BS EN 14181:2004 - QAL2 CEMs Functional Test Report · TE's 1, 2 & 4 12th July 2013 1- ......

Process Operator & Address Main Contact at Site Type of Process

Installation Name

Permit Number

Permit Reference

Date(s) of Test(s) / Sampling:

Report Date Parameters MeasuredVersion

Report By:

MCERTS Number:

MCERTS Level:

Technical Endorsements:

Report Approved By:

MCERTS Number:

Business Title:

Technical Endorsements:

Signature: ESG Job Number

ESG Laboratory Performing this Work: Your Contact at ESG: For technical enquiries contact:

East Kilbride Laboratory David Hay Andy Tiffen

2-4 Langlands Place Senior Team Leader Tel: 0161 477 3004

Kelvin South Business Park Tel: 01355 247 514 Fax: 0161 480 4642

East Kilbride Fax: 01355 249 669 Email: [email protected]

G75 0YF Email: [email protected]

Tel: 01355 246 730

MM 07 885

Mcerts Level 2 - Team Leader

TE's 1, 2, 3 & 4

LEK09311

Volatile Organic Compounds (VOCs)

Peripheral Measurements

Note - CEMS Functional testing and

associated reporting do not form part of

ESG's Mcerts accreditation.

SWI

770

BS EN 14181:2004 - QAL2 CEMs Functional Test Report

Novartis

Ringaskiddy

County Cork

Noel Aherne

Ireland

Waste Incinerator

Andy Tiffen

MM 05 640

MCERTS Level 2 - Team Leader

TE's 1, 2 & 4

12th July 2013

1

-

CEMs Functional Checks: 5th June 2013

Total Particulate Matter

Oxides of Nitrogen

Carbon Monoxide

Sulphur Dioxide

Tel: +353 21 4862374

Email: [email protected]

Cormac Dunne Hydrogen Chloride

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Title Page

Contents

CEM System Documentation & Records

Section 1 - Alignment and Cleanliness

Section 2 - Sampling Systems

Section 3 - Leak Testing

Section 4 - Zero and Span Check

Section 5 - Linearity Checks

Section 6 - Interferences

Section 7 - Zero and Span Drift (Audit)

Section 8 - Response Times

Section 9 - Service Report

2

3

4

4

4

4

5-11

12

12

12

13

Contents

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Site operate a management system to cover Maintenance, Calibration and Training.

Site have a plan of the CEM system

Site have manuals for the following:

All CEMs instruments which are stored in ACFNT cabinets

Data handling systems which are stored in Site services offices

Software which are stored in Site services offices

Site have a maintenance schedule which is stored in Maximo system database

Site have a CEMs log book which is stored in Log book in CEMs room

Site have a list of essential spares

Spare parts are stocked at site

If the CEM malfunctions, site will switch to backup or call ABB engineer

Site has a permitted CEM downtime of 4 Hours

Site have a service contract witth the CEM supplier

Site keep copies of service reports

There is easy and safe access to the CEM system

Reference gases can be injected at both the analyser inlet and through the sample system

Site hold training records for site personnel that operate the CEM

The site operator has audited the CEMs provider

The site operator has not audited the monitoring organisation

Auditing records are available

The operator plans to audit soon

CEM System Documentation & Records

Quality System

Paperwork

Maintenance

Training Records

Auditing

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Cross Stack Analyser Only, (Site or Service Engineer)

Condition Notes

Internal Check of the analyser

Cleanliness of the optics

Flushing Air Supply

Obstructions in the optical path / stack

If analyser has been removed from the stack to demonstrate any of the above then check the following:

Contamination Control (internal check of optical surfaces) e.g. Could be % transmission.

Additional Notes

Visual Inspection of Sampling System (All CEMS Types).

Present Condition Notes

Sampling Probe(s)

Sampling Lines

Conditioning System

Sample Pump

Power Supply

Connections (All)

Filters

Nox converter

Additional Notes

Leak Check perfomed as per CEMs manual Result Notes

50

50

10

10

-

-0.1O2 20.9 % 20.94 86

Pollutant Span Gas units

HCl

100 mg/m3

1.1

15.89 0.2

0

mg/m3 15.97 016.1

20 mg/m3

mg/m3 779.3

SO2 100.4

0.4

Concentration

CO 100

800

mg/m3 99.7

NO

VOC

O2 (wet)

Section 3 - Leak Testing

Pass O2 reading at 0.1% for system zro

Section 4 - Zero & Span Check

Daily ELVSystem Check Response

Time T90

122

120

129

N/A

125

400

Yes

Yes

No

Yes

Yes

No N/A

Yes

Good

Clean

Checked by ABB

Operating at correct setpoint

N/A - Hot wet system

OK

Section 2 - Sampling Systems

Clean

CleanYes

Section 1 - Alignment and Cleanliness

Clean

Clean

Clean

None

Alignment of the measurement system OK

OK

Span Zero

within specified flow

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-0.49 PASS-0.078

9.29

9.27

9.28 148.44

148.28

148.60 86.25

85.88

86.0715.9

6.67

16.00

16.00

16.00

15.9

15.8

A Dc Dc rel Result

Gas conc

injected

Section 5 - Linearity

1.014

Yc (Cem

reading) a Xi-Xz Yi(Xi-Xz) (Xi-Xz)^2 B

ResidualsCalculation of Regression line (as per annex B of EN 14181:2004)

VOC

-0.001

12.00 11.8 5.21 62.49 27.12

12.00 11.8 5.19 62.25 26.91

0.36 PASS

8.00 7.8 1.24 9.90 1.53

12.00 11.8 5.21 62.49 27.12 0.058

8.00 7.8 1.23 9.82 1.51 0.085 0.53 PASS

8.00 7.8 1.23 9.82 1.51

4.00 4.0 -2.60 -10.41 6.77

4.00 4.0 -2.60 -10.41 6.77

-0.16 PASS

0.00 0.0 -6.55 0.00 42.94

4.00 4.0 -2.60 -10.41 6.77 -0.026

0.00 0.0 -6.55 0.00 42.94 -0.019 -0.12 PASS

0.00 0.0 -6.55 0.00 42.94

0.00 0.0 -6.55 0.00 42.94

0.00 0.0 -6.55 0.00 42.94

-0.12 PASS

Test Result PASS

0.00 0.0 -6.55 0.00 42.94 -0.019

y = 1.014x - 0.001R² = 0.999

0

2

4

6

8

10

12

14

16

18

0 2 4 6 8 10 12 14 16 18

Ca

l G

as

mg

/m3

CEM mg/m3

VOC linearity chart

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EPA Export 04-01-2017:02:05:27

60.00 61.1 16.88 1012.57 284.81

60.00 61.2 16.98 1018.57 288.19

80.00 80.6 36.38 2910.10

80.00 80.7 36.48 2918.10

1323.23 0.101 0.10 PASS

1330.51

80.00 80.9 36.68 2934.10

101.30 100.6 56.38 5710.91

1345.14

1.077 1.06 PASS3178.27

Yc (Cem

reading) a Xi-Xz Yi(Xi-Xz) (Xi-Xz)^2 B

101.30 100.9 56.68 5741.30

A Dc Dc rel Result

101.30 101.1 43.04 56.88 5761.56 3234.90

3212.19

1.009 -1.600

-0.113 -0.11 PASS

60.00 61.1 16.88 1012.57 284.81

CO

Calculation of Regression line (as per annex B of EN 14181:2004) Residuals

Gas conc

injected

40.00 43.0 -1.22 -48.95 1.50

40.00 42.9 -1.32 -52.95 1.75

-1.75 PASS

20.00 22.8 -21.42 -428.48 458.98

40.00 43.0 -1.22 -48.95 1.50 -1.774

20.00 22.9 -21.32 -426.48 454.70 -1.517 -1.50 PASS

20.00 23.0 -21.22 -424.48 450.45

0.00 0.4 -43.82 0.00 1920.53

0.00 0.6 -43.62 0.00 1903.04

1.11 PASS

0.00 0.6 -43.62 0.00 1903.04

0.00 0.4 -43.82 0.00 1920.53 1.129

Test Result PASS

0.00 0.4 -43.82 0.00 1920.53 1.095 1.08 PASS

0.00 0.5 -43.72 0.00 1911.77

y = 1.009x - 1.600R² = 0.999

0

20

40

60

80

100

120

0 20 40 60 80 100 120

Ca

l G

as

mg

/m3

CEM mg/m3

CO linearity chart

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Test Result PASS

17621.93

0.00 1.2 -331.25 0.00

160.00 156.3 -176.15 -28184.38

109728.14

31029.66

-0.983

1.583

1.036 -1.480193994.11

194523.00

193817.97 0.10 PASS

320.00 310.8 -21.65 -6928.76

480.00 465.2 132.75 63718.86

468.83

640.00 622.0 289.55 185310.48

800.00 772.9 342.86 440.45 352358.10

441.05

440.25 352198.10

352838.10

83837.82

773.5

772.7

(Xi-Xz)^2 B A Dc Dc rel Result

NO


Gas conc

injected

Yc (Cem

reading) a Xi-Xz Yi(Xi-Xz)

288.25

287.95

130.45

129.45

-21.45

-20.25

-177.65

-176.55 -28248.38

-28424.38

-6480.76

-6864.76

62134.86

62614.86

184286.48

184478.48

-1.754

83086.69

82913.83

17016.58

16756.69

460.20

410.16

31560.37

31170.74

0.812

PASS

PASS

PASS

PASS

800.00

800.00

640.00

640.00

480.00

480.00

320.00

320.00

160.00

160.00

-0.22

0.20

-0.12

0.030.248

620.7

620.4

462.9

461.9

311.0

312.2

154.8

155.9

2.6

0.8

1.8

1.3

-329.85

-331.65

-330.65

-331.15

0.00

0.00

0.00

0.00

0.03 PASS

0.00

0.00

0.00

0.00

0.00 0.6 -331.85 0.00 110126.00 0.202

109661.90

109331.00

109993.30

108802.59

-0.108 -0.01 PASS

y = 1.035x - 1.479R² = 1

0

100

200

300

400

500

600

700

800

900

0 100 200 300 400 500 600 700 800 900

Ca

l G

as

mg

/m3

CEM mg/m3

NO linearity chart

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550

60.00 58.3 16.37 982.00 267.87

60.00 58.2 16.27

80.00 79.5 37.57 3005.33

80.00 79.3 37.37 2989.33

1411.25 -0.553 -0.55 PASS

1396.27

80.00 79.2 37.27 2981.33

100.00 98.9 56.97 5696.67

1388.80

-0.408 -0.41 PASS3245.20

100.00 99.0 57.07 5706.67

100.00 99.2 42.86 57.27 5726.67

3256.60

1.008 0.5933279.47

B A Dc Dc rel Result

SO2


Gas conc

injected

Yc (Cem


60.00 58.4 16.47 988.00 271.15

(Xi-Xz)^2

976.00 264.60 0.647 0.65 PASS

40.00 38.4 -3.53 -141.33 12.48

40.00 38.5 -3.43 -137.33 11.79

0.67 PASS

20.00 18.0 -23.93 -478.67 572.80

40.00 38.4 -3.53 -141.33 12.48 0.671

20.00 18.2 -23.73 -474.67 563.27 1.164 1.16 PASS

20.00 18.1 -23.83 -476.67 568.03

0.00 0.2 -41.73 0.00 1741.67

0.00 0.2 -41.73 0.00 1741.67

-0.79 PASS

0.00 0.1 -41.83 0.00 1750.03

0.00 0.2 -41.73 0.00 1741.67 -0.794

Test Result PASS

0.00 0.2 -41.73 0.00 1741.67 -0.727 -0.73 PASS

0.00 0.1 -41.83 0.00 1750.03

y = 1.007x + 0.592R² = 0.999

0

20

40

60

80

100

120

0 20 40 60 80 100 120

Ca

l G

as m

g/m

3

CEM mg/m3

SO2 linearity chart

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EPA Export 04-01-2017:02:05:27

12.00 9.7 2.65 31.83 7.04

12.00 9.6 2.56

16.00 13.5 6.47 103.56

16.00 13.4 6.39 102.28

41.89 -0.218 -1.09 PASS

40.86

16.00 13.3 6.23 99.72

20.00 16.7 9.64 192.85

38.84

-0.238 -1.19 PASS92.98

20.00 16.7 9.67 193.45

20.00 16.8 8.57 9.82 196.45

93.55

1.201 0.14296.48


HCl


Gas conc

injected

Yc (Cem


12.00 9.6 2.54 30.51 6.46

(Xi-Xz)^2

30.75 6.57 0.322 1.61 PASS

8.00 6.1 -0.90 -7.18 0.81

8.00 6.2 -0.80 -6.38 0.64

2.47 PASS

4.00 2.9 -4.08 -16.31 16.63

8.00 6.1 -0.97 -7.74 0.94 0.495

4.00 3.0 -3.98 -15.91 15.82 0.319 1.59 PASS

4.00 2.9 -4.16 -16.63 17.29

0.00 0.1 -6.90 0.00 47.58

0.00 0.2 -6.81 0.00 46.34

-1.59 PASS

0.00 0.1 -6.96 0.00 48.41

0.00 0.1 -6.91 0.00 47.72 -0.318

Test Result PASS

0.00 0.3 -6.75 0.00 45.53 -0.362 -1.81 PASS

0.00 0.2 -6.80 0.00 46.21

y = 1.201x + 0.141R² = 0.997

0

5

10

15

20

25

0 2 4 6 8 10 12 14 16 18

Ca

l G

as

mg

/m3

CEM mg/m3

HCl linearity chart

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16.72 16.6

12.54 12.4 3.37 42.31 11.38

12.54 12.4 3.38 42.43 11.45 0.158 0.76 PASS

8.36 8.4

7.61 127.30

16.72 16.6 7.59 126.97

57.97 0.069 0.33 PASS

57.67

16.72 16.6 7.57 126.63

20.90 20.9 11.95 249.83

57.36

-0.168 -0.80 PASS142.89

20.90 20.9 11.95 249.83

20.90 20.9 8.96 11.95 249.83

142.89

1.013 -0.147142.89


O2


Gas conc

injected

Yc (Cem


12.54 12.4 3.38 42.43 11.45

(Xi-Xz)^2

-0.58 -4.82 0.33

8.36 8.4 -0.56 -4.65 0.31

-0.06 PASS

4.18 4.2 -4.84 -20.22 23.39

8.36 8.4 -0.60 -4.98 0.36 -0.013

4.18 4.1 -4.87 -20.34 23.68 0.136 0.65 PASS

4.18 4.1 -4.85 -20.26 23.49

0.00 0.2 -8.75 0.00 76.50

0.00 0.2 -8.75 0.00 76.50

0.2 -8.76 0.00 76.67

0.00 0.2 -8.75 0.00 76.50 -0.096 -0.46 PASS

0.00

Test Result PASS

0.00 0.2 -8.76 0.00 76.67 -0.086 -0.41 PASS

0.00 0.2 -8.76 0.00 76.67

y = 1.013x - 0.146R² = 0.999

0

5

10

15

20

25

0 5 10 15 20 25

Ca

l G

as

%

CEM %

O2 linearity chart

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Does Site Perform QAL 3 ? Frequency ? Inspected ?

Have Site Calculated Sams? Do Site use Control Charts Type

By

Shewart

CEMs measurement uncertainty budget

Yes

Yes

If there is a failure of the QAL2 or AST, ESG refer to the MCERTS testing data, and

determine whether any significant interferents are likely to be present in the stack. If

interferents are present, ESG will determine the extent to which such interferents may

introduce a bias into the measurements from the CEM.

A test shall be undertaken if the

process gases to be monitored

contain components that are known

interferences, as identified during

QAL1 and there is a failure of the

QAL2 or AST which could be due to

interferents

Monthly Yes

Section 6 - Interferences

Section 8 - Response time

see section 4 for details

Yes

Section 7 - Zero and Span drift (Audit)

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Does CEM have QAL1 certification?

Dry

15MC030015/02

Gases Used

Yes

Equipment used for functional test

20.9

200

Sigrist

wet

Certificate Number

ABB

ABB

ABB

Range

ACFNT

mg/m3

%

%

Note: For WID Processes the minimum MCERTS Certified Range must be 1.5 times the process ELV or less, for LCPD this multiplier is 2.5 times. E.g if a process has an ELV of

10mg/m3, then under WID the minimum MCERTS Certified Range of the CEMS should be 0 - 15mg/m

3 or less.

or

Instrument

Oxygen

CO

HCl

20.9

MC060081/03

ABB

Expiry Date

Serial Numbers

Calibration Dates

Techmon Gas Divider

Dec-12

MC030016/04

MC030016/04

HPC730

0.05Photometer

LEK 018

FTIR

FTIR

Zirconia

ACFNT

wet

FTIR

ACFNT

wet

wet

FTIR

Technique

MC030016/04

MC030016/04

MCERTS

Certificate

Number

75

75

15

ABB

VOC

FTIR

Model

ACFNT

ACFNT

ABB

Water

MC030016/04

MC030016/04

ABB

ABB

MultiFID mg/m3

Measurement

-

75 mg/m3

(SIRA)

Minimum

MCERTS

Certified

FTIR

wet

wet

FID

Instrument

200

MC030016/0415

15

mg/m3

200

75

SO2

Pollutant

Section 9 - Service Report

Gas

NO

%)

Dust wet

ACFNT

Stackguard

wet

Wet

mg/m3

200

NO2 mg/m3

Units

(mg/m3

ppm

wetACFNT

CEM

System

Provider

Range

mg/m3

mg/m3

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BS EN 14181:2004 - QAL2 CEMs Functional Test Report · TE's 1, 2 & 4 12th July 2013 1- ......

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Transcript of BS EN 14181:2004 - QAL2 CEMs Functional Test Report · TE's 1, 2 & 4 12th July 2013 1- ......