately before the missing data period and the hour immediately after 

the missing data period. 

b For a missing data period more than 3 hours but less than or equal to 24 

hours, substitute data shall be calculated using the maximum hourly 

concentration recorded by the concentration monitor for the previous 30 

days to the missing data period. 

c. For a missing data period greater than 24 hours, substitute data shall be 

calculated using the maximum hourly concentration recorded by the 

concentration monitor for the 365 days previous to the missing data period. 

d. Whenever the data from the concentration monitor has been available for 

less than 90 percent of the total operating hours of the equipment during the 

previous 365 days, substitute data shall be calculated using the highest 

hourly concentration recorded during the service of the monitoring system. 
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Section No. 10 

Date: 0 1 -Dec-98 

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Revision No. 0 

Revision Date: 0 1 -Dec-98 

- 10.0 OUALITY ASSURANCE 

The purpose of quality assurance is to ensure that only the most accurate data is 

ultimately reported to the agency, and that the highest degree of equipment operation is 

maintained. 

10.1 Data Validation Criteria 

Data must be considered invalid if any of the following occur: 

a. Any part of the monitoring system fails, which affec-RE- the data being 

collected. 

b. If the calibration error for the O2 analyzer exceeds the "Out of Control" 

limit of 1% O2 at either the zero or span calibrations. 

c. If the calibration error for the NOx analyzer exceeds the "Out of Control" 

limit of 5% of NOx span range at either the zero or span calibration. 

d. If the calibration error for the SO, analyzer exceeds the "Out of Control" . 

limit of 5% of SO, span range at both the zero and span calibration. 

e. If the NOx raw input value for the NOx analyzer does not fall within the 0- 

95% of the NOx span, indicating an "Out of Range" condition. 

f. For the SO, or total sulfur analyzer, the same "Out of Range" limi-RE- in 

criteria (e) above apply., 

g. If the calibration error of a stack flow monitor exceeds 6% of the span 

range. 

h. If the monitored process is shut down and no emissions or pollution is 

being emitted. 

1. The out of control period begins with the hour of completion of the failed 

test and ends with the hour of completion of a satisfactory test. 

10.2 Data Reduction Criteria 

a. All averages must be calculated using valid data only. 
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Section No. 10 

Date: 01-Dec-98 

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Revision No. 0 

Revision Date: 0 1-Dec-98 

b. All valid 1-minute average readings within a 15-minute 

period will be averaged to produce a valid 15-minute average. 

c. An hourly average will be considered valid if it contains either all four 15- 

minute averages, or under certain conditions, at least two valid 15-minute 

averages. 
INDUSTRY INTERNATIONAL INC. 

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Continuous Emissions Monitoring System 

Quality Assurance/Quality Control Plan 

Section No. 11 

Date: 0 1 -Dec-98 

Page No.: 40 of 66 

Revision No. 0 

Revision Date: 01-Dec-98 

- 11.0 SCHEDULE OF ACTIVITIES 

11.1 Frequency of System Calibration 

The frequency at which the system calibration must be performed is as follows: 

11.1.1 Daily Calibrations 

Perform a calibration to test, record and compute the calibration error of each 

SO,, NOx and O2 analyzer at least once each day approximately 24-hours apart 

for determining the SO,, NOx and O2 analyzers zero and span drif-RE-. The 

calibration error calculations are based on the analyzer parameters summarized 

below. 

11.1.1.1 0, Analyzers 

A. The zero gas shall be N2 gas at zero percent concentration. 

B. The span gas shall be O,/CO gas mixture with .concentration based 

on the analyzer range. 

C. The O2 analyzer ranges are 0-10% and 0-25%. 

11.1.1.2 NOx Analyzers 

a. The zero gas shall be N2 gas at zero percent concentration. 

b. The NO, span gas concentration shall be based on the analyzer 

range. 

c. The NOx analyzer ranges are 0-25ppm, 0-SOppm, 0-100ppm and 0- 

250ppm. 

11.1.1.3 SO, Analyzer 

a. The zero gas shall be N2 gas at zero percent concentration. 

b. The SO, span gas concentration shall be based on the analyzer 

range. 

c. The SO, analyzer ranges are 0-SOppm, 0-250ppm and 0-5OOppm. 

11.1.1.4 Total Sulfur Analyzer 

a. The zero gas shall be N2 gas at zero percent concentration. 

b. The sulk span gas concentration shall be based on the analyzer 

range. 
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Section No. 1 1 

Date: 0 1 -Dec-98 

Page No.: 4 1 of 67 

~evision'~~. 0 

Revision Date: 01 -Dec-98 

c. The total sulk analyzer range is 0-200ppm. 

11.2 Frequency of Preventive Maintenance 

Preventive maintenance procedures, as outlined in Section 8.0 of this QAIQC, shall be 

implemented daily, bi-weekly and monthly. This will assure minimum downtime and 

accurate data recovery for the CEMS system. 

11.3 Schedule of System Audi-RE11.3.1 Relative Accuracy Test Audit 

Relative accuracy test audit and bias test shall be performed semi-annually and no 

less than 4-months apart for each CEMS system, in accordance with the Chapter 

2, Subdivision B Paragraphs 10, 1 1, and 12, and Attachment B of RECLAIM 

Protocol for Rules 20 1 1 and 2012. 

Relative accuracy tes-RE- may be performed on an annual basis rather than on a 

semi-annual basis if the relative accuracy during the previous audit for the 

monitoring system and the emission rate measurement system is 7.5 percent or 

less. 
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, r.. Continuous Emissions Monitoring System 

Quality AssuranceIQuality Control Plan 

Section No. 12 

Date: 01 -Dec-98 

Page No.: 42 of 67 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

- 12.0 SYSTEM AUDIT PROCEDURES 

System audi-RE- are necessary to 'provide an assessment of the accuracy of the data 

generated by the CEMS. The following audit procedures will be implemented. 

12.1 Relative Accuracy Test Audit 

Test the relative accuracy test data set and the relative accuracy test audit data se-RE- for 

NOx pollutant concentration monitors, NOx emission rate measurement system, SO, 

pollutant concentration monitors, fuel gas sulh content monitor, SO, emission rate 

measurement system and stack gas volumetric flow measurement system, using the 

procedures outlined below. 

12.1.1 Relative Accuracy Test Requirement for Emission Measurement 

The emission measurement shall meet a relative accuracy requirement of being 

less than. or equal to 20 percent of the mean value of the reference method test 

data in unit of lblhr. Relative accuracy is calculated by the equations in Section 8 

of 40 CFR, Part 60, Appendix B, Performance Specification 2. The emissions 

rate measurement shall also meet the specifications in RECLAIM Protocol 

SCAQMD rules 201 1 and 2012, Appendix A, Attachment B (Bias Test). 

12.1.2 Relative Accuracy Test Requirement for Stack Gas Volumetric Flow 

Measurement System 

The stack gas volumetric flow measurement system shall meet a relative accuracy 

requirement of being less than or equal to 10 percent of the mean value of the 

reference method test data in unit of DSCFH. Relative accuracy is calculated by 

the equations in Section 8 of 40 CFR 60, Appendix B, Performance Specification 

2. The stack gas volumetric flow measurement system shall also meet the 

specifications in RECLAIM Protocol SCAQMD rules 201 1 and 2012, Appendix 

A, Attachment B (Bias Test). 

12.1.3 Bias Test 

The Bias Test compares the CEM test data se-RE- and the Source Tester's test 

audit data se-RE-. These are checked for NOx and SO, pollutant concentration 

monitors; fuel gas sulfur content monitors; stack flow monitors and emissions rate 
INDUSTRY INTERNATIONAL INC. 

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*._ Continuous Emissions Monitoring System 

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Section No. 12 

Date: 0 1 -Dec-98 

Page No.: 43 of 67 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

measurement systems using the procedures outlined in RECLAIM Protocol 

SCAQMD rules 201 1 and 2012, Appendix A, Attachment B (Bias Test). 

12.2 Cylinder Gas Audit 

All calibration gases used during certification test- and quality assurance and quality 

control activities shall be certified according to 40 CFR 60, Appendix F, Section 5.1 -2. 

Prior to connecting the cylinder gases to the CEMS system, record the cylinder gas 

manufacturer, serial number, expiration date and gas concentration. This information and 

certification document for the cylinder gas shall be kept. 

Expiration dates on the cylinder gas must be checked. Expired cylinder gases must not be 

used for certification test or any quality assurance and quality control activities. 

12.3 Record Keeping 

Copies of written report received from testing firms and laboratories of procedures and 

details specific to the installed CEMS that were to be used by the testing firms and 

laboratories for relative accuracy test audit, such as sampling and analysis methods, shall 

be kept. 
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Section No. App. A 

Date: 0 1 -Dec-98 

Page No.: 44 of 66 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

APPENDIX A 

SYSTEM CONFIGURATION 
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Section No. App. A 

Date: 0 1 -Dec-98 

Page No.: 45 of 66 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

TABLE A 

CEMS UNIT SPECIFICATIONS 

INDUSTRY INTERNATIONAL INC. 

LOS ANGELES FACILITY 

Source ID 

ST1 

1 1 -LG- 1000 

20-LG-200 

30-LG-341 

Parameter 

02 

CO 

NOx 

so2 

0, 

CO 

NOx 

so2 

O2 

CO 

NO, 

SOz 

O2 

CO 

NO, 

SO, 

0, 

CO 

NOx 

so2 

0, (wet) 

NOx 

02 (dry) 

SO, (LOW) 

SO2 (HIGHJ 

Stack Flow 

0, 

CO 

NOx 

so2 

02 

CO 

NO, 

so2 

- 

3 1 -LG-3000 

41-MG-02 

56-LG-1,2 

58-LG- 1 

Manufacturer 

Raymond 

Raymond 

Raymond 

Calculated 

Raymond 

Raymond 

Raymond 

Calculated 

Raymond 

Raymond 

Raymond 

Calculated 

Raymond 

4R 

Raymond 

Calculated 

Raymond 

Raymond 

Raymond 

Calculated 

4R 

Raymond 

Raymond 

Raymond 

RachFlo 

Raymond 

Raymond 

Raymond 

Calculated 

Raymond 

Raymond 

Raymond 

Calculated 

Model 

Number 

70R 

88OA 

121B 

70R 

88OA 

121B 

70R 

880A 

121B 

70R 

3300A 

121B 

70R 

88OA 

121B 

WDG IV 

121B 

70R 

890 

890 

Mass II 

70R 

880A 

951 A 

70R 

88OA 

951 A 

Method 

Paramagnetic 

NDIR 

Chemiluminescence 

Paramagnetic 

NDIR 

Chemiluminescence 

Paramagnetic 

NDIR 

Chemiluminescence 

Paramagnetic 

NDlR 

Chemiluminescence 

Paramagnetic 

NDIR 

Chemiluminescence 

Zirconium oxide 

Chemiluminescence 

Paramagnetic 

UV Fluorescence 

UV Fluorescence 

Differentialpressure 

Paramagnetic 

NDlR 

Chemiluminescence 

Paramagnetic 

NDIR 

Chemiluminescence 

Span Range 

0 - 10% 

0 - 2000 pprn 

0 - 250 ppm 

0 - 10% 

0 - 400 ppm 

0 - 50 ppm 

0 - 10% 

0 - 400 ppm 

0 - 50 ppm 

' 0-10% 

0 - 500 ppm 

0 - 100 ppm 

0 - 10% 

0 - 400 ppm 

0 - 50 ppm 

0 - 25% 

0 - 100 ppm 

0 - 25% 

0 - 500 ppm 

0-2000 ppm 

0 - 2,223,000 scfh 

0- 10% 

0 - 400 ppm 

0 - 25 ppm 

0- 10% 

0 - 400 ppm 

0 - 25 ppm 

Conc. Range 

0.4- 7.9 % 

37 - 1969 pprn 

0 - 400 ppm 

0 - <50 ppm 

3-5% 

0 - 350ppm 

0 - a5 ppm 

0 - <50 ppm 

3-5% 

0 - 350ppm 

0-a5ppm 

0 - <50 ppm 

0 - 3.15% 

0 - 40 ppm 

O - 40 ppm 

0 - <50 ppm 

3-5% 

0 - K350 ppm 

0 - a5 ppm 

0 - <50 ppm 

10 - 20% 

0 - <50 ppm 

10 - 20% 

0 - <70 ppm 

0 - 1,265,000 scfh 

3-5% 

0 - 35Oppm 

0 - a5 ppm 

0 - <50 PPM 

3-5% 

0 - 350ppm 

0 - <25 ppm 

0 - <50 PPM 
INDUSTRY INTERNATIONAL INC. 

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Section No. App. A 

Date: 0 1 -Dec-98 

Page No.: 46 of 66 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

TABLE A (cont.) 

CEMS UNIT SPECIFICATIONS 

INDUSTRY INTERNATIONALINC., INC. 

LOS ANGELES FACILITY 

Model I1 Number 

Source ID Method Span Range Conc. Range 

02 (wet) 

I CO 

NO, 

so2 

02 (dry) ' Stack Flow 

Parameter 

4R 

Raymond 

Raymond 

Raymond 

Raymond 

RachFlo 

Manufacturer 

WDG IV 

880A 

951 A 

890 

70R 

Flowmeter 

Zirconium oxide 

NDIR 

Cherniluminescence 

W Fluorescence 

Paramagnetic 

Differential Pressure 

Zirconium oxide 

Cherniluminescence 

NDIR 

0 - 10% 

0 - 200 pprn 

0 -100 pprn 

0 -25Oppm 

0- 10% 

0 - 10 mmscfh 

0 - 10% 

0 - 50 pprn 

0 - 500 pprn 

.9 - 7.4 % 

56.7 - 119.4 pprn 

1.4 - 10 pprn 

36.2 - 121.0ppm 

7-9% 

0 - 200,000 scfh 

0 - 5.5% 

0 - 40.6 pprn 

0 - 350 pprn 

0 - 14.2 pprn 

0.8 - lj:5% 

0 - 930 pprn 

40 to 105 pprn 

0 - <SO pprn 

4R 

Raymond 

4R 

Calculated 

JI I I 

704~3-1 7 n 1 Raymond 

(* 

Paramagnetic 

NDIR 

Chemiluminescence 

0 - 10% 

0 - 1000 pprn 

0 - 250 pprn 

Raymond 

Raymond 

Raymond 

Calculated 

' ',-,- 

3.2 - 22.8% 

3 - 56 pprn 

1 - 79 pprn 

0 - <SO pprn 

-2 

CO . 

NO, 

so2 

Paramagnetic 

NDIR 

Cherniluminescence 

- - - 

Raymond 

Raymond 

Raymond 

Calculated 

Raymond 

Raymond 

Calculated 

0 - 25% 

0 - 1000 ppm 

0 - 100 pprn 

1.6 - 20% 

7 - 49 pprn 

0 - <I50 pprn 

0 -<50ppm 

Paramagnetic 

NDIR 

Chemiluminescence 

Paramagnetic 0- 10% 

0- 10% 

0 - 1000ppm 

0 - 250 pprn 

- - - 

Raymond 

Raymond 

Raymond 

Calculated 

Sulfur Alert 

RachFlo 

5000 

0 -2OOppm 

900 - 1400 

btu/scf 

0.6 - 1.0 spec. 

88 SS. Total Sulfur 

Heat Value/ 

Spec. Gravity 

4R 

RachFlo 
INDUSTRY INTERNATIONAL INC. Section No. App. B 

LOS ANGELES, CA Date: 01-Dec-98 

Continuous Emissions Monitoring System Page No.: 47 of 66 

( F-. Quality AssuranceIQuality Control Plan Revision No. 0 

Revision Date: 01-Dec-98 

APPENDIX B 

DAILY AND WEEKLY 

OPERATIONAL CHECK FORM 
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Section No. App. B 

Date: 0 1 -Dec-99 

Page No.: 49 of 67 

Revision No. 0 

Revision Date: 0 1-Dec-99 

INDUSTRY INTERNATIONALINC. 

Daily CEMS System Verification Form FORM 0 

Verify and complete the corresponding column for each day on all of items listed below. 

Date 

Verified By 

B 

1. 

2. 

3. 

4. 

5. 

Step Procedure at Recorders 

Examine strip chart recorder operation - 

printing legibly and operating normally. 

Check if ink and paper are sufficient to 

operate for the next 24 hours. 

Review the last automatic calibration data. 

Log actual readings of zero and span, and 

calculate the zero and span calibration error 

(drift). 

Compare the calculated calibration error 

(drift) to the "Out of Range" and "Out of 

Control" limit. If the calibration error 

exceeds the limit, report to the supervisor; 

take corrective action and log problem; 

corrective action taken, and period of invalid 

data. 

M T W Th F S Su 
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Section No. App. B 

Date: 0 1 -Dee99 

Page No.: 49 of 66 

Revision No. 0 

Revision Date: 0 1 -Dec-99 

INDUSTRY INTERNATIONALINC. 

Daily CEMS System Verification Form FORM Q 

Verify and complete the corresponding column for each day on all of items listed below. 

Date 

Verified By 

B 

1. 

2. 

3. 

4. 

5. 

Step Procedure at Recorders 

Examine strip chart recorder operation - 

printing legibly and operating normally. 

Check if ink and paper are sufficient to 

operate for the next 24 hours. 

Review the last automatic calibration data. 

Log actual readings of zero and span, and 

calculate the zero and span calibration error 

(drift). 

Compare the calculated calibration error 

(drift) tc the "Out of Range" and "Out of 

Control" limi-RE-. If the calibration error 

exceeds the limit, report to the supervisor; 

take corrective action and log problem; 

corrective action taken, and period of invalid 

daca. 

M T W 

I 

Th F S Su 
INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions Monitoring System h Quality AssuranceIQuality Control Plan 

Section No. App. C 

Date: 0 1 -Dec-98 

Page No.: 50 of 66 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

APPENDIX C 

ROUTINE MAINTENANCE OPERATIONS 
INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

,+,- Continuous Emissions Monitoring System 

Quality AssuranceIQuality Control Plan 

Section No. App. C 

Date: 0 1 -Dec-98 

Page No.: 5 1 of 67 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

Trends are taken each morning and the CEMS calibration display for all CEMS is printed. 

Those CEMS that failed deviation specification are looked at first by the Analyzer Technicians 

assigned to that specific CEMS system. 

Those CEMS that passed the morning calibration are inspected visually and any problem that is 

noticeable is, corrected. 

Scheduled monthly and quarterly preventative maintenance (PM) is done according to scheduled 

planning. 

Mandatory PM's are done on a regular basis using INDUSTRY INTERNATIONAL INC.'s 

Preventative Maintenance work orders. Calibration per manufacturers specifications is a 

requirement on all mandatory PM's. 

All trends are to be taken within half hour of start of shift. 

,d-- All analyzers that are manually calibrated will have an automatic calibration done to update the 

report This will be followed by the latest calibration report. 

Report required: 

1. Calibration Report 1 

2. Calibration Report 2 

3. Calibration Report 3 
INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions Monitoring System 

Quality Assurance/Quality Control Plan 

Section No. App. C 

Date: 0 1 -Dec-98 

Page No.: 52 of 66 

Revision No. 0 

Revision Date: 0 1-Dec-98 

P.M. REPORT Date: 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

1 I 

12 

13 

14 

15 

16 

1 0-LG- 1 00 

1 1 -LG- 1000 

20-LG-200 

3 0-LG-3 0 1 

3 1 -LG-3 000 

4 1 -MG-0 1 

56-LG-1,2 

58-LG-1 

61-ST-1 

58-LG-1 

70-LG- 1,2,3 

80-LG- 1 

80-LG-2 

86-RY-900 1 

Calorimeter 

88-WW-001 

CEM 

CEM 

CEM 

CEM 

CEM 

CEM 

CEM 

CEM 

CEM 

CEM 

CEM 

CEM 

CEM 

CEM 

BTU Analyzer 

Total Sulfur 
INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions Monitoring System 

Quality Assurance/Quality Control Plan 

Section No. App. D 

Date: 0 1 -Dec-98 

Page No.: 53 of 67 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

APPENDIX D 

RECOMMENDED 

SPARE PARTS INVENTORY 
-a 

INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions Monitoring System 

Quality Assurance/Quality Control Plan 

Section No. App. D 

Date: 0 1 -Dec-98 

Page No.: 54 of 67 

Revision No. 0 

Revision Date: 0 1-Dec-98 

RECOMMENDED SPARE PARTS LIST 

RAYMOND MODEL 755 PARAMAGNETIC 

OXYGEN 0, (DRY) ANALYZER - 

PART NO. DESCRIPTION QTY 

RE-861 652 Heater . 1 

RE-809374 Fuse, 3A, 120VAC, F4 1 

(Pkg. of 15) 

RE-861 649 Fuse, Thermal, F-2, F-3 2 

RAYMOND MODEL 121B CHEMILUMINESCENCE 

- NOINOX ANALYZER 

- 

PART NO. DESCRIPTION OTY 

RE-632782 Temperature Sensor . I 

Replacement Pens 

A128969 Replacement Pen Cartridge 

(For 4-6 Pen Model Only) 

A243 77 1 Blue Replacement Pens 

A243772 Red Replacement Pens 

A243773 Green Replacement Pens 

A243770 Annotation (For 1-3 Pen Model Only) 

Replacement Chart Paper 

Specify Roll or Z-Fold 

RE-632784 Silicone Rubber Connector 

RE-617124 Heater-Boot Assembly 
- - INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions Monitoring System 

Quality AssuranceIQuality Control Plan 

Section No. App. D 

Date: 01-Dec-98 

Page No.: 57 of 67 

Revision No. 0 

Revision Date: 01 -Dec-98 

RECOMMENDED SPARE PARTS LIST 

RACH SERIES 2000 

OXYGEN 0, - (WET) ANALYZER 

PART NO. DESCRIPTION 

Sensor: 

P/N 70409SE Furnace Assembly 

P/N 7 1 697KE Type "K Thermocouple 

P/N 80418SE Sensor Board 

P/N 71063SE Zirconium Oxide Cell 

P/N 71 807KE Thermostat (Lift-off Enclosure) 

P/N 72589KE Thermostat (Hinged Enclosure) 

Remote Calibration Unit (RCU): 

P/N 39003 JE Air Regulator 

P/N 37013JE Regulator Gauge 

P/N 3 6022 JE Aspirator Air Solenoid Valve 

P/N 36023 JE Calibration Gas Solenoid Valve 

P/N 37030JE Flow Meter 

Control Unit: 

P/N 902 19VE Display Module 

P/N 90253VE Power SupplyKeypad Module 

P/N 80436SE Auto Calibration Card 

P/N 80439SE Backplane Assembly 

P/N 80457SE Wiring Card 

P/N 80440SE Processor Board 

P/N 42373JE Display 
-. INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions Monitoring'System 

Quality Assurance/Quality Control Plan 

Section No. App. D 

Date: 0 1 -Dec-98 

Page No.: 58 of 67 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

RECOMMENDED SPARE PARTS LIST 

RACHFLO SERIES 3000 

STACK FLOW ANALYZER 

PART NO. DESCRIPTION QTY 

Auto-Purge Panel, High Capacity (SST): 

205- 160-00 Fuse, 2-Amp SAG . 2 

205-9 15-00 Solenoid N.C. 2-Way . 1 

205-920-00 Solenoid N.O. 2-Way . 1 

865-300-00 Valve, with Mtg. Plates - 1 

865-275-00 Valve, 3-Way BallPhact . 1 

265- 120-00 Filter with Housing . 1 

265-130-00 Pressure Regulator, 0- 150 psi . 1 

205-005-00 Relay, PET 148 1 . I 

865-1 75-00 Valve, 2-Way Ball . 1 

Flow with Cal: 

205-1 60-00 Fuse, 1 -Amp . 2 
INDUSTRY INTERNATIONAL INC. Section No. App. D 

LOS ANGELES, CA Date: 01-Dec-98 

Continuous Emissions Monitoring System Page No.: 59 of 67 

Quality Assurance/Quality Control Plan Revision No. 0 

Revision Date: 0 1 -Dec-98 

RECOMMENDED SPARE PARTS LIST 

4R SCIENTIFIC'S SULFURDETECT MODEL 6200 

TOTAL SULFUR ANALYZER 

PART NO. DESCRIPTION QTY 

1109-01 Spring , Pressure Block 2 

1 136-02 Belt, Take-up Drive 1 

140 1-03 Flowmeter, Sample . 1 

140 1-04 Flowmeter, Hydrogen . 1 

P 1501-01 Reaction Tube, Ceramic 10 

2127-01 Filter Humidifier . 1 

2128-01 Flowmeter . 1 

2 1 75-02 Diode, Rectifier 1 

2601-01 Motor, Tape Drive . 1 

2603-01 Thermocouple, Type S 1 

8301-01 Pressure Block 1 

8302-01 Detector 1 
~. - INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions ~onitoring's~stern 

Quality Assurance/Quality Control Plan 

Section No. App. D 

Date: 0 1 -Dee98 

Page No.: 60 of 67 

Revision No. 0 

Revision Date: 01-Dec-98 

RECOMMENDED SPARE PARTS LIST 

RACH CAL 50 SERIES 

CALORIMETER 

PART NO. DESCRIPTION QTY 

Prec. Gas Req. and Solenoid Valve: 

03-101 1-OA00 Coil 1 10V, 50160 Hz . 1 

5 1 - 1002-OA00 Cover 1 

52- 1000-OA00 Diaphragm . 2 

61-1001-OA00 Diaphragm Disc *b* 

2 

Control Unit: 

61 -1 065-OA00 Disc, ISOP 1 100 2 

63- 1025-OAOO Ring, ISOP 1 100 . 1 

49- 100 1 -0A00 Spring 2 

63- 1001 -0A00 0-Ring 1 

49- 1002-OA00 Spring 1 

64- 1003-OA00 Thermal/Expansion Tube . 1 

.- 
a- INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions ~onitoring'systern 

Quality AssuranceIQuality Control Plan 

Section No. App. D 

Date: 0 1 -Dec-98 

Page No.: 6 1 of 67 

Revision No. 0 

Revision Date: 01-Dec-98 

59- 1003-OA00 Rubber Gasket. 1 

18- 1082-OA00 Temperature Indicator. 1 

42- 1002-OA00 Air Orifice 1.2mm . 1 

RECOMMENDED SPARE PARTS LIST 

RACH CAL 50 SERIES 

CALORIMETER (Continued) 

PART NO. DESCRIPTION OTY 

Air Control Valve: - 52- 100 1 -0A00 Diaphragm . 1 

61-1016-OA00 Diaphragm Disc 1 

52-1 002-OA00 Diaphragm . 1 

49- 1004-OA00 Spring 1 

61-1017-OA00 Spring Disc . 2 

61-1018-OA00 Diaphragm Disc 2 

Base Plate Assembly: 

03-1 004-OA00 Spark Ignitor, 120VAC 1 

25-1 103-OAOO Pressure Switch 3" W.C. SPDT 2 
INDUSTRY INTERNATIONAL INC. 

i *- LOS ANGELES, CA 

Continuous Emissions Monitoring System 

Quality Assurance/Quality Control Plan 

Section No. App. D 

Date: 0 1-Dec-98 

Page No.: 62 of 66 

Revision No. 0 

Revision Date: 0 1-Dec-98 

25-1012-0A00 Pressure Switch 411.6" W.C. SPDT . 1 

89-1098-1AO Electrode 1 
INDUSTRY INTERNATIONAL INC. * - f LOS ANGELES, CA 

Continuous Emissions Monitoring System 

Quality Assurance/Quality Control Plan 

Section No. App. D 

Date: 0 1 -Dec-98 

Page No.: 63 of 66 

Revision No. 0 

Revision Date: 0 1 -De c-98 

RECOMMENDED SPARE PAR-RE- LIST 

RYAN MODEL HR2400 

STRIP CHART RECORDER (30- PO^ 

PART NO. DESCRIPTION QTY 

P/N B9627AY Chart Paper, 25mm per division on the time axis . 3 

P/N B9627AZ Color Ribbon Cassette 10 
-~ INDUSTRY LNTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions Monitoring'System 

Quality Assurance/Quality Control Plan 

Section No. App. D 

Date: 0 1 -Dec-98 

Page No.: 64 of 67 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

RECOMMENDED SPARE PARTS LIST 

RAYMOND PROGRAMMABLE CONTROLLER PLC 5/20 

DATA ACQUISITION SYSTEM 

PART NO. DESCRIPTION QTY 

PLC 5/20 Programmable Controller . 1 

(Processor Module) 

45-A2B Universal 110 Chassis . 1 

45-IFE Analog Input Module . 1 

- 

45-OFE Analog Output Module 1 

45-IBD Series B DC (1 0-30V) Input Module 1 

45-OW16 Series B Electromagnetic Relay Contact Output Module 1 

2705-ND002 Series A Redipanel Keypad Module . 1 

(Operator Interface) 

Power Supply . . . 1 

Lithium Battery 1 

Cable between Power Supply and Processor . 1 
INDUSTRY INTERNATIONAL INC. - LOS ANGELES, CA 

Continuous Emissions Monitoring'System 

Quality Assurance/Quality Control Plan 

Section No. App. E 

Date: 0 1 -Dec-98 

Page No.: 65 of 67 

Revision No. 0 

Revision Date: 0 1 -Dec-98 

APPENDIX E 

DIAGNOSTIC TESTS 
- INDUSTRY INTERNATIONAL INC. 

LOS ANGELES, CA 

Continuous Emissions Monitoring System 

Quality AssuranceIQuality Control Plan 

Section No. App. E 

Date: 01-Dec-98 

Page No.: 66 of 67 

Revision No. 0 

Revision Date: 0 1-Dec-98 

Sample System Bias Test 

The sample system bias test shall be performed on an "as needed" basis to trouble shoot 

problems with any NOx or SO, analyzers or sample system using the procedure outlined 

below. 

1. Perform "remote" (calibration gases are applied through sample system and probe 

assembly back to the analyzers) calibration on all analyzers by initiating zero and 

span calibrations manually. 

2. Record the actual zero and span calibration readings for each analyzer resulting 

from the above remote calibration. 

3. Perform a "local" (calibration gases are applied directly to analyzers bypassing 

the sample system) calibration on each analyzer by initiating the zero and span 

calibration manually. 

4. Record the actual calibration reading for each analyzer resulting from the above 

local calibration. 

5. Determine the bias for each analyzer, by calculating the differences between the 

zero and span concentration values (in ppm) obtained from calibration data 

recorded in step 2 and step 4 above. 

6. The analyzer passes the bias test if the bias is less than * 5% of the range for the 

zero, and high ranges calibration gasses. Ref. SCAQMD Method 100.1.