NCD003446721_19900703_Celeanse Corporation - Shelby Fiber_FRBCERCLA RD_60% Remedial Design and Draft Remedial Action Work Plan OU-2 - Appendix II Trial Burn Plan-OCR

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Westinghouse Environmental
and Geotechnical Services. Inc.
5050N013
•
OPERABLE UNIT 2
4000 DeKalb Technology Parkway, NE
Suile 250
Atlanta, Georgia 30340
[phone]
FAX [phone]
60% REMEDIAL DESIGN REPORT AND
DRAFT REMEDIAL ACTION WORK PLAN
HOECHST CELANESE CORPORATION
SHELBY, NORTH CAROLINA
WESTINGHOUSE PROJECT 4124-85-0S0N
DOCUMENT CONTROL BS0S0N-0227
APPENDIX II
TRIAL BURN PLAN
Prepared For:
WESTINGHOUSE ENVIRONMENTAL AND
GEOTECHNICAL SERVICES, INC.
Atlanta, Georgia
and
HOECHST CELANESE CORPORATION
Shelby, North Carolina
Prepared By:
GDC ENGINEERING, INC.
April 1990
A Westinghouse Electric Corporation subsidiary.
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GDC ENGINEERING INC.
Consulting Engineers, Hydrogeologists & Environmental Scientists
SPECIALIZING IN WASTE MANAGE,'),IENT AND SITE RESTORATION
TRIAL BURN PLAN
ON-SITE INCINERATION AND SOLIDIFICATION
HOECHST CELANFSE CORPORATION
SHELBY, NORIB CAROLINA
Submitted To:
HOECHST CELANESE
P.O. BOX 87
SHELBY, NC 281S1-0087
Prepared By:
GDC ENGINEERING INC.
822 NEOSHO A VENUE
BA TON ROUGE, LOUISIANA 70802
APRIL 23, 1990
822 NEOSHO AVENUE , BATON ROUGE, LOUISIANA 70802 , [phone] , FAX [phone]
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[GcD] GDC ENGINEERING INC.
Consulting Engineers. Hydrogeologists & Environmental Scientists
SPECIALIZING IN WASTE M.ANAGEMrnT AND SITE RESTOR.ATION
TABLE OF CONTENTS
INTRODUCTION
1.0
2.0
TRIAL BURN TFST FLAN
SUMMARY
1.1 TRIAL BURN PERSONNEL RESPONSIBILITIES
1.2 PROCESS OPERATIONS OVERVIEW
1.2.1 Operating Plan
1.2.2 Process Operating Parameters
1.3 OPERATING PLAN
1.3.1 Blending of Trial Burn Feed
1.3.2 Optimization of Incineration System
1.3.3 Pre-Test Sampling and Analytical
1.3.4 Trial Burn
I. 3 .5 Process Operating Parameters
1.4 FEED MA TERLU, DESCRIPTION
1.4.1 Waste Feed Material
1.4.2 Material Stabilization
1.5 PRINCIPAL ORGANIC HAZARDOUS CONSTITUENT
INCINERATION SYSTEM DESCRIPTION
GENERAL DESCRIPTION
2.1 WASTE MATERIALS FEED SYSTEM
2.1.1 Fe--..d Hopper
2.1.2 Paddlewheel Sealing Mechanism
2.1.3 Waste Depth Control Mechanism
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TABLE OF CONTENTS
(continued)
2.2 ROTARY KILN SYSTEM
2.2.1 Rotary Kiln Case
2.2.2 Refractory
2.2.3 Heating Equipment
2.2.4 Kiln Temperature Control
2.2.5 Ash Recovery System
2.3 SECONDARY COMBUSTION CHAMBER
2.4 AIR POLLUTION CONTROL EQUIPMENT
2.4.1 Gas Quenching Duct
2.4.2 Particulate Removal Chamber
2.4.3 Gas Contacting Chamber
2.4.4 Turbulent Agglomerator
2.4.5 Entrainment Separator
2.4.6 Exhaust Fans
2.4. 7 Exhaust Stack
INCINERATION SYSTEM DRAWINGS
3.0 THERMAL TREATMENT UNIT EVALUATION
SUMMARY
3.1 INCINERATOR -TECHNICAL DISCUSSION
3.1.1 Excess Air
3.1.2 Temperature
3.1.3 Residence Time
3.1.4 Mixing
3.1.5 Stack Emissions
3.2 INCINERATOR DESIGN
3.2.1 Operating Conditions
3.2.2 W·1Ste Characteristics
3.3 DESIGN BASIS ASSUMPTIONS
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802
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TABLE OF CONTENTS
(continued)
4.0 SAMPLING AND MONITORING PLAN
4.1 PROCESS STREAM SAMPLING
4.1.1 Solid Waste Feed Material
4.1.2 Product (Ash)
4.1.3 Scrubber Influent Sampling
4.1.4 Scrubber Effluent Sampling
4.1.5 Exhaust Gas Sampling
4.2 CONTINUOUS EMISSION MONITORING
4.3 CONTINUOUS MONITORING PROCEDURES
4.3.1 Sample Acquisition and Conditioning
4.3.2 Sample Analysis
4.4 PROCESS MONITORING
4.4.1 Incineration System Interlocks
5.0 INCINERATION SYSTEM PROCESS MONITORING AND CONTROLS
GENERAL
5.1 INCINERATION SYSTEM MONITORING
5.1.1 RK Interlocking Alarms
5 .1. 2 SCC Interlocking Alarms
5.1.3 APCE Interlocking Alarms
5.1.4 RK Non-Interlocking Alarms
5.1.5 SCC Non-Interlocking Alarms
5.1.6 APCE Non-Interlocking Alarms
5.1.7 RK Warn Alarms
5.1.8 SCC Warn Alarms
5.1.9 APCE Warn Alarms
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TABLE OF CONTENTS
(continued)
5.2 EMERGENCY AND UPSEf CONDffiONS AND ACTIONS
5.2.1 RK Interlocking Alarms
5.2.2 SCC Interlocking Alarms
5.2.3 APCE Interlocking Alarms
5.2.4 RK Non-Interlocking Alarms
5.2.5 SCC Non-Interlocking Alarms
5.2.6 APCE Non-Interlocking Alarms
5.2.7 RK Warn Alarms
5.2.8 SCC Warn Alarms
5.2.9 APCE Warn Alarms
6.0 QUALITY ASSURANCFJQUALITY CONTROL PROCEDURES
6.1 SAMPLING APPARATUS
6.1.1 Dry Gas Meter and Orifice Meter
6. 1.2 Thermocouples
6.1.3 Pitot Tubes
6.2 QUALITY CONTROL SAMPLES
6.2.1 Blank Samples
6.2.2 Field-Biased Samples
6.2.3 Duplicate Samples
6.3 SORBENT MEDIA QUALITY
6.4 SAMPLE TRANSPORT AND CUSTODY
6.5 FIELD SAMPLE PROCEDURES
6.6 LABORATORY CUSTODY PROCEDURES
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7.0 ANALYTICAL PROCEDURES
7.1 PRESAMPLING ACTIVmES
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TABLE OF CONTENTS
( continued)
7.2 SAMPLE PREPARATION
7.2. l GRU Feed Material
7.2.2 Analysis of Volatile POHCs in Feed Samples
7 .2.3 Processed Material
7.2.4 Scrubber Effluent
7.2.5 Exhaust Gas
7.3 ANALYTICAL METHODS
7 .3.1 Gravimetric Determinations of Particulate Matter
8.0 DATA REDUCTION AND REPORTING
8.1 DATA REDUCTION
8.2 DATA REPORTING
APPENDIX A -ANALYTICAL QUALITY ASSURANCFJQUALITY CONTROL PLAN
APPENDIX B-SITE SPECIF1C HEALTH AND SAFETY PLAN
APPENDIX C -SCHEDULES
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
LIST OF TABLES
Table I. I
Table 2.1
Table 2.2
Table 2.3
Table 4.1
Table 4.2
Table 4.3
Table 4.4
Table 8.1
LIST OF FIGURES
Figure 1-1
Figure 1-2
Figure 1-3
Figure 2-1
TABLE OF CONTENTS
(continued)
Summary of Thermal Treatment Parameters for GDC Mobile Incineration
System
Primary Chamber Specifications
Secondary Combustion Chamber Specifications
Air Pollution Control Equipment Specifications
Analyzer Specifications of Continuous Monitors
Summary of Analytical Testing for Each Phase of Trial Burn
Schedule for Sampling and Analyses During Each Phase of Trial Burn
Summary of Analytical Methods for Trial Burn Samples
Sampling and Monitoring Results Summary
Area Map Showing Hoechst Celanese, Shelby Location
Trial Burn Matrix
Trial Burn Organii.ation
Diagram of Mobile Thermal Treatment System
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INTRODUCTION
The Hoechst Celanese plant located in south-central Cleveland County, North Carolina,
manufactures polyester polymer resin and filament yarn. In the past various wastes have been
buried in several area around the plant. Portions of the plant production wastes included
dimethyl terephtalate, ethylene glycol, titanium dioxide and antimony trioxide. A Consent
Decree for the clean up of the wastes was signed by Hoechst Celanese and submitted to EPA for
processmg.
The selected remedial action for the Hoechst Celanese, Shelby facility as outlined in the
Record of Decision (ROD) includes the following remediation activities:
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excavation of approximately 2000 cubic yards (yd') of glycol recovery unit (GRU)
sludges. The 2000 yd' includes a known GRU volume of 1500 yd' plus an
additional l foot (ft) of soil below the GRU/soil interface
excavation of approximately 1200 yd' of burn pit residuals
excavation of approximately 600 yd' of plastic chips
excavation of approximately 110 yd' of stream sediments
incineration of GRU sludges and associated soils
chemical fixation (solidification) of incinerator ash, plastic chips, burn pit residuals
and stream sediments
On-site disposal of inert solidified materials
Regrading and vegetation.
Hoechst Celanese has selected GDC Engineering Inc. (GDC) of Baton Rouge, LA, to
provide the remediation services required to comply with the Consent Decree. The services that
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802
Introduction
Page 2
GDC will provide during the remediation activities include, but are not limited to,: excavation
of the waste material, thermal treatment of the GRU materials and solidification of the GRU ash,
plastic chips, bum pit residuals and stream sediments.
GDC will use a rotary kiln incineration system that consists of a feed system, a rotary
kiln, a secondary combustion chamber and air pollution control equipment. The rotary kiln is
a direct fired rotating chamber that volatilizes the organics in the waste material, which
subsequently enter into the secondary combustion chamber. The secondary combustion chamber
utilizes fossil fuel to maintain destruction temperatures of up to 2200 degrees Fahrenheit. The
combustion off-gases from the secondary chamber go into the air pollution control system for
quenching, removal of particulate and neutralix.ation of the acid gases before exiting the system
through the exhaust stack. The incineration system is designed to comply with all established
environmental regulations for hax.ardous waste processing and incineration. Upon erection of the
transportable system at the Shelby plant site, the incinerator will be subjected to a trial bum to
establish its performance on the specific hax.ardous waste materials on the site.
This document presents a detailed description of the mobile incineration system, a
description of the operating parameters within which the system is expected to operate, and a
summary of the system shutdown instrumentation and procedures which will occur in the event
of a process upset. This plan also includes a schedule for the system optimix.ation and testing,
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Introduction
Page 3
a summary of the proposed incinerator operating conditions for the trial burn, a description of
the monitoring and sampling techniques and analytical procedures which will be used to
implement the tests, and a program for the analysis of the data with an interpretation of the
results.
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822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 I 504) 383-8556 FAX[phone]
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1.0 TRIAL BURN TEST PLAN
SUMMARY
This section contains the procedures for the comprehensive sampling and performance
monitoring during the trial bum tests of GDC Engineering Inc.' s mobile incineration
system at the Hoechst Celanese, Shelby plant facility. The plant site is located in south-
central Cleveland County east of North Carolina Highway 198, approximately 1 mile
north of Earl, NC and 6 miles south of Shelby, NC. Its location is shown on the map in
Figure 1-1.
The incineration system consists of a rotary kiln (RK), a secondary combustion chamber
(SCC), air pollution control equipment (APCE) and a process control center (PCC). The
rotary kiln is a direct fired rotating chamber that volatilizes the organics in the waste
material. The organic laden gases exiting the rotary kiln (RK) flow through a cyclone
separator that removes heavy particulates and into the secondary combustion chamber
(SCC). The secondary combustion chamber (SCC) utilizes supplemental fossil fuel to
maintain destruction temperatures of up to approximately 2200 degrees Fahrenheit (°F).
The combustion off-gases from the secondary combustion chamber will enter the air
pollution control equipment (APCE) which consists of a quench section, a two chamber
particle contact section, a particulate agglomeration section, an acid absorption and
neutralization section, an entrainment separation section and an exhaust section. The
unit has a total heat dissipation of 20 million Btu/hr and a contained material feed capacity
up to 2500 pounds per hour.
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PROPOSED TEST MATRIX GDC MOBILE INCINERATION SYSTEM
TRIAL BURN
Test Day Test No. Feed PFS Temp. sec Temp. Est. Feed
Rate*(lbs/hr}
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Material
1 1 Stab. 1600 2200 2125
2 Grub 1400 2200 2125
3 Waste 1200 2200 2125
2 4 Stab. 1600 1800 2125
5 Grub 1400 1800 2125
6 Waste 1200 1800 2125
3 7 Stab. 1600 2200 2000
8 Grub 1400 2200 2000
9 Waste 1200 2200 2000
Feed Rate is based on mixed grub material with a specific gravity of 1.16
and a heating value of 7,800 Btu/lb. Actual feed rate will be determined
during the optimization period.
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Page 1.2
The incineration of stabilized solid wastes will be conducted in accordance with the
"Guidance Manual for Hazardous Waste Incinerator Permits" (SW-966), July 1983, issued
by the EPA Office of Hazardous Waste and Emergency Response. RCRA regulations
governing the thermal destruction of hazardous wastes require the demonstration of
99.99% Destruction and Removal Efficiency (DRE) for the Principal Organic Hazardous
Constituents (POHCs). This DRE determination is made by comparing the POHC
concentrations in the feed to the thermal treatment unit with those in the incineration
product and exhaust gases as determined by sampling and analyses during the treatment
period. The trial bum test will be conducted over a three (3) day period as shown on the
Trial Bum Matrix, Figure 1-2.
Samples will be collected from four process streams on each of the three days of the test
bum and also during one or two days of a pretest run prior to the actual demonstration:
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Feed to the Thermal Treatment Unit
Ash from the thermally treated material
Scrubber effluent
Exhaust gas
Results obtained from the analysis of the stack gas during the trial bum will allow
operating personnel to optimize operating parameters to ensure complete destruction of
hazardous constituents present in the waste.
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX[phone]
Page 1.3
I .I TRIAL BURN PERSONNEL RESPONSIBILITIES
An organization chart for the trial burn of the GDC mobile incineration system used for
the Hoechst Celanese, Shelby project is presented in Figure 1-3. The Trial Bum
Coordinator will have the authority and responsibility to coordinate the activities of the
Incinerator Operations personnel and the Test Team sampling crew. Mechanical operation
of the mobile incinerator will be the responsibility of the Incinerator Operations Manager.
Under the direction of the GDC Incinerator Operations Manager, the Coordinator will
assist the operating personnel during start-up and optimization of the incineration system.
The Coordinator will monitor the operating conditions and ensure that the incineration
system is operated within the parameters established by the regulatory agencies.
The Sampling Field Director will be responsible for the proper collection of all samples
specified in the sampling and monitoring plan. He will keep the Trial Bum Coordinator
informed of overall progress and problems or potential problems on a timely basis. He
will also be responsible for the proper shipment of samples to the analytical laboratory
as outlined in the project Quality Assurance Plan.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
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TRIAL BURN ORGANIZATION
I Incin. Oper. Manager I
I Trial Burn Coordinator I
Team Incineration
Manager Operations
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Analytical Crew QA/QC Coordinator
Lab Director
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Laboratory
Technicians
Page 1.4
1.2 PROCESS OPERATIONS OVERVIEW
The sampling and monitoring plan for the trial burn has been designed so that effective
incineration of the waste material can be verified. The comprehensive program includes
a one (I) to three (3) day pre-trial burn test and the actual trial burn for the mobile
incineration system. The pre-test will be conducted during the optimization of the
incinerator and will involve minimum testing on the stack emissions and ash residuals to
ensure that the incinerator is operating within regulatory guidelines. The trial burn will
consist of a minimum of three (3) replicate thermal treatment runs at the specified
operating conditions to assess system performance in accordance with EPA RCRA
guidelines.
Pursuant to the Resource Conservation and Recovery Act (RCRA) regulations contained
in 40 CFR Part 264, stack emissions monitoring must be conducted for the following
parameters when an incineration system is first used for the destruction of hazardous
waste:
o Oxygen
o Carbon monoxide
o Hydrochloric acid
o POHC(s)
o Total particulate matter
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In addition, a system will be provided to automatically monitor and record specific
prom, parameren, ioc!OOiog fool rare arnl oomb~tioo ~m-w ffl'ffi ~ Lu:
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX [phone] I
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Page 1.5
The trial bum program has been designed to evaluate the effectiveness of GDC's mobile
rotary incineration system in the destruction of GRU material and to establish process
operating conditions and maximum throughput for processing the waste maierial. The
program will consist of a minimum of three (3) sampling runs conducted on su=ssive
days, as previously outlined in this section. It is anticipated that one test will be
performed during each day of the program. For each run, samples will be collected from
four process streams:
o Waste material feed
o Processed material ash
o Scrubber effluent
o Exhaust gas
Samples of the processed residues and scrubber water will be collected during the trial
bum program for analyses of a surrogate POHC to determine the overall destruction
effectiveness of the system in accordance with EPA RCRA guidelines. Analytical
procedures are outlined in Appendix A.
Monitoring and recording of key operating parameters will also be conducted during each
run. The specific sampling and monitoring approaches are presented in the following
sections. A summary of the sampling and monitoring plan for the trial bum tests appear
in Table 4.2. Table 4.3 contains a summary of the monitoring plan that will be used
during final processing of the GRU material.
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX[phone]
1.3
Page 1.6
OPERA TING PLAN
The work activities required to successfully complete the trial bum program
include the blending of the trial bum feed material with the surrogate POHC
(naphthalene), the optimization of the mobile incineration system, a pre-test
sampling and analytical phase to ensure that the incinerator is operating properly
and the actual trial bum test.
1.3.1 Blending of Trial Bum Feed
The feed material for the trial bum will be the stabilized GRU material described
in Section 1 .4. The naphthalene will be blended into the stabilized GRU material
prior to the Trial Bum test to produce a feed with approximately 2,000 ppm of the
surrogate POHC. The trial bum feed material will be mixed with the pugmill
that is being used to mix the GRU material with sawdust for incineration.
Approximately 75 tons of GRU waste will be mixed with sawdust and spiked with
naphthalene as feed for the incineration system during the trial bum.
1.3.2 Ol)timization of Incineration System
The incineration system will be put into service after the initial run-in and
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Page 1.7
system for burning waste at the highest possible throughput. The optimization of
the incineration system may require a period of 720 operating hours and will be
conducted in accordance with EPA regulations 40 CFR 270.62. During the system
optimization, waste material from the stockpile will be processed after the
established operating parameters and conditions are met. As the waste processing
continues, adjustment will be made to the operating temperatures, flows and
residence times to establish the optimum operating parameters required for
obtaining complete burnout at the highest possible throughput.
1.3.3 Pre-test Sampling and Analytical
The pre-trial burn test is a 1 to 3 day period of minimum sampling and analytical
activities that will confirm that the incineration system is operating within
regulatory guidelines while processing waste. The pre-test will be performed
during the incinerator optimization phase. During the sampling runs for the pre-
test, stabilized GRU material that has blended with naphthalene will be used as
feed for the incin,eration system. Samples will be taken from the feed, ash and
scrubber water streams and analyzed as per Table 4.3. Any adjustments required
on the incineration system to ensure destruction of the POHC will be made during
the remaining optimization time.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Page 1.8
I. 3 .4 Trial Burn
The trial burn consists of testing the Rotary Kiln Primary Chamber, the Secondary
Combustion Chamber and the Air Pollution Control Equipment while processing
the stabilized GRU material described in Section 1.4.2.
The first task on the trial burn program agenda will be the performance of
miscellaneous equipment tests as outlined in Section 4.4.1. When all of the system
monitoring, alarm and interlock units have been checked out and after the
miscellaneous tests have been completed, the furnace will be brought to optimum
operating conditions in accordance with the RCRA operational parameters. When
these operating conditions have been attained, feed from the stabilized GRU
material stockpile will be introduced to the rotary kiln. When all operational
parameters are within the limits outlined in Table 1.1, the incineration system will
process material for approximately one work shift (8 to 12 hours). During this
period, all operating conditions will be maintained within the established
parameters, and the Incinerator Operations Manager will inform the Trial Burn
Coordinator that the sampling can begin.
York Research Consultants, has been selected to implement the Sampling Plan and
will be responsible for collection of required samples, i.e.; waste feed material,
processed material ash, scrubber effluent, and samples obtained from the exhaust • r.:-;J . . ®IB~~u
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX [phone]
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Page 1.9
gas. York Research Consultants will also be responsible for furnishing required
instrumentation and analyzing for specific gaseous components of the exhaust gas,
such as nitrogen oxides (NOx), carbon monoxide (CO), carbon dioxide (CO,) and
oxygen (0,).
When the sampling has been completed, the Sampling Field Director will inform
the Trial Burn Coordinator. The Coordinator will then inform the Incinerator
Operations Manager to record the total amount of feed material processed during
the sampling run. After the final emissions test is completed, processing of the
stabilized GRU waste will continue under the parameters agreed upon with the
Regulatory Agency for the Trial Burn until the data has been analyzed and the
processing parameters are finalized for incineration of the waste.
1. 3. 5 Process Operating Parameters
Table 1.1 contains the proposed process conditions for the incineration of the
stabilized GRU material.
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TABLE 1.1
SUMMARY OF THERMAL TREATMENT PARAMETERS
FOR GDC MOBILE INCINERATION SYSTEM
Parameter Anticipated' Control'
Value Limits
Waste Feed
Solid feed rate (tons/hr) 1.00 NA
POHC' concentration in feed (%) 0.20 NA
POHC' feed rate Obs/hr) 50.00 NA
Combustion Conditions
Residence time (sec) 2.05 2.0 -3.0
Destruction temperature ('F) 2000.00 2000 + 100
Oxygen ( % 0,) 5.00 4.0 -6.0
Carbon dioxide(% CO,) 14.00 NA
Carbon monoxide (ppm CO) 20.00 0.0 -100.0
Emissions
Combustion gas NO, (ppm) 125.00 NA
HCl removal(%) 99.00 NA
Particulates (gr/dsct) 0.08 NA
POHC DRE(%) 99.99 NA
EPA
Required'
Value
NA
NA
NA
NA
NA
NA
NA
NA
NA
99.00
0.08
99.99
The Anticipated Values for process combustion conditions and emissions are based on
previous sampling and monitoring programs with thermal treatment technology where
results showed complete destruction of hazardous compounds and conformance with
Resource Conservation and Recovery Act regulations.
The Control Limits for the Hoechst Celanese -Shelby thermal treatment project present
the range of operation for specific parameters which will ensure complete POHC
destruction and emission control.
The EPA Required Value for specific operational parameters are the standards and
guidelines established under the Resource Conservation and Recovery Act for the thermal
destruction of hazardous waste.
Naphthalene will be used as surrogate POHC during the trial burn due to the low level
of Appo,di, VIII="'"""" i, <ho GRU mareri,J ® IB ~ ~ u
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Page I.IO
1.4 FEED MATERIAL DESCRIPTION
The feed material used during the trial bum program will be the stabilized wasie materials
present on the Hoechst Celanese, Shelby plant site.
1.4.1 Waste Feed Material
The physical characteristics of the waste material before being stabilized are
summarized below.
Parameter
Moisture, %
Ash,%
Heating Value,
Btu/lb
GRU Material
6 -40% range
1.3% average
2,000-7,800 range
5400 average
AVERAGE ANALYSIS OF GRUB MATERIAL
(Dry weight basis, mg/kg)
Parameter
Carbon
Hydrogen·
Oxygen
Nitrogen
Sodium
Chlorine
Antimony
Arsenic
Barium
Cadmium
Chromium
Lead
822 NEOSHO AVENUE
Concentration
36.1 % average
7.8% average
54.8% average
0.003% average
0.004% average
0.013--0.05 % range
4,000 mg/kg average
<0.05 mg/kg average
0.01 mg/kg average
<0.01 mg/kg average
<0.03 mg/kg average
<0.005 mg/kg average
BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Mercury
Selenium
Silver
1.4.2 Material Stabilization
<0.0005 mg/kg average
<0.005 mg/kg average
<0.05 mg/kg average
Page I. 11
The GRU material is either a moist, semi-viscous (like toothpaste) or a dry, hard,
friable material. To facilitate handling of the GRU material from the pits to the
incineration system, the waste will be stabilized with sawdust. Sawdust was
chosen as the preparation additive for several reasons. First, sawdust exhibits
excellent absorption characteristics for the highly organic liquids found in the GRU
material. Second, the incineration of the sawdust, unlike additives such as flyash,
will essentially generate no additional ash. Minimizing the quantity of stabilized
· ash for on-site burial is consistent with regulatory guidelines on waste
minimization. Third, sawdust is a material that is available in sufficient quantities
and at an economical cost in the Shelby, NC area. Finally, sawdust is compatible
with the waste as far as BTU and moisture content is concerned.
Based on the volume and characteristics of the waste materials, the feed will
blended in a LQ part waste to Q.ll parts sawdust proportion.
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1.5
Page 1.12
PRINCIPAL ORGANIC HAZARDOUS CONSTITUENT
RCRA regulations governing the incineration of hazardous wastes require that a trial burn
be run on the principal organic hazardous constituent (POHC). The POHC must be an
Appendix VIII compound that is present in the waste. If more than one Appendix VIII
compound can be identified as being present in the waste stream, the selection of the
POHC is a matter of judgement based on the difficulty of incineration and the quantity
of that compound present.
The major organic components of the waste to be incinerated at the Shelby site have been
identified as:
0
0
0
0
Ethylene Glycol
Diethylene Glycol
Triethylene Glycol
Ethylene Glycol Terephthatate Oligimers
None of these wastes is listed in 40 CPR 261 Appendix VIII. In addition, the sensitivity
of available analytical methods for determination of ethylene glycol is poor. Likewise,
identification of the terephthalate ester oligimers present in the feed cannot be specifically
.jdentified or precisely quantitated. For. these reasons, naphthalene will be used as a
surrogate POHC during the trial burn. Naphthalene was chosen as the surrogate POHC
because it meets the incinerability requirement and it can be analyzed with high precision.
-1
@~~~D
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Page 1.12
Table D-1 of Appendix D of the EPA document "Guidance on Setting Permit Conditions
and Reporting Trial Bum Results" lists naphthalene as a Class 1, or very stable,
compound. As Class 1 compounds are the most difficult to incinerate and with a
concentration of approximately 2,000 ppm, it is proposed that naphthalene be use as a
surrogate POHC for the Trial Bum of the mobile hazardous waste incinerator.
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX [phone]
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"' "' 0 <O
" -M N .;
" Cl z z ::,
"' <D
! 2 0 1
f't*liif-tih·''\mJ;''*·t;,whifP@i¥##¥4P'"i@f@ti!i#\Wi@#¥¥iwJ ··
5CIJ O 1XX) 200) 3CXXl 400'.) 5COO
L rt;~, F·'"¥S J , ;v,~ -. -. ;;;;pjf-; ·iii#
SCALE 7.::' FEET .
NOTE: CONTOUR INTERVAL 20 FEET
REPRODUCED FROM BLACKSBURG 7½ Mlt-.i: QUADRANGLE
(1971)
SITE LOCATION MAP
HOECHST CELANESE CORP.
-------------------
Test Day Test No.
1 1
2
3
2 4
5
6
3 7
8
9
Figure 1-2
PROPOSED TEST MATRIX
GDC MOBILE INCINERATION SYSTEM
TRIAL BURN
Feed PFS Temp. sec Temp. Est. Feed
Material Rate*(lbs/hr)
Stab. 1600 2200 2125
Grub 1400 2200 2125
Waste 1200 2200 2125
Stab. 1600 1800 2125
Grub 1400 1800 2125
Waste 1200 1800 2125
Stab. 1600 2200 2000
Grub 1400 2200 2000
Waste 1200 2200 2000
'
* Feed Rate is based on mixed grub .material with a specific gravity of 1.16
and a heating value of 7,800 Btu/lb. Actual feed rate will be determined
during the optimization period.
rn rn m ~ TI
-------------------
FIGURE l-3
TRIAL BURN ORGANIZATION
I Incin. Oper. Manager I
,
I Trial Burn Coordinator I
Test Team Incineration
Project Manager Operations
I I I
Sampling Crew Analytical Crew QA/QC Coordinator
Field Director Lab Director
I I
Sampling Crew Laboratory
Technicians
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2.0 INCINERATION SYSTEM DESCRIPTION
GENERAL DESCRIPTION
'
GDC Engineering Inc.'s mobile incineration system shown in Fig. 2-1, consists of a
feed system, a rotary kiln, a secondary combustion chamber and air pollution control
equipment. The rotary kiln is a direct-fired rotating chamber that volatilizes the organics
in the waste material, which subsequently enter into the secondary combustion chamber.
The secondary combustion chamber utilizes supplemental fossil fuel to maintain
destruction temperatures up to approximately 2200 degrees Fahrenheit ('F). The
combustion off-gases from the secondary chamber go into the air pollution control
' j
equipment for quenching, removal of particulate and acid gas neutralization before exiting
the system through the exhaust stack.
Waste is continuously supplied to the rotary kiln by a feed system consisting of a live
bottom hopper, a weigh ,belt conveyor, and a screw feeder. The live bottom hopper is
located at grade for ease of filling with a front-end loader. It has negative taper sides to
eliminate bridging and is fitted with a variable speed drive to meter the contaminated
material onto the weigh belt conveyor. The weigh belt conveyor moves the waste from
'
the hopper to the rotary lciln feed screw. By adjusting the speed of the feed screws, the
feed rate to the kiln can be controlled within the desired range.
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Page 2.2
The rotary kiln is a horizontal refractory-lined cylinder which turns about its horiwntal
axis. It is set at approximately two degrees inclination. The kiln rotates, continually
exposing the waste matefial surfaces to the heat and oxygen as the feed moves through
the chamber. The kiln utilizes a fossil fuel burner to vaporize the moisture and organic
contaminants and remove them from the waste feed. The volatiles are partially burned
in the kiln and then pass into the secondary combustion chamber. The solid residue (ash)
exits the kiln through a wet ash collection system that minimizes ingress of ambient air.
The exhaust gases from the kiln enter the secondary chamber where they are heated to
1800 to 2200"F by a fossil fuel burner and combustion air control system. Contaminants
in the flow stream are d~troyed by the turbulent conditions that prevail in the secondary
combustion chamber.
The hot gases ex.it the secondary chamber and enter the air pollution control equipment
for gas clean-up to meet the stringent requirements placed on stack gases for hydrogen
chloride, sulfur oxides and particulate emissions. The incinerator off gases first enter a
vertical "wet approach" quench duct. The gases are saturated and quenched to the
adiabatic dewpoint by two air atomizing cluster nozzles. The gases then enter the first
of two fiberglass re-enforced plastic (FRP) contact chambers where atomizing nozzles are
used to intimately mix scrubber liquid with the particulates and acid gases present in the
gas stream to effect primary removal of the high loading solids and the initial
neutralization of the acid gases. Subsequently, the gases enter the second contact chamber
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 r,,.,1ij),00 &.~]
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Page 2.3
where a finer distribution of droplets is sprayed to contact and remove smaller particulate
matter. The gases then enter the turbulent agglomeration zone. The finest droplets are
then sprayed in a vortex of a specially modified exhauster where turbulence, mixing and
centrifugal separation take place. The droplets that escape separation in the fan are
removed in the entrainment separator. The entrainment separator (mist eliminator) utilizes
a chevron blade bank which provides plug free performance followed by mesh eliminator
banks with higher capture efficiency.
The trial bum for the incineration system will be conducted in accordance with the EPA
Office of Solid Waste and Emergency Response's "Guidance Manual for Hazardous Waste
Incinerator Permits (SW-966)", dated July, 1983. RCRA regulations governing the
thermal destruction of ha-rardous waste, require the demonstration of a POHC destruction
and removal efficiency (DRE) of99.99%. This DRE determination is made by comparing
the POHC(s) concentration in the waste material to the results of exhaust gas, ash and
scrubber water sampling performed during the treatment period.
2.1 WASTE MATERIALS FEED SYSTEM
The waste materials feed system incorporates a live bottom hopper a transfer weigh belt
{
conveyor, and a screw feeder to move the waste into the rotary kiln. The contaminated
waste will be excavated, mixed, stabilized and stored for incineration as described. The
st,1,mu,1 ..i m;,ol ~tori• wm be "'""'""" from~, moclq;T~i Will b~ TI
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Page 2.4
a front end loader. The feed will then be transferred from the live bottom hopper onto
the weigh belt conveyor and moved to the kiln feed screw. The feed screw then conveys
the feed material into the rotary kiln.
2.1.1 Feed Hopper
The feed hopper is a fabricated carbon steel hopper located at grade for ease of filling
with a front end loader. It has negative taper sides to eliminate bridging and is fitted with
variable speed screws to :move the contaminated soil to the belt. The feed hopper drops
feed onto a covered transfer belt conveyor which elevates the material from grade level
to the inlet of the kiln feed screw.
2.1.2 Kiln Feed Screw
The kiln feed screw provides for continuous feeding of the kiln. The screw stops
approximately one foot from the inside edge of the frontplate. This distance is adjustable
to provide a plug of material in front of the screw. This plug seals the air ingress into
the kiln and protects the ·screw from radiant heat. The screw is designed with a tapered
shaft to prevent compression of the material during feeding. The screw feeder is
hydraulically driven and.provides for automatic reversal in the event of a jam.
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Page 2.5
2.2 ROTARY KILN SYSTEM
The rotary kiln (RK) is a rotating refractory-lined cylinder that is 45'0" long and 7'6"
feet inside refractory diameter. It is set at approximately two degrees inclination for
gravity movement of the solids through the kiln. The kiln is hydraulically driven from
0.20 rpm to 1.0 rpm, producing waste residence times of 10 to 40 minutes. The internal
volume of the kiln is approximately 1,980 cubic feet. The kiln is equipped with a positive
seal system to prevent excessive ambient air from being drawn through the cylinder.
A feed hood, lined with A.P. Green Super Hybond Plus plastic refractory, or equal,
incorporates a hydraulically driven feed. screw, the kiln burner and air injection system.
The kiln is supported by four forged steel trunions, one driven and three idlers. A
hydraulic drive system provides for ease of start-up and variable speed.
2.2.1 Rotazy Kiln Case
The rotary kiln case is constructed of 5/8" carbon steel plate. The kiln is approximately
8'3" OD and 45'0" long. The feed hood, kiln cylinder and ash hood are mounted on a
common structural steel base for ease of transport and mobilization.
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Page 2.6
2.2.2. Refractozy
The refractory lining is 9" RKB (rotary kiln brick). The refractory is designed for
operating temperatures in excess of 2400"F.
2.2.3 Heating EQµipment
The rotary kiln will be operated at temperatures of approximately 1400 to 2000°F. At this
temperature the kiln will heat the waste material to a level sufficient for removal of
moisture and organics. A 6 MM BTU/hr gas burner mounted in the discharge end of the
chamber supplies heat directly to the waste moving through the kiln. The burner unit
includes an internal, manually ignited premix pilot, that is equipped with its own mixer
to ensure stability.
The burner is equipped with alarms and safety interlock devices that will protect the
combustion system and personnel in case of emergency. The safety devices include a
manually reset, shut-off valve in the main gas line that is interlocked with high and low
gas pressure switches in the gas line and a low pressure switch in the combustion air line.
The burner interlock sysiem will automatically shut off fuel in case of power, air or gas
failure.
Combustion air for the burner is provided by a direct driven air blower that is equipped
with a filter and silencer unit. The air flow to the burner is regulated by an automatic
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control valve acting in conjunction with the wne temperature controller. A pres.sure_. . .. I
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Page 2.7
signal taken downstream of the air control valve is sent to the gas flow control valve to
ensure that the gas flow follows the air flow in the correct ratio at all firing rates.
2.2.4 Kiln Temperature Control
Control of the temperature in the kiln is provided to maintain an operating temperature
of 1400 to 2000"F. An automatic valve in the combustion air header is used to control
air flow to the burner. Gas flow follows the air flow in correct ratio through an automatic
proportioning valve. Over temperature protection is furnished with separate instruments
using Type K chromel-alumel thermocouples.
2.2.5 Ash Recovery System
The incinerator ash exits the kiln through a wet ash removal system. The ash drops from
the end of the kiln into a water-filled sump. The water cools the ash and acts as a seal
to minimize air infiltrati:>n into the kiln. A hydraulically driven drag chain conveyor
transfers the material from the ash hood to an elevation sufficient to fall into a screw
blender conveyor. The screw blender conveyor provides a point where cementing
materials can be added and mixed with the ash. Makeup water to the sump is supplied
from the scrubber blowdown supplemented by fresh water as required. Polymers are
automatically fed to the ash sump to enhance settling. The kiln discharge hood is fitted
with a fixed tube and slide gate for collection of hot dry samples of ash before it drops
into the cooling sump. i tIDIBffi~U
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Page 2.8
2.3 SECONDARY COMBUSTION CHAMBER
The secondary combustion chamber is designed to prevent the buildup of particulate or
salts. The flue gases from the kiln will carry over both particulates and salts. These
materials would separate from the flue gas flow and be deposited on the bottom refractory
if horizontal sections were used.
The secondary combustion chamber is a vertical upfired/cement ell/downfired system.
The flue gas from the kiln enters the sec in an upflow mode and passes the sec burner
system. The material then flows up to the cement ell. The cement ell provides a reversal
in flow direction without a horizontal section. The material then flows to a downflow
section which is connected to the quench system.
This system provides several advantages. There are no horirontal sections and therefore
the entrained particulate is either deposited in the ash system or the quench system. In
a similar fashion, molten salts cannot pool on the refractory. This greatly extends the life
of the refractory. The tum of the cement ell provides additional mixing to promote
complete combustion.
The secondary combustion chamber is approximately 7' in diameter by 20' overall. The
system is provided with a 6 MM BTU/hr. burner/air injection system to control the
secondary operating tem!)erature. A combustion air fan provides air as required by the
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822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 (504) 383·8556 FAX(504)383•2789
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Page 2.9
system controls. The burner system is designed to provide turbulence for the complete
mixing of the kiln flue gases, auxiliary fuel, and combustion air. The burner is equipped
with a spark ignited premix pilot to ensure ignition of the waste.
The combustion chamber is sized to develop a turbulent flow region of high temperature
gases. The mixing of hot gases and fumes is maintained here causing rapid consumption
of the combustible constituents. The energy for the turbulent mixing is generated by using
the combustion air injected into the secondary combustion chamber.
The temperature is maintained in the residence chamber by modulating fuel input to the
burner section. The air flow is set to achieve a certain oxygen level, usually 4 % to 8 % ,
in the exhaust gases. The fuel modulates, mimicking the variations in the combustibles
in the gas stream. Since the oxygen consumption per unit BTU is roughly the same for
many combustibles, the exit gas does not vary over a wide range when the fume heating
value fluctuates.
The combustion monitoring equipment includes a manual reset, shut-off valve in the main
gas line. This valve is interlocked with high and low pressure switches in the gas line and
a low pressure switch in the combustion air line. The system will automatically shut off
fuel in the case of power, air or gas supply failure.
The gas temperature is measured by a shielded thermocouple located above the quench
section. Oxygen level is measured prior to the quench section. [ID(2ffi~1
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Page 2. 10
2.4 AIR POLLUTION CONTROL EQIBPMENT
The air pollution control equipment (APCE) system consists of a gas quenching duct, a
particulate removal chamber, a gas contacting chamber, a turbulent agglomerator, an
entrainment separator, induced draft exhaust fans and an exhaust gas stack. The air
pollution control equipment system is a high efficiency, Turbotak wet scrubber which
cleans the incinerator flue gas of both particulates and acid gases.
2.4.1 Gas Ouenchin~ Duct
The gas quenching duct is a vertical cylindrical tube with an inside diameter of 7'6" and
a length of 6'. The duct is constructed of Hastelloy C-276 material. The quenching duct
contains three (3) sets of air atomizing nozzles that create a situation where wetted
'
particulates can only imj>inge on a falling film of water, eliminating the potential for
buildup.
The hot gases from the secondary combustion chamber flow downward through the
quenching duct where an, irrigated "out of gas flow" wash ring is utilized to eliminate the
wet/dry interface and prevent buildup of deposits.
2.4.2 Particulate Removal Chamber
I The particulate removal chamber (first contact chamber), located at the bottom of the gas
quenching inlet duct, is constructed of FRP. The chamber is equipped with an internal
impingement plate to unload the heavier and larger particulate and atomizing nozzles that
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Page 2.11
inject a caustic dosed spray to start neutralization of the acid gases. The interior surfaces
are irrigated to preclude the deposition of particulate.
A caustic solution for acid neutralization is injected into the gas quenching duct and at the
inlet to the removal chamber through air atomizing nozzles.
2.4.3 Gas Contacting Chamber
The gas contacting chamber is constructed of FRP and is equipped with an internal
impingement plate for unloading particulates and atomizing nozzles to spray the incoming
gases. The chamber is tuned with a smaller droplet size distribution to provide capture
of smaller particulate and to provide more surface area for acid gas neutralization.
Droplet size is adjustable by changing the air supply pressure as well as the amount of
water sprayed. All interior surfaces are fully irrigated to prevent buildup of particulate.
2.4.4 Turbulent Agglomerator
The turbulent agglomerator is a modified industrial fan that is driven by a 25 Hp/700 rpm,
3/60/440 volt motor. The turbulent agglomerator provides intense turbulence to complete
the job of particulate agglomeration and to complete acid gas absorption and
neutralization. The centrifugal action of the fan removes the bulk of the entrained liquids
and agglomerates. The fan also will generally provide for the scrubber system pressure •
drop. The fan is continuously irrigated with a falling film of water across the impeller
bl-arul ""'""' whkh mi,imi,es """" -"" """"" pam,rn hm•m ~ TI
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Page 2.12
2.4.5 Entrainment Separator
The entrainment separator is constructed of FRP and is equipped with a chevron blade
section, a mesh section and spray bars with hydraulic spray nozzles. The gases from the
turbulent agglomerator pass first through the chevron blades which uses inertial impaction
by accelerating the gases through a bent path to preclean the entrained liquids down to 15
microns. The mesh section then completes the process by polishing the gas stream down
to 0.5 microns or less. Spray water is injected into the separator through hydraulic
nozzles located at the inlet of each section of entrainment media.
2.4.6 Exhaust Fans
The main exhaust fan is an induced draft (I.D.) fan that evacuates the flue gases by taking
suction downstream of the entrainment separator and exhausts to the atmosphere through
the stack. The main I.D. fan is inlet vane controlled with a variable frequency drive.
The main fan is driven by a 25 Hp, 700 rpm, 3/60/440 volt motor.
The emergency exhaust system consists of an identical fan that operates upon loss of main
I.D. fan. As the main I.D. fan is slowing down, the emergency fan kicks in
automatically, thereby maintaining negative draft on the incineration system. The
emergency I.D. fan is driven by a 25 Hp, 3/60/440 volt motor.
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Page 2. 13
2 .4. 7 Exhaust Stack
The exhaust stack is a 2' LD., 35' high FRP stack. The stack is equipped with a sampling
platfonn, sampling ports and an access ladder. The stack is provided with inlet ducts (2)
from the main I.D. fan and from the emergency I.D. fan.
[ID 00 ill ~ TI
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
TABLE 2.1
PRIMARY COMBUSTION CHAMBER SPECIFICATIONS
GENERAL
Type
Material of Construction
External Dimensions
Weight
Configuration
Nominal Feedrate
Process Capabilities
Rotational Speed
DRIVE SYSTEM
Type
Components Driven
Speed Reducer
Control System
HEATING SYSTEM
Manufacturer
Rotary kiln
5/8" carbon steel plate with 1/2" tire sections
7'6" ID X 45'0" long
35,000 pounds steel
One (1) control zone with countercurrent/concurrent gas flow
2,500 lb/hr depending on waste characteristics
300 -2000°F, 30 -40 minute material residence time,
0.20 to 1.0 revolutions per minute
Redundant hydraulic drive motors directly connected to the
trunion shaft
Rotary kiln via trunion drive
Not required
Dial adjustment at control panel by varying the volume flow
of hydraulic fluid
North American or equal
6MM BTU/hr
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I Burner Capacity
Natural Gas Flow
Temperature Range
100 scfm -each burner
1400 to 2000°F [IDOJffi~TI' I
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone] I
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REFRACTORY
Type
Manufacturer
TABLE2.1
(Continued)
Castable, RKB and plastic
A. P. Green Co. or equal
Thickness 6" on feed hood, 9" RKB in the kiln and 8" hybond plus
plastic on ash hood
Maximum Sustained 2400"F
Surface Temperature
ASH DISCHARGE SYSTEM
Type Cooling sump with discharge conveyor and sampling ports
for dry ash collection
Capacity 100 ft'
Material of Construction Carbon steel
COMBUSTION AIR BLOWER
Type Centrifugal
Manufacturer North American or equal
Model Number TBD
Material of Construction Carbon steel
Capacity 1250 scfm
Pressure Capability 4-6"
Motor 2 HP
Control System Variable Inlet Vane (VIV)
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
TABLE2.2
SECONDARY COMBUSTION CHAMBER SPECIFICATIONS
GENERAL
Type Gas-fired
Material of Construction Carbon steel, 3/8" minimum wall thickness
Process Chamber Volume 1100 ft'
Weight 8,000 pounds steel
Configuration Vertical combustion chamber with cement ell
Residence Time at > 2.0 seconds
Maximum Flow Rate
Process Capabilities 2400"F, 0 -200 % excess air
HEATING SYSTEM
Type Forced draft burner
Manufacturer North American or equal
Model Number
Fuel
Maximum Heat Release
Turndown Ratio
TBD
Natural gas @ 15 psi
6 MM BTU/hr
8 to 1
Manually adjustable air registers Air Supply System
Flame Safety System Continuous pilot flame monitor, automatic fuel shutoff and
purge system interlocked with secondary chamber sensor
REFRACTORY
Burner Chamber
Type Castable refractory
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 I 504 l 383-8556 FAX [phone]
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TABLE 2.2
( Continued)
Materials of Construction 60% Alumina insulating refractory
Manufacturer A. P. Green Co. or equal
Thickness 6 •
Maximum Sustained 2400°F
Surface Temperature
COMBUSTION AIR SUPPLY SYSTEM
Type
Manufacturer
Model Number
Material of Construction
Capacity
Pressure Capability
Motor
Control System
Number Air Ports
Diameter
Centrifugal
North American or equal
TBD
Carbon steel
1250 CFM
4•
2HP
Variable Inlet Vane (VIV)
TBD
TBD
TBD Configuration
Control System Manually-operated damper at blower
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone]
fID ill ill ~ TI
FAX [phone]
TABLE 2.3
AIR POLLUTION CONTROL EQUIPMENT SPECIFICATIONS
SCRUBBER
Type
Components
Manufacturer
Quench Chamber
Type
Material
Spray Nozzles
Range of Operation
Pressure Drop
Scrubber Liquor
Liquor Required
Effluent Handling
Flow Control System
Liquor Control System
High efficiency, low to medium energy wet scrubber
Quench chamber, particulate removal chamber, gas
contacting chamber, agglomerator, entrainment separator,
ID fan and stack
Turbotak Inc.
Vertical cylindrical tube
Hastelloy C-276
2 sets of air atomizing nozzles
10,000 to 30,000 ACFM, 1600°F to 2200°F gas inlet
temperature, 165"F to l 95"F gas exit temperature
< .5 inches water column
Water and NaOH
50 gpm (maximum) @ 40-60 psi
External holding tank with recirculation pump, liquor
makeup as required
Manual, preset constant
Pressure gauges, flow meters, and manually adjustable flow
control valves
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Particulate Removal Chamber
Type
Material
Spray Nozzles
Range of Operation
Pressure Drop
Scrubber Liquor
Liquor Required
Effluent Handling
Flow Control System
Liquor Control System
Gas Contacting Chamber
Type
Material
Spray Nozzles
Range of Operation
822 NEOSHO AVENUE
TABLE2.3
( Continued)
Knockout drum with baffle plate
FRP
2 sets of air atomizing nozzles
2,000 to 10,000 ACFM, 180 to 200°F gas inlet tempera-
ture, 165 to 190°F gas exit temperature
0.5 -1.0 inches water column
Water and NaOH
5-10 gpm (maximum)@ 40 -60 psi
External holding tank with recirculation pump, liquor
makeup as required
Manual, preset constant
Pressure gauges, flow meters, and manually adjustable flow
control valves
Knockout drum with impingement plate
FRP
2 sets of air atomizing nozzles
2,000 to 10,000 ACFM, 180°F to 200°F gas inlet
temperature, 165°F to 190°F gas exit temperature
BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Pressure Drop
Scrubber Liquor
Liquor Required
Effluent Handling
Flow Control System
Liquor Control System
Turbulent Agglomerator
Type
Manufacturer
Model Number
Material of Construction
Capacity
Pressure Capability
Motor
Spray Nozzles
Range of Operation
Scrubber Liquor
Liquor Required
Effluent Handling
TABLE 2.3
(Continued)
0.5 -1.0 inches water column
Water and NaOH
2-5 gpm (maximum) @ 40 -60 psi
External holding tank with recirculation pump, liquor
makeup as required
Manual, preset constant
Pressure gauges, flow meters, and manually adjustable flow
control valves
Centrifugal pressure blower
Plastair
40
FRP
TBD
2" WC
TBD
I set of air atomizing nozzles
2,000 to 10,000 ACFM, 180 to 200°F gas inlet temperature,
I 65 to 185°F gas exit temperature
Water and NaOH
2-4 gpm (maximum)@ 40 -60 psi
External holding tank with recirculation pump, liquor
makeup as required
@[fJgJ[}LJ
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
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Liquor Control System
Entrainment Se_parator
Type
Material
Spray Nozzles
Range of Operation
Pressure Drop
Scrubber Liquor
Liquor Required
Effluent Handling
Flow Control System
Liquor Control System
Main Exhaust Fan
Type
Manufacturer
Model Number
Material of Construction
Capacity
TABLE 2.3
(Continued)
Pressure gauges, flow meters, and manually adjustable flow
control valves
Mist eliminator with chevron blades and mesh section
FRP
3 sets of hydraulic nozzles
2,000 to 10,000 ACFM, 180 to 200°F gas inlet temperature,
165 to 185°F gas exit temperature
1.0 -2.0 inches water column
Water
1-2 gpm (maximum)@ 40 -60 psi
External holding tank with recirculation pump, liquor
makeup as required
Manual, preset constant
Pressure gauges, flow meters, and manually adjustable flow
control valves
Centrifugal pressure blower
Plastair
40
FRP
TBD
Pressure Capability 10.5" WC @ [fJ !iJ ~ rt
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Motor
Range of Operation
Flow Control System
Liquor Control System
Exhaust Stack
Type
Material
Internal Diameter
Height Above Grade
Sampling Ports
TABLE 2.3
( Continued)
2,000 to 10,000 ACFM, 180 to 200°F gas inlet temperature
Variable speed, AC frequency controlled
Pressure gauges, flow meters, and manually adjustable flow
control valves
Self-supporting
FRP
2 ft
35 ft
4
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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-------------------
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SAMPLING
PORTS
SCRUBBER
STACK
ENTRAINMENT
SEPARATOR
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CONTACT
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~=rt--n-----_L_--,-,-,-----+-
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Shelby, North Caroll na
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[GcDJ
3.0 THERMAL TREATMENT UNIT EVALUATION
SUMMARY
Incineration is an engineered process in which thermal oxidation at a high
temperature modifies materials. The consequences of incineration are a reduction
in the volume of wastes and the virtually complete destruction of organic
compounds. Carbon dioxide, water vapor and ash are the principal products of
incineration.
Temperature, residence time, oxygen concentration, and the degree of air/waste
mixing achieved are the primary variables affecting combustion efficiency in any
thermal treatment unit design. The theoretical significance of these interrelated
variables is discussed in the following section.
In general, two major factors are involved in evaluating these variables as they
relate to unit design. The first factor is whether or not the temperature, residence
time, and excess air level, along with the degree of mixing achieved in the unit,
are adequate for waste destruction. The second factor is whether or not the
proposed operating conditions are achievable, since temperature, excess air,
residence time, and mixing are all interrelated.
OOOOffi~U
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 I 504) 383-8556 FAX [phone]
Page 3.2
The principal operating conditions that affect the overall soil detoxification
efficiency of the incineration process are the solid phase residence time, the
primary chamber (kiln) operating temperature and the heat transfer rate to the solid
waste. Since a portion of the organic constituents present in the waste feed is
simply volatilized in the primary chamber, overall system performance also
depends on the efficient destruction of the constituents in the afterburner. The
primary process variables which affect afterburner performance are afterburner
temperature, gas residence time, turbulence and oxygen levels.
Furthermore, the characteristics of the waste itself can influence overall system
performance. The difficulty of thermal destruction of certain organic constituents,
the presence of organic species which are precursors to products of incomplete
combustion, the organic concentration in the waste feed, and the ease or difficulty
of volatilization of the organic components in the waste must all be addressed
prior to actual incineration of the waste burn.
WOOill~U
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX[phone]
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3.1
Page 3.3
INCINERATOR -TECHNICAL DISCUSSION
3.1.1 Excess Air
The most basic requirement of any combustion system is a sufficient supply
of air to completely oxidize the feed material. The stoichiometric, or
theoretical air, requirement is either calculated from the chemical
composition of the feed material or determined by actual testing. If perfect
mixing could be achieved and organic burnout occurred instantaneously,
then only the stoichiometric requirement of air would be needed. Neither
of these phenomena occur in real-world applications, however, so some
excess air is always required to ensure adequate waste/air contact. Excess
air is usually expressed as a percentage of the stoichiometric air
requirement. For example, 50% excess air implies that the total air supply
to the incinerator is 50 % greater than the stoichiometric requirement.
In general, the residual oxygen concentration in the exhaust gas should
exceed 3% oxygen, not to be confused with 3% excess air, to ensure
adequate waste/air contact in the secondary combustion zone. Additional
excess air may also be required for cooling. The minimum requirement
for a given thermal process unit depends on the degree of mixing achieved
and waste specific factors.
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX [phone]
Page 3.4
3.1.2 Temperan1re
Three basic questions should be considered in evaluating whether or not a
proposed operating temperature is sufficient for waste destruction:
I) Is the temperature high enough to heat all waste components (and
combustion intermediates) above their respective ignition
temperatures and to maintain combustion?
.2)
3)
Is the temperature high enough for complete reaction to occur at
the proposed residence time?
Is the temperature within normal limits for the materials of
construction and/or attainable under the proposed operating
conditions?
Complete waste combustion requires a temperature, and heat release rate,
in the unit high enough to raise the temperature of the incoming waste
constituents above their respective ignition temperatures. In almost all
cases where combustion intermediates are more stable than the original
waste constituents, higher temperatures are required for complete
combustion of the intermediates than the parent compound destruction.
Since heat transfer, mass transfer, and oxidation all require a finite length
of time, temperature requirements must also be evaluated in relation to the
proposed residence time in the secondary combustion chamber. Heat
transfer, mass transfer, and kinetic reaction rates all increase with
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fID mm ~u•
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX [phone] I
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Page 3.5
increasing temperature, lowering the residence time requirements. For
realistic residence times, however, temperatures higher than those needed
for ignition may be required to complete the combustion process.
3.1.3 Residence Time
In addition to temperature and excess air, residence time is a key factor
affecting the extent of combustion. This variable, also referred to as
retention time or dwell time, is the mean length of time that the waste is
exposed to the high temperature in the process unit. It is important in
designing and evaluating thermal processors because a finite amount of time
is required for each step in the heat transfer/mass transfer/reaction pathway
to occur.
For detoxification of contaminated soils/sludges via thermal treatment,
discrete (although short) time intervals are required for heat transfer to the
surface of the waste, organic volatilization, mixing with oxygen in the gas
stream, and reaction, which itself involves a series of individual steps
depending on the complexity of the waste's molecular structure. The total
time required for these processes to occur depends on the temperature in
the combustion zone, the degree of mixing achieved, and the waste matrix.
rn oo ill ~ u
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Page 3.6
Residence time requirements increase as combustion temperature is
decreased, as mixing is reduced, and/or as the size of discrete waste
particles is increased.
3.1.4 Mixing
Temperature, oxygen, and residence time requirements for waste
destruction all depend to some extent on the degree of mixing achieved in
the combustion chamber. This parameter is difficult to express in absolute
terms, however. Many of the problems involved in interpreting burn data
relate to the difficulty involved in quantifying the degree of mixing
achieved in the process unit, as opposed to the degree of mixing achieved
in another unit of different design.
In afterburners, the degree of mixing is determined by the specific burner
design (i.e., how the primary air and waste/fuel are mixed), combustion
product gas and secondary air flow patterns in the combustion chamber,
and turbulence.
In general, turbulence is an expression relating the physical relationship of
fuel and combustion air in the furnace chamber. A high degree of
turbulence (intimate mixing of air and fuel) increases the efficiency of the
combustion process. Burning efficiency is enhanced with increased surface
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822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone] I
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Page 3.7
area of fuel particles exposed to the air. Turbulence helps to increase the
particle surface area by promoting fuel vaporization and exposing the fuel
particles to the air in a rapid manner to initiate rapid combustion.
Turbulence is related to the dimensionless Reynolds number for the
combustion gases, expressed as:
Re= VD'
K
where D' = combustion chamber diameter, ft
V = gas velocity, ft/ s
K = kinematic viscosity, fr/ sec
Turbulent flow conditions exist at Reynolds number of approxima~!ly 2,300
and greater. Below this Reynolds number, laminar or transition flow
prevails and mixing occurs only by diffusion.
Additional mixing is achieved by the interaction of the high velocity exhaust
stream entering the chamber, the secondary combustion air jets, and the
supplemental burner flame pattern. High CO and O, readings will indicate
inadequate mixing, and the firing rate and excess air rate to the afterburner
can be increased, if necessary, to increase turbulence and correct this
problem. High CO with low O, is also indicative of a starved air condition
in the furnace.
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX [phone]
'Page 3.8
3.1.5 Stack Emissions
Air pollutant emissions from the incineration unit will be minimal. Small
quantities of non-haz.ardous pollutants such as CO and NOx (normal
byproducts of all combustion processes) will be emitted. The oxidation
reactions which convert CO to CO, occur at temperatures above 1500 to
1600°F. Since the secondary chamber will be operated at temperatures in
excess of 1800°F and sufficient excess air will be available for the reaction,
low CO levels ( < I 00 ppm) will be maintained in the flue gas.
3.2 INCINERATOR DESIGN
As stated above, the principal operating parameters that affect the overall soil
detoxification efficiency of the incineration process are the solid phase residence
time, the primary chamber (kiln) operating temperature, and the heat transfer rate
to the solid material. Since a portion of the organic constituents present in the
waste feed is simply volatilized in the primary chamber, overall system
performance also depends on the efficient destruction of the constituents in the
afterburner. The primary process variables which affect afterburner performance
are afterburner temperature, gas residence time, and oxygen levels.
Furthermore, the characteristics of the waste itself can influence overall system
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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Page 3.9
the presence of organic species which are precursors to products of incomplete
combustion, and the organic concentration in the waste feed must also be addressed
prior to actual incineration of the waste burn.
3. 2. I Qperatini: Conditions
o Primary Combustion Chamber Temperature
0
0
822 NEOSHO AVENUE
Incineration research and testing has verified that detoxification of
soil can be achieved with primary chamber temperatures less than
1,200 degrees Fahrenheit. In keeping with these waste tests, the
control temperature for the primary chamber shall be vaiied from
between 1,200 and 2,oocrF. The minimum temperature required
for detoxification of the contaminated soil be will determini::d during
the trial burn. The primary chamber temperature is regulated by
a control loop which includes a thermocouple, a proportional
controller, and a dedicated power center.
Primary Chamber Residence Time
The primary chamber residence times are adjustable between 10 and
40 minutes. These residence times are based on a furnace, effective
length of 45 feet. The residence time shall be set by adjiusting the
rotational speed of the kiln.
Secondary Chamber Temperature
Data from previous incineration projects and laboratory testing found
that TSCA and RCRA destruction efficiencies were obtiLined with
secondary chamber temperature between 1,550 and 2,200"F.
Temperatures of 1,600 to 2,200"F are generally tested during the
trial burn to determine the minimum temperature rec1 uired for
destruction. These temperatures will be maintained by a.djustment
of supplemental fuel and air or quench medium input to the
secondary chamber.
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Page 3.10
Secondary Chamber Residence Time
Secondary combustion chamber residence time is not an independent
variable. For a process unit of fixed volume and relatively consistent
feed, residence time is influenced by the temperature and excess air
rate employed. Gas flow rate at any point along the length of the
combustion chamber is a function of the temperature at the point,
the amount of excess air added up to that point, and the extent to
which the combustion reactions are completed at that point.
Therefore, calculation of the residence time requires a knowledge
of the temperature profile, excess air profile, and waste conversion
profile along the combustion chamber.
Since this detailed information can rarely, if ever, be determined
with a reasonable degree of accuracy, an alternate approach is
normally adopted. In this approach, the secondary chamber volume
(V) is divided by the exhaust gas flow rate ( q) specified at the
desired operating temperature and total excess air rate:
t =_y
q
Given a nominal design secondary chamber exhaust gas rate of
20000 acfm at 2200"F for the proposed waste and a chamber volume
of ,770 ft', the resulting residence time is 2.3 seconds.
Primary and Secondary Chamber Combustion Air
Combustion air input to the primary and secondary chambers will
be adjusted based on chamber temperature and secondary chamber
exhaust carbon monoxide and oxygen content. As feed enters the
primary chamber, the operator will adjust air input to either or both
chambers to maintain an oxygen level in excess of 3 % and a carbon
monoxide level below 100 ppm in the secondary chamber exhaust
or lower, as necessary, to achieve a 99.9 percent combustion
efficiency.
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Depending on the concentration of moisture and combustibles in the
feed material, the air to the primary chamber will be adjusted to
control temperature above the level demonstrated during the trial
bum. Thus, if the combustible content of the waste is high, a low
air combustion process will prevail.
In either case, the air flow to the secondary chamber will be
adjusted to maintain the set point temperature and produce an
oxygen concentration above 3 percent and a carbon monoxide
concentration below 100 ppm.
Waste Feed Rate
The waste feed rate to the primary chamber is limite:l by the
rotational speed of the kiln and the solids feed residence time
required for complete waste detoxification, and the combustion
product velocity in the kiln. The rotational speed of the kiln
determines the solids feed residence time while the combustion
product gas velocity impacts the particulate carryover from the kiln.
Furnace Draft
Both the primary and secondary chamber will be operated under a
slight negative pressure to assure all contaminants are destroyed
before being emitted into the atmosphere. The draft pressure in the
primary chamber will be maintained at approximately -0.1 inches
WC at its highest pressure point. The draft on the system is induced
by the exhaust blower.
3.2.2 Waste Characteristics
The waste characteristics that can affect overall system performance include
but are not limited to heating value, moisture content, halogenated
compounds content and toxic metals content.
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Heating Value
The heating value of a waste corresponds to the quantity of heat
released when the waste is burned, commonly expressed as Btu/lb.
Ber...ause combustion reactions are exothermic, all organic wastes
have some finite heating value. The magnitude of this heating value
must be considered in establishing operating conditions for an
incineration system. In general, the heating value of a solid waste
material has the greatest impact on incinerator feed throughput rate.
The highest feeds rates are achieved with low-BTU, low-moisture-
content soil. The lowest throughput rates are associated with high-
BTU materials. Figure 3-1 illustrates the difference in throughput
ralP'..s related to changes in the heating value.
Moisture Content
High moisture content usually, though not always, has a negative
impact on the incinerator throughput rate. Because water is an
ultimate oxidation product, it has no heating value. A portion of
the heat generated by the combustion of the organics in the waste
is consumed in vaporizing and heating the moisture up to
incineration temperature. Therefore, high-moisture content feed
reduces the throughput rate. High moisture in the feed can also
cause thermal shock to the refractory at the inlet to the rotary kiln
and ignition quenching at the beginning of the volatiles burnout
zone.
Th~ latter phenomena has a negative effect on the solids time-
temperature profile in the kiln and can reduce the organic burnout
efficiency. However, for high-BTU content wastes, high-moisture
content can be desirable for its cooling effect in the kiln.
The effects of varying moisture contents in wastes with a constant
BTU value are shown in Figure 3-2.
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Halogenated Compounds Content
Chlorine is commonly present in the contaminated soils, sludges and
organic liquids found at hazardous waste sites. Organic chlorine
is converted to HCl in the combustion process. With the organic
chlorine normally found at waste sites, destruction can be achieved
at secondary combustion chamber temperatures of 1600°F or higher.
The HCl must then be scrubbed from the gas in the air 1xillution
control equipment. A high chlorine content may reduce the system
throughput if the air pollution control equipment is not sized
properly to remove the HCl at normal feed rates.
Toxic Metals Content
Volatile toxic metals can be vaporized in the kiln and secondary
combustion chamber and subsequently condensed as very fine
particulate in the quench and scrubbing system. This p,esents a
submicron particle emissions problem with the added concern of
particle toxicity.
A second problem with toxic metals is that they remain in the ash
residue in a form susceptible to leaching as determined by the EP
and TCLP tests. The leaching characteristics of metals in
incinerator ash are difficult to predict because they depend on case-
specific factors such as the ash matrix, chemical forms of the
metallic species in the feed and the primary chamber operating
co:iditions.
3.3 DESIGN BASIS ASSUMPTIONS
GDC Engineering Inc. has devised an incineration system to decontaminate the
wastes at the Hoechst Celanese plant in Shelby, NC, based on the following
assumptions:
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Waste Knalysis
moisture 40%
carbon 36.1 %
hydrogen 7.8%
oxygen 54.8%
nitrogen 0.003%
sodium 0.004%
chlorine 0.03%
ash 1.3%
antimony 4,000 mg/kg
lead 0.75 mg/kg
.upper 5,440 BTU/lb
heating
value
arsenic < 0.05 mg/kg
barium < 0.1 mg/kg
cadmium < 0.01 mg/kg
chromium< 0.03 mg/kg
lead < 0.005 mg/kg
mercury < 0.0005 mg/kg
selenium < 0.005 mg/kg
silver < 0.05 mg/kg
Waste Characteristics
average
average
average
average
average
average
average
average
average
average
average
Page 3.14
range 6-40%
range 0.013-0.05%
range 87-6,400mg/kg
range <0.02-53 mg/kg
range < 2000-7800
BTU/lb
0 Mixture of GRU material and soil with no large rocks, debris or
other foreign objects.
0
0
Scrubber effluent water can be discharged into the plant treatment
system after any pretreatment.
Waste analysis can be described in general by duLong's
approximation.
The incinerator is designed to process approximately 2,500 lbs/hr of waste with
an average of 30% moisture and a heating value of 5000 BTU/lb.
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-------------------12
11
10
9
~ L ::, 8 0 .r::.
L~ o m 7 a. "O
m C ..a 0 6 -m ~::,
~ 0 -.r::. a f--5 O'. ~
"O ~ 4 ~ "-
3
2
1,000.00 2,000.00 3,000.00 4,000.00 5,000.00
BTU per pound of Feed Material
--i.-..l ;._\ i.,.,_ f I i J I ; i
GENERAL EFFECT OF BTU ON FEED RA TE HOECHST CECANl=SE CORP.
Remediation Project
Shelby, North Carolina
GD C c:~~L~~~~~~~r~, INC. ~o....,w_N_._J_c _,2_/_,2_/_e_9_-+P-R_o_J_._N_o_._9_o_-s_o_3_~
ENG.Cc· SHEET OF
(504 )383·8556
fl22 kEOSHO AVENU[
ft A.TON ROUGE, LA. 70~02 CHK D.
r:1
FIGURE.NO .. •
3-1
-------------------
3
2.8 f--
2.6 f--
2.4 I-
2.2 f--
~ L ::, 2 -0 r.
L~ • m 1.8 -
0. 'O m C 1.6 -.0 0 -m ~:, 1.4 f--• 0 ~ r. 0 f-(l'.~ 1.2 f--
'O • 1 f--• lL
0.8 f--
0.6 f--
0.4 f--
0.2 -
0 ' ' I
0.10 0.20 0.30
Per Cent Moisture in Feed Material
GENERAL EFFECT OF MOISTURE
ON FEED RATE
HOECHST CELANESE CORP.
Remediation Project
Shelby, North Carolina
GDC ENGINEERING INC. OWN. Jc 12112/89 PROJ. N 0. 90-503
CONSULYtHC [NGINE[RS t"'.:CE_N_G--------,~-----'-----1
· cc-r /,-./r,_/<;?7 SHEET OF
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BIi.TOH ROUGE• LA. 701!102 · 3-2 ,. -.... -·----··----------.... -----------------------'----------
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4.0 SAMPLING AND MONITORING PLAN
4.1 PROCESS STREAM SAMPLING
A summary of the sampling procedures that will be used during the trial bum for the
Hoechst Celanese, Shelby project are presented in this section. Table 4.2 presents the
comprehensive sampling and monitoring schedule for the trial burn. All sampling and
monitoring will be conducted according to this plan. Grab samples of the feed streams,
the processed material ash and the scrubber effluent stream, Figure 4-1, will be collected
at appropriate time intervals for preparation of representative composite samples. All
container sizes are presented for example only and may vary during the actual test runs.
4.1.1 Solid Waste Feed Material
A grab sampling procedure will be used to obtain samples of the solid waste feed
to the inlet of the RK feed hopper. A sample will be collected approximately
every fifteen minutes during periods of stack sampling each day of the pr,etest burn
and the actual trial burn. These samples will be collected in a wide-mouth glass
jar which will be sealed with a Teflon-lined screw cap. The samples collected
during the sampling period each day will subsequently be composited by the
analytical laboratory to produce a flow-proportioned composite sample fo:r analysis.
The composite sample will be of such a size that it can be split into replicate
samples for any f:dditional analyses that may be required.
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Page 4.2
Feed rate data will be furnished to the laboratory with each day's samples for the
purpose of determining the amount of each sample that will be required for
producing the daily flow proportioned composite.
The first grab sample will be taken when stack sampling has begun. No feed
samples will be taken after stack sampling has been completed.
4.1.2 Product <Ash)
The product (ash) from the incineration system will be collected from the discharge
chute of the kiln. A grab sample will be taken every fifteen minutes during the
sampling periods iof the trial bum. The grab samples will be collected in stainless
steel I-liter beakers, equipped with handles. When the sample has cooled enough
to handle, an aliquot will be taken (measured in a clean glass container of
appropriate sire) and added to a glass composite sample container. This container
will be capped with a Teflon-lined cap after each aliquot addition. Flow
proportioned increments of subsequent grab samples of the ash will be added for
each grab sampling event. At the end of each sampling period, the container for
the composite sa.,iple will be sealed and thoroughly mixed by shaking until a
homogeneous sample is obtained. This composite sample will be sent to the
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laboratory for analysis.
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4.1.3 Scrubber Influent Samplini:
Duplicate samples of scrubber influent water will be collected in glass jars with
Teflon-lined screw caps, at the beginning of each sampling run. One sample will
be submitted to the analytical laboratory at the end of each sampling day, and the
duplicate sample will be retained for possible future use.
4.1.4 Scrubber Effluen'. Samplini:
The scrubber effluent will be sampled for analyses of the POHC content for use
in the determination of the destruction efficiency. The scrubber water sampling
location will be a tap on the scrubber unit which is shown in Figure 4-1.
Two-ounce grab samples of the scrubber water will be taken every fifteen minutes
during the sampling period. Eight (8)-ounce glass jars will then be filled to the
top and sealed with Teflon-lined caps. At the end of each sampling period, a flow
proportioned COll)posite sample for that period will be made from these samples
in a glass jar which will be sealed with a Teflon-lined cap.
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4.1.S Exhaust Gas Sampling
During each sampling run, exhaust gas emissions will be sampled for subsequent
determination of POHC content and other parameters which will be described in
this Section.
An EPA Modified Method S (MM5) sampling train will be used during the
sampling program to obtain samples for analysis of semivolatile POHCs. A
separate Method S sampling train will be utilized to collect samples for particulate
and HCI analyses. A Method 0030 (VOST) sampling train will be used to collect
samples for analysis of volatile organics. The sampling train is described in detail
in Appendix A.
4.1.S.1 Pa,"ticulate Matter and HCL
Particulate matter and hydrochloric (HCI) acid species will be
simultaneously sampled using a Method S sampling train. The
im;,inger solutions of the standMd reference method system will be
modified to include 1.0 N NaOH (second impinger) to ensure the
efficient collection of HCI.
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Samples will be collected from a representative number of sampling
points in the 24-inch diameter stack. The number and location of I
these points will be determined in accordMce with EPA Reference
Method I. Sampling times will be based upon the RCRA DRE .
requirements for the test program and the anticipated concentrations I
of POHC's in the waste feed material. All sampling and leak check
procedures will be conducted in accordMce with the requirements
of the referenced method. --~ I
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Page 4.5
I Pa.."'ticulate matter will be recovered from the front half of the
sampling train (nozzle, probe, and filter housing). The associated
particulate filter will be replaced in its original Petri dish for
transport to the laboratory for subsequent analysis. The impinger
solutions will be measured volumetrically and recovered for
transport to the laboratory.
All components of the sampling train that have the potenti;;~ to come
in contact with samples for organic analysis will be subjected to
rigorous cleaning procedures prior to their use. All glassware will
be capped with solvent rinsed aluminum foil for transport to the job
site.
The organic sorbent and field solvents will be subjected to QA/QC
evaluations in accordance with USEPA Level I procedures prior to
th~ir use at the Hoechst Celanese, Shelby, facility.
'
A field biased blank train will be assembled and recovered in the
field in conjunction with each phase of the trial burn to quantify any
biases introduced through the handling and transport of the samples.
Upon completion of the sampling run, the train will be sealed and
removed to a designated clean area for recovery. The front half of
the train will be brushed and rinsed with appropriate solvents. The
front half rinse will be recovered into a pre-cleaned an1ber glass
bottle with a Teflon cap liner. The container will then be sealed.
The particulate filter will be replaced into its original glass Petri dish
and sealed for transport. The sorbent module will be sealed with
its original ground glass joints.
The volume of the condensate will be measured in a pre-cleaned
gri.duated cylinder and transferred to an amber glass container. The
back half of the train (back half of the filter impinger) will be rinsed
with solvent into the recovered condensate sample. The: container
will then be vented and sealed.
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4.1.5.2
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Page 4.6
Sampling For Semivolatile Organics
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The concentration of the organic species of interest in the I
combustion gas from the incineration system will be quantified using
the Modified Method 5 train described in SW-846, Method 0010.
A complete summary of this sampling system and method is I
presented in Appendix A. ·
The sampling train will consist of a glass-lined, heat traced probe I
with a stainless steel, button hook nozzle with an attached
thermocouple and pilot tube assembly. A glass fiber filter heated
to 248 (+/-25) degrees F., a water-cooled condenser, and sorbent I
module containing pre-cleaned XAD-2 resin, maintained at < 68
degrees F. are located downstream of the probe assembly. The
organic module components shall be oriented to direct the flow of I
condensate formed vertically downward from the conditioning
section, through the adsorbent media, and into the condensate
knockout trap. The knockout trap is usually similar in appearance I
to an empty impinger directly underneath the sorbent module; it may
be oversized but should have a shortened center stem (at a
minimum, one-half the length of the normal impinger stems) to I
collect a large volume of condensate without bubbling and
overflowing into the impinger train. All surfaces of the organic
module contacted by the gas sample shall be fabricated of I
borosilicate glass, Teflon, or other inert materials. .
! ' To determine the stack-gas moisture content, four 500-ml impingers,
connected in series with leak-free ground-glass joints, follow the
knockout trap. The first, third, and fourth impingers shall be of the
Greenburg-Smith design, modified by replacing the tip with a 1.3-
cm ('I, inch) I.D. glass tube extending about 1.3 cm('!, inch) from
the bottom of the outer cylinder. The second impinger shall be of
the Greenburg-Smith design with the standard tip. The first and
second impingers shall contain known quantities of 1.0 N NaOH
solution. The fourth shall contain a known weight of silica gel or
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equivalent desiccant. Purification of the XAD-2 resin used for the I
collection of the semi-volatile organics will be carried out according
to the procedure described in Section 4.3.1.3 of Appendix A.
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4.2
4.1.5.3
4.1.5.4
Page 4.7
Sampling for Volatile Organics
Volatile organics from the stack gas effluent of the incinerator will
be collected and analyzed by the procedures outlined in Methods
5030 and 8240, SW-846. This method employs a 20-liter sample
of effluent gas containing volatile POHCs which is withdtawn from
the effluent source at a nominal flow rate of 1 liter/min .. , using a
glass-lined probe and a volatile organic sampling train (VOSn. The
volatiles are collected on Tenax traps which are subsequently
thermally desorbed for GC/MS analysis. Purification of lhe Tenax
re~in prior to use will follow the same protocol described for the
XAD-2 resin in Section 4.3.1.3 of Appendix A.
This method will be calibrated by the procedure described in Method
0030 with the exception that an appropriate amount of
monochlorobenzene will be added to the calibration solution in
addition to the other compounds described.
I
Sampling for Oxides of Nitrogen
Oxides of nitrogen (NO.) emissions sampling will be conducted in
accordance with the procedures set forth in EPA Method 7.
Continuous sampling of exhaust gas for the NO, determination will
be conducted during each sampling run. The stack sampk:r will use
an EPA approved continuous ultraviolet NO, analyzer.
CONTINUOUS EMISSION MONITORING
Continuous monitoring of the exhaust gas will be conducted for oxygen, carbon
monoxide, and carbon ~ioxide. The sampling location for the continuous monitoring
system of oxygen will be' at the outlet of the secondary chamber, while carbon monoxide
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Page 4.8
be equipped with a sami:le conditioning system and each will be calibrated prior to and
during use as required.
Continuous monitoring for indicators of POHC destruction efficiency, such as oxygen,
carbon monoxide and carbon dioxide levels, process temperatures, residence times and
feed rates is utilized to ensure complete control of system parameters required for efficient
POHC destruction. Sin~ there are no techniques available for continuous monitoring of
POHC emissions, the EPA has adopted this procedure as a means of ensuring complete
POHC destruction for operation of the system after completion of the Trial Bum Sampling
and Monitoring Program. System interlocks are provided to automatically terminate the
feed of contaminated material to the system whenever such operating parameters deviate
from setpoints established to ensure complete POHC destruction.
4.3 CONTINUOUS MONITORING PROCEDURES
i
A continuous monitoring system will be used to monitor exhaust gas carbon monoxide,
carbon dioxide, and oxygen levels during the trial bum and throughout the incineration
project. The continuous monitoring system will consist of a sample gas conditioning
system, gas analyzers, and data acquisition and recording system.
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Page 4.9
4.3.1 Sample Acxiuisition and Conditioning
The exhaust gas will be sampled from the afterburner exhaust duct for oxygen
and from the stack for carbon monoxide and carbon dioxide. Th•! carbon
monoxide and carbon dioxide samples will be drawn through a gas conditioning
system. The conditioning system is designed to deliver a sampk stream
representative of the exhaust gas stream to the sample analysis substream. Since
the stream must be clean and dry for proper analyzer operation, a spun glass fiber
filter followed sequentially by a mist filter, secondary filter, and a thermo electric
condenser are used for particulate and moisture removal. A system for the
introduction of zero and span gases is also included for analyzer calibration.
The Thermox Oxygen Meter does not require sample conditioning.
4.3.2 Sample Analysis
The carbon monoxide concentration will be determined using a Non-Dispersive
Infrared (NDIR) Carbon Monoxide Analyzer with measuring range of O to 500
ppm full scale. The analyzer will be calibrated at O percent carbon monoxide with
ultra pure nitrogen and two other appropriate span gases before and after each
sampling run and periodically throughout the Hoechst Celanese, Shelby, project.
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Page 4.10
A calibration equation will be determined from a linear regression of these known
gas concentrations versus instrument response. The equation used · to convert
instrument signal to concentration units is as follows:
Concentration = m(response) + b, where;
m = slope of calibration curve
response = instrument signal (volts)
b = intercept of calibration curve
Oxygen concentrations will be determined using a Thermox Oxygen Analyzer with
a measuring range of 0 to 22 percent oxygen full scale. The analyzer will be
calibrated with a zero and two span gases in an analogous fashion to the previously
described carbon monoxide monitor.
Carbon dioxide concentrations will be determined using a NDIR Carbon Dioxide
Analyzer with a measuring range of Oto 40 percent carbon dioxide. This monitor
will be calibrated with a zero and two span gases in an analogous fashion to the
previously described carbon monoxide and oxygen monitors.
Table 4.2 lists the specifications for all of the above instruments.
The continuous emissions monitors will be calibrated once a day during the
sampling program from cylinders containing (plus or minus 1 percent) calibration
gases. This gas will be prepared according to USEPA protocol. The monitors will
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Page4.ll
also be certified by York Research Consultants during the trial bum tests to assure
consistency of tl:ese instrument readings with the independent analyses of the
process gases by other analytical methods as described previously.
4.4 PROCESS MONITORING
Throughout the entire incineration processing program, system operating parame:ters will
be monitored and recorded. The parameters to be monitored include, but are not limited
to, the following:
o Primary chamber temperature
o Secondary chamber temperature
o Contaminated material feed rate
o Primary chamber residence time
o Calculated secondary chamber residence time
o System pressure (draft)
o Oxygen in the· secondary chamber exit gases
o Carbon monoxide concentration in stack exhaust gases
o Carbon dioxide in stack exhaust gases
System alarms and interlocks are very important to any process control system since they
aid the operator in supervising the overall operation of the process vari2bles and
equipment, and provide for automatic control of system parameters, such as fetxl cutoff,
in the event of system upset. An alert is initially indicated by a horn mounted in the
control cabinet followed by the lighting of a module in the annunciator panel which
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FA:< [phone]
Page 4.12
silenced by pressing the Alarm Acknowledge pushbutton. The illuminated module on the
'
annunciator will stay lit ':!owever, until the trouble is resolved.
The annunciator panel also incorporates a "TEST" button. This button will be used to
test for burned out light bulbs behind the panels. This does not test each device, only the
alarm panel. It is recommended that the alarm panel test be exercised each shift.
In the case of any control panel alarm the operator will first confirm that the alarm is
based on an actual occurrence and is not a malfunction of a sensing element. In all cases
a visual inspection of an.indicated failed device should be performed. Also,
process conditions up stream and downstream of an alarm location should determine the
validity of the alarm. In the case of a false alarm, a process upset can be avoided by
emergency manual operation of the system or the directly affected device.
A complete description of the incineration system monitoring and control systems are
presented in Section 5.0.
4.4.1 Incineration System Interlocks
Prior to a:iy incineration start-up, all system interlocks will be tested to
verify proper operation. The interlocks include, but are not limited to, the
following:
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@ill /II rs H• ""·" •• __ : -. • .4 u· ~ :: ·-·
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Page 4.13
o Rotary kiln failure
o Ash cooling screw failure
o Primary chamber pressure high ( 30 seconds)
o Feed chute damper closed
o Feed prep section temperature high
o Primary chamber temperature high ( 5 minutes)
o Primary chamber temperature low
o Primary exhaust temperature high ( 5 minutes)
o Secondary temperature low
o Secondary chamber burner failure
o Secondllry exhaust temperature high ( 30 seconds)
o CO high ( 2 minutes)
o ID fan failure
The emergency backup power system and quench system will also be tested
during the miscellaneous testing task.
A complete description of the incineration system monitoring and control
systems is presented in Section 5.0.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
CD N N
z m
0 (/)
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► < m z
©perating Scale
Sensitivity Ranges en ► ~perating Temp.
:IJ ~nalysis Method
Gl
!T1 tinearity
C
~eproducibility
►
~rift
0 N
Joi se Leve 1
~ w CD w m u, u,
°'
,,
► X
u,
0 ,..
w CD w "' __,
CD "'
(----
·,·~-•-i --·----' __ .-•
,--------. -. ~-:-.:.J r_ ·::} i L _ __,,,.__
s·~'.;~: .. ·
L.-------
c.:::·., ,
l-~ ;_ -
TABLE 4.1
ANALYZER SPECIFICATIONS OF CONTINUOUS MONITORS
.C.0.2 ANALYZER
0-20%, CO2 full scale
0-40% CO2 , full scale
24 to 122 degrees F
Nondispersive Infrared
+/-1% of full scale
+/-1% of full scale
+/-2% of full scale
per week in both
zero and span
0.5% of full scale
in most sensitive
range
CO ANALYZER
0-200 ppm CO, full scale
0-500 ppm CO, full scale
24 to 122 degrees F
Nondispersive Infrared
+/-1% of full scale
+/-1% of full scale
+/-2% of full scale
per week in both
zero and span
0.5% of full scale
in most sensitive
range
Q2 ANALYZER
0.5-21.9 % 02, full scale
32 to 122 degrees F
Zirconium Oxide
Electrochemical Cell
+/-1% of full scale
0.1% of sensor output
per month
C. ·-;_j -------------------
-0, "' "' z m 0 (J) I 0 )> < m z C m CD )> ___, 0 z OJ 0 C Gl !'1 r 0 C iii )> z )> "'-' 0 0, 0 "' -;;; 0 ~ w 0, w a, "' "' O> ~ )> X -;;; 0 ,. w 0, "' "' "'-' 0, "' - - -GC/MS ~ yolatiles 1. Feed 4·5 o Sptke 1 o OupUcate 2. Processed 4·5 Material (ash) o Sp! ke o Duplicate 3. Scrl.t:iber Water o Spike o Ol4)l icate o Blank 4. Stack Gas 4·5 o Spike 1 o Duplicate o Blank Total: 16· 19 §J c:;;-:::· c::.,. ~.·.· .. C::L., c::::-· ' u --GC/MS jemf~!atilu 4-5 1 4-5 4-5 1 1(fnlet water) 4-5 1 22·25 --- -- ---TABLE 4.2 _, OF ANALYTICAL TESTING REQUIRED FOR THE TRIAL &JIN EP Toxicity Total Metals fi4eta!s Ontr {EPTOX L ist2 4·5 1 4-5 4·5 1 5·6 11-13 Total Chlorjdf: 4·5 4-5 1 1(fnlet water) 11·13 !ill 4·5 5·6 Total Particylates 4·5 5·6 -----~ IQ£ fil 4·5 1 4(fnlet water) 3 9·10 3
co ~ "' "' z TABLE 4.3
m 0 SCHEDULE FOR SAll'LIIIG All> AIIAI.YSES DURING THE TRIAL Bll!N (f)
I 0
► < Parameters Saq,I Ing Saq,I Ing Total No. Of Field
~ream For Anal:t:sis Besoous i bj! U:t: Sgie T~ F reoJene:t: ~ D!::52~ I !catts Blanks
C
'f. Feed Volatiles (GC/MS) Sanplfng Contractor Grab 15-Mfnute 1-2 Pretest Spike
Semivolatiles (GC/MS) (for Coq:,osfte) Intervals Coq:,osfte Saq:,les, Spike
3 Test S8111)les
CD Total Chloride 15-Mfnutes
► -l TCLP Metals (total) 15-Mfnute 0 1-2 Pretest 1 Spike z Intervals COCll)Osfte S9R1Jles, :JJ 3 Test Sarrples 0 C ~ Processed Volatiles (GC/MS) Sanplfng Contractor Grab 15 Minute 1 ·2 Pretest Spike
r Material Semfvolatiles (GC/MS) (for Coq:,osite) Intervals COIJ1X)sfte Saq>les, Spike
0 (esh) EP toxicity (metals) 3 Test Sarrples Spike C TCLP Metals iii ► TCLP Metals (total) Saq::,ling Contractor Grab 15-Mfnute 1-2 Pretest Spike z Cfor Coq:,osfte) Intervals Cocrposite Sanples, ► 3 Test Sa,rples --< 0 i Scrubber Semivolatiles (GC/MS) SBfl1lling Contractor Grab 15-Mfnute 1-2 Pretest Spike
Water (for Corrposite) Intervals Corrposfte Saq:,les,
Total Chloride Spike Inlet Water roe < F fl terec:t> Spike Inlet Water
i. Stack Gas Semivolatiles (GC/MS) Saq::,lfng Contractor MM·5 R111/Day 4·5 Spike ~ Volatiles (GC/MS) Method 0030 R111/0ay 4·5 Spike w co Particulates MM·5 R111/Day 4·5 w HCL MM·S Run/Day 4·5 6, u, NO Cont. Monitor Continuous u, co,co2 Continuous a, N0IR
02 §J El ectrochemi cal Continuous
Cell Monitor
5. Exhaust Gas 02 Saq:,ling Contractor Electrochemical Continuous -n eel l Monitor ► X ~' vi 0 ~ w r:--:---co w
"' c:..::--,_ .
--< -· ,. co
"' s: - -
c:-··i - --- ---------- ---
-a, "' "' z m 0 en I 0 )> < m z C m CD )> ---< 0 z :D 0 C Gl !TI r 0 C cii ,; z )> --., 0 a, 0 "' '" 0 ~ w a, w "' "' "' a, .,, "' ;,< "' 0 ~ w a, w " --., a, "' -~ 1. Feed --2. Processed Material (ash) 3. Scrtilber ~ater 4. Stack Gas §J §B $~ ~ c-:;_\ - -- -- - -- ---- -TABLE 4.4 SUIWIY Of ANALYTICAi. IETIIOOS FCII TRIAL BU!N SAIW'LES Ana\ysls Volatiles (GC/MS) Semivolatllea (GC/MS) Total Chloride Volatiles (GC/MS) Semivolatiles (GC/MS) EP Toxicity (Metals Only) TCLP Metals (Total) Semfvolatfles (GC/MS) Total Chloride TOC Volatiles (GC/MS) Semivolatiles (GC/MS) Particulates HCL "ethod(s) 8240, 511-846 8270, 511-846 8240, SW-846 8270, 511-846 Analysis by 6000 or 7000 series methods, Extraction by 1310, S~-846 Method 8270, 511·846 Method 9252, 511·846 Method 9060, sw-846 Method 8240, SW-846 Method 8270, 511·846 Gravimetric SAC Methods 403 --~
-------------------
1
V✓aste ~►
1.WASTE FEED MATERIAL
2.INCINERATOR ASH
3.SCRUBBER INFLUENT
4.SCRUBBER SLOWDOWN
5.STACK EXHAUST GASES
!Fuel
Primary
Kiln
Secondary
Combustion 1 ~-
Chamber
WATER'IN !3
Scrubber 1 ~
Blow Down
Stack
II I
i==
HOECHST CELANESE CORP:
SAMPLING STREAMS
Shelby, North Carolina
GOC ENGINEERING INC. DWN.
JC 12/11/89 PROJ. N 0. 90-503
CON SU LT ING [NGIN.,., r=E:-:-N-:-G-. --------+-S_H_E_E_T _____ -1
Cf, 12,/0,IN OF
822 NEOSHO AV[NU( l"":-C'.":"HK...,_.-:-D-. ~~--1-"=+-"-'---+-----------1
!ATON ROUGE' LA. 70002 • FIGURE NO. . 4-1
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5.0 THERMAL TREATMENT UNIT PROCESS MONITORING AND CONTROLS
SUMMARY
Presented in the following sections is a list of system alarms, including function of each
alarm, its cause, and corrective action. The alarm list is divided into three classes:
"Interlocking", "Non-Interlocking", and "Warn" alarms.
Interlocking alarms cause the automatic feed cutoff, the controlled automatic shutdown
of certain critical components, and/or the operation of the diesel driven backup I.D. fan
and emergency quench water pump of the pollution abatement system. These shutdowns
are designed into the control system to ensure proper waste processing and for component
protection. Non-Interlocking alarms do not cause controlled automatic shutdowns but do
indicate operational problems in the system. Both Interlocking and Non-Interlocking
alarms require urgent attention. They have both visual and audible annunciation at both
the Process Control Center (PCC) and on the equipment floor. The 'Warn' alarms are
pure! y screen messages to the Process Control Room Operator.
The alarm lists are grouped according to their location in the system:
RK -Rotary Kiln
SCC -Secondary Combustion Chamber
APCE -Air Pollution Control Equipment
The system has light indicator panels at each module, as well as a central annunciator
panel mounted on the outside of the Process Control Center (PCC). The light indicator
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Page 5.2
panels show the current status of all major components in that area by using green
indicator lights to signify on (or normal) conditions and red indicator lights to show alarm
conditions. The central annunciator panel contains an alarm horn used to sound an alarm
condition in any of the system modules and three (3) red indicator lights to show the
equipment which is in alarm (RK, SCC, APCE). A red flashing strobe light (one each -
mounted on top of the p2.I1el per module) confirms the module in alarm.
Inside the PCC trailer there is an operator console which also has the 3 red lights which
indicate the module in alarm. In addition, there is a set of green indicator lights arranged
by module to indicate motors are "on" or some other necessary conditions are normal.
The PCC operator console also has an alarm horn to sound an alarm condition in the
system modules.
There is also a two terminal computer system which includes graphic screens that
duplicate the green and r:d indicator lights of the panels on the 3 modules. There is an
alarm message for every alarm and an alarm summary of the current unresolved alarms.
5.1 INCINERATION SYSTEM MONITORING
5 .1.1 RK Interlocking Alarms:
Alarms which cause combustion shutdown and auto feed cutoff to
RK:
M::ster Off
[ID [Af ill~ u
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5.1.2
5.1.3
822 NEOSHO AVENUE
Combustion Air Pressure Low
Main Gas Pressure Low
Main Gas Pressure High
Primary Exhaust Temperature High
Page 5.3
Alarms which cause auto feed cutoff of RK solid waste:
Burnout Air Pressure Low
Feed Hopper Stopped
System Draft Pressure Low
A£h Discharge Conveyor Stopped
sec Interlocking Alarms:
Alarms which cause combustion shutdown and auto feed cutoff to
RK:
Master Off
Combustion Air Pressure Low
Main Gas Pressure Low
Main Gas Pressure High
Alarms which cause auto feed cutoff of RK:
APCE Duct O, Analyzer Alarm
APCE Interlocking Alarms:
Alarms which cause auto feed cutoff to RK (If alarm:; are not
corrected within 1 hour, controlled shutdown of the RK and/or
sec combustion systems by an operator are necessary):
Master Off
Main ID Fan Off
Alarms which cause auto feed cutoff to RK:
Quench Backup Thermocouple In Use
Quench Temperature HI-HI lill 00 ill ~ lf
BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
[Geo] I
5.1.4
5.1.5
5.1.6
822 NEOSHO AVENUE
Page 5.4 I
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CO(@ 7% 0,) Rolling Average HI-HI I
Effluent pH LO-LO
Alarms which do not cutoff feed but do cause component I
shutdowns:
Caustic Tank Level Low
Mixing Tank Level Low
Effluent Tank Level Low
Compressor #I Trouble
Compressor #2 Trouble
RK Non-Interlockinc Alarms
Cross-Over Duct Temperature High
Ash Discharge Temperature High
Chamber Temperature Low Deviation
SCC Non-Interlockin& Alarms
Pilot Burner Off
APCE Duct O, Low
APCE Non-Interlockinc Alarms
Scrubber Fan Off
Caustic Pump Off
D.ustic Mix Pump Off
Effluent Pump #1 Off
Effluent Pump #2 Off
Emergency Quench Water Flow LO-LO
Quench Nozzle #I Water Flow LO-LO
Quench Nozzle #2 Water Flow LO-LO
Entrainment Sep. Stage I Water Flow LO-LO
Entrainment Sep. Stage 2 Water Flow LO-LO
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Entrainment Sep. Stage 3 Water Flow LO-LO I
Srnilibtt N-I ~~, Mi, Fmw ~® IB fu ~ ~
1
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Scrubber Nozzle 2 Caustic Mix Flow LO-LO
Scrubber Nozzle 3 Caustic Mix Flow LO-LO
Scrubber Nozzle 4 Caustic Mix Flow LO-LO
Sc:11bber Nozzle 5 Caustic Mix Flow LO-LO
Wash Ring Water Flow LO-LO
System Draft Pressure LO-LO
pH m-LO Deviation
Quench Nozzle 1 Air Pressure LO-LO
Quench Nozzle 2 Air Pressure LO-LO
Scrubber Nozzle 1 Air Pressure LO-LO
Scrubber Nozzle 2 Air Pressure LO-LO
Scrubber Nozzle 3 Air Pressure LO-LO
Scrubber Nozzle 4 Air Pressure LO-LO
Scrubber Nozzle 5 Air Pressure LO-LO
Entrainment Separator Differential Pressure HI-HI
System Air Flow Lo-LO
Make-up Water Pressure Low
S~kCO, m-m
Sti.ck Temperature m-m
S12.ek Velocity m-m
Fan Dampers Not in Position
Caustic Tank Temperature LO
Caustic Tank Temperature m
5.1.7 RK Warn Alarms
5.1.8
To be determined
SCC Warn Alarms
Combustion Chamber Temperature HI-LO Deviation
AP,CE Duct Temperature High
APCE Duct O, Low
AFCE Duct O, High
Page 5.5
rIDWfil~U
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FA): [phone]
S.1.9 APCE Warn Alarms
Quench Temp High
Effluent pH Low
Stack Velocity High
Stz.ck CO, High
Stack CO (7% 0,) High
Stack CO (7% 0,) Rolling Average High
Emergency Quench Water Flow Low
Quench Nozzle 1 Water Flow Low
Quench Nozzle 2 Water Flow Low
Entrainment Sep. Stage 1 Water Flow Low
Entrainment Sep. Stage 2 Water Flow Low
Entrainment Sep. Stage 3 Water Flow Low
Scrubber Nozzle 1 Caustic Mix Flow Low
Scrubber Nozzle 2 Caustic Mix Flow Low
Scrubber Nozzle 3 Caustic Mix Flow Low
Scrubber Nozzle 4 Caustic Mix Flow Low
Scrubber Nozzle 5 Caustic Mix Flow Low
Wash Ring Water Flow Low
Quench Nozzle 1 Air Pressure Low
Quench Nozzle 2 Air Pressure Low
Scrubber Nozzle 1 Air Pressure Low
Scrubber Nozzle 2 Air Pressure Low
Scrubber Nozzle 3 Air Pressure Low
Scrubber Nozzle 4 Air Pressure Low
Scrubber Nozzle 5 Air Pressure Low
En1trainment Separator Differential Pressure High
System Air Flow Low
System Draft Pressure Low
Page 5.6
5.2 EMERGENCY AND UPSET CONDffiONS AND ACTIONS
S.2.1 RK Interlocking Alarms
1) Alarms which cause combustion shutdown and auto feed cutoff
to RK:
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
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0
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Page 5.7
Master Off
This alarm indicates that Power to the RK operational panel
has been turned off.
Response:
A. Check the RK Operational Panel to determine that
power is available.
B. If Power is available at the panel, then Press 'Master
Start' Pushbutton at the panel to have 'Master On'.
Combustion Air Pressure Low
This alarm occurs when the combustion air pressure drops
below a preset minimum value. This alarm is one of the
interlocks to close the main gas valve.
Response:
A.
B.
C.
D.
Check the indicator lights to see if the combustion
air blower is running. If not, restart blower.
Check for blown fuses and/or tripped overload heaters
and replace/reset as necessary.
Check for fouled inlet filter and/or blower impellers.
Check motor starter for correct operation.
E. Check wiring to motor and replace if necessary.
F. Repair/replace motor as necessary.
Main Gas Pressure Low
BATON ROUGE. LOUISIANA 70802 [phone] FAX[phone]
822 NEOSHO AVENUE
0
Page 5.8
Response:
A. Inspect the gas line and/or main pressure reducing
regulator for leaks or other obvious damage. Make
sure all petcocks in the gas line are closed. Check
incoming gas line pressure and compare with
prescribed value.
B. If there is no obvious damage and measured pressure
is OK, then attempt to restart the system. If the
problem persists, then check the operation of the
pressure switch and replace if it is found to be
defective.
Main Gas Pressure High
This alarm occurs when the main gas pressure rises above
a preset minimum value. This alarm is one of the interlocks
that closes the main gas valve.
Response:
A. · Check the setting of the main gas reducing regulator
B.
C.
and correct as necessary.
Check the incoming gas line pressure and compare
to the prescribed value.
Check for correct operation of the main gas high
pressure switch.
o Primary Exhaust Temperature High
A thermocouple monitors temperature in the primary exhaust
duct and the alarm is initiated by the temperature instrument
when the exhaust temperature exceeds a preset value
(20SO"F).
Deactivates burner solenoids until the temperature alarm
point is no longer exceeded.
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Page 5.9
Response:
A. Check instrument reading against them1ocouple,
disagreement indicates possible thermocouple or
temperature loop failure.
B. If the high temperature is correct, and the difference
between the exhaust temperature and th~, furnace
temperature is not significantly high:
1.
2.
If the burner solenoid has not already been
shutdown automatically, close the gas hand
valves.
If the exhaust temperature is increasing
rapidly, manually close the burnout air damper
using the controller or the damper lever until
the high temperature returns to normal. The
burnout air damper may be opened gradually
to re-establish process. The high temperature
can be caused by a fluctuation in BTU value
of the waste. Adjust burnout air flow first,
then evaluate whether a change in feed rate
is necessary.
3. Ensure furnace draft is not excessive
(< O.l"WC).
Alarms which cause auto feed cutoff to RK:
Burnout Air Pressure Low
This alarm occurs when the burnout air pressure drops below
a preset minimum value. This alarm is one of the interlocks
to close the main gas valve.
Response:
A.
BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
822 NEOSHO AVENUE
0
0
B.
C.
D.
E.
F.
Page 5.10
air blower is running. If not, restart blower.
Check for blown fuses and/or tripped overload heaters
and replace/reset as necessary.
Check for fouled inlet filter and/or blower impellers.·
Check motor starter for correct operation.
Check wiring to motor and replace if necessary.
Repair/replace motor as necessary.
Feed System Stopped
A set of contacts in the motor starter monitors the operation
of the feed hopper screw motor. In the event of a motor
failure, the alarm will be initiated causing the feed system
to shut down.
Response:
A. Visibly verify the alarm by observing the feed hopper
motor. If it has not stopped, the trouble may be
electrical.
B. If the motor has stopped and a prolonged inspection
or maintenance appears necessary, begin normal
shutdown procedures.
System Draft Pressure Low
A pressure transmitter in the discharge module monitors draft
in the furnace and the aiarri1 is activated when the transmitter
senses a decrease in draft to the point of furnace
pressurization.
Deactivates feed after 5 minutes.
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Page 5.11
Response:
A.
B.
C.
D.
E.
F.
G.
Verify that the unit is pressurized. Look for smoke
and heat being emitted from the feed hopper.
Temporarily put the furnace draft control on manual
and increase the induced draft blower damper opening
to prevent smoke emissions.
Check the primary pressure controller ~~tpoint to
verify that it is not set above the alarm setpoint.
Verify that the induced draft blower is operating
("Induced Draft Blower Off" light and "Emergency
Backup Activated" light should not be illuminated):
1. Check induced draft fan drive system for
malfunction;
2. Inspect system for blown gaskets, open ports
or access covers or other damage that may
be allowing air to enter the system.
Check induced draft blower damper and damper
actuator for correct operation.
Check primary chamber combustion air blower and
damper for proper operation. (i.e damper open more
than controller calling for).
If the exhaust system seems to be operating correctly,
check the transmitter and sensing lines for plugging.
If pressurization cannot be corrected, or if an
extended inspection and maintenance appears
necessary, begin normal shutdown procedures.
BATON ROUGE, LOUISIANA 70802 [phone] FA( [phone]
822 NEOSHO AVENUE
0
3)
Page 5.12
Ash Discharge Conveyor Stopped
A magnetic sensing element monitors the movement of the
inclined ash conveyor screw, and the alarm is initiated when
the element detects that the conveyor system has stopped
moving.
Deactivates the feed system immediately.
Response:
A.
B.
C.
Verify that the screw is not moving. If it is
operating, a failure in the speed sensing circuit is
indicated. If prolonged inspection or maintenance
appears necessary, begin normal shutdown
procedures. If the screw is not moving, check the
following: Inspect screw for foreign objects possibly
causing a jam; check the motor and drive train for
possible damage.
Check the RK operational panel for a tripped breaker.
Check on/off switch and local disconnect for proper
position.
If prolonged inspection or maintenance appears
necessary, the system should be shut down following
normal shutdown procedures.
Alarms which cause rone combustion shutdown:
o Firing Zone Overtemp
A thermocouple monitors the temperature in the firing rone,
and the alarm is initiated by an overtemp instrument when
the rone temperature exceeds a preset value (1800°F).
Deactivates burner gas solenoid valve if the automatic mode
has been selected.
BATON ROUGE, LOUISIANA 70802
~ r□)(i\RS? []) LIO LA.I l( Li
[phone] FAX [phone]
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Page 5.13
Response:
A.
B.
C.
D.
Check the overtemp thermocouple causing the alarm.
If the reading on the overtemp instmment is
excessively high, the thermocouple circuit has failed ..
At the first cooldown of the system, repair the
thermocouple circuit.
If in Auto, ensure that the gas solenoid valve is shut
down. If not, do so manually. If in Auto, the
heating system should come back on once the
temperature has dropped below 1800°F. If in Hand,
switch to Auto when the temperature falls below
1800°F and the heating system should return to
service.
Ensure that the furnace draft is not excessive. If the
draft is found to be excessive, close the damper to
return to normal draft.
Reduce combustion air supply by closing the
combustion air blower damper. Leave the damper
closed until the high temperature has reduced to
normal process temperature, then gradually increase
the damper opening to regain the process.
5.2.2 SCC Interlocking Alarms
822 NEOSHO AVENUE
1)
0
Alarms which cause combustion and auto feed cutoff to RK:
Master Off
This alarm indicates that Power to the sec operational Panel
has been turned off.
Response:
A. Check the SCC operational Panel to determine that
Power is available.
BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
822 NEOSHO AVENUE
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B.
Page 5.14
If power is available at the Panel, then Press 'Master
Start' pushbutton at the panel to have 'Master On'.
Combustion Air Pressure Low
This alarm occurs when the combustion air pressure drops
below a preset minimum value. This alarm is one of the
interlocks to close the main gas valve.
Response:
A.
B.
C.
D.
E.
F.
Check the indicator lights to see if the combustion
air blower is running. If not, restart blower.
Check for blown fuses and/ or tripped overload heaters
and replace/reset as necessary.
Check for fouled inlet filter and/or blower impellers.
Check motor starter for correct operation.
Check wiring to motor and replace if necessary.
Repair/replace motor as necessary.
o Main Gas Pressure Low
This alarm occurs when the main gas pressure drops below
a preset minimum value. This alarm is one of the interlocks
that closes the main gas valve.
Response:
A. Inspect the gas line and/or main pressure reducing
regulator for leaks or other obvious damage. Make
sure all petcocks in the gas line are closed. Check
incoming gas line pressure and compare with
prescribed value.
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Page 5.15
B. If there is no obvious damage and measured pressure
is OK, then attempt to restart the system. If the
problem persists, then check the operation of the
pressure switch and replace if it is found to be
defective.
Main Gas Pressure High
This alarm occurs when the main gas pressure rises above
a preset minimum value. This alarm is one of the interlocks
that closes the main gas valve.
Response:
A.
B.
Check the setting of the main gas reducing regulator
and correct as necessary.
Check the incoming gas line pressure and compare
to the prescribed value.
C. Check for correct operation of the main gas high
pressure switch.
Alarms which cause auto feed cutoff to RK:
Secondary Chamber Overtemp
This alarm occurs when the temperature in the i;econdary
chamber exceeds the maximum setpoint.
Response:
A. Go to the sec operational panel and check the
temperature reading on the secondary chamber
temperature instrument. if the instrument displays
the message 'Input 1 failure', then check the wiring
of the thermocouple to the instrument and
repair/replace as necessary. If there are no problems
with the wiring, then the thermocouple must be
replaced.
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822 NEOSHO AVENUE
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B.
Page 5. 16
If in the control trailer, compare the temperature
reading on the sec graphic overview screen. If this
temperature is well below the overtemp setpoint then
the thermocouple on the overtemp instrument
probably needs to be replaced.
APCE Duct O, Analyzer Alarm
This alarm occurs when the oxygen detected by the oxygen
sensor in the APCE duct is below the LO-LO oxygen
setpoint of the oxygen analyzer.
Response:
A. Increase the setpoint of the excess air controller.
o Excess Air Pressure Low
This alarm occurs when the pressure of the excess air line
drops below a preset minimum value.
Response:
A.
B.
C.
Check the indicator lights to see if the combustion
air blower is running. If not, restart blower.
Check for blown fuses and/or tripped overload heaters
and replace/reset as necessary.
Check for fouled inlet filter and/or blower impellers.
D. Check motor starter for correct operation.
E.
F.
Check wiring to motor and replace if necessary.
Repair/replace motor as necessary.
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822 NEOSHO AVENUE
Page 5.17
APCE Interlocking Alarms
I)
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Alarms which cause auto feed cutoff to RK (If alarms are
not corrected within I hour, controlled shutdown of RK
and/or sec combustion systems by an operator are
necessary):
Master Off
This alarm indicates that power to the APCE operational
panel has been turned off.
Response:
A. Check the APCE Operational Panel to determine that
power is available.
B. If power is available at the panel, then press 'Master
Start' to have 'Master On'.
Main ID Fan Off
This alarm occurs when the induced draft fan is not running.
During normal operation of the system, if this alarm occurs
the diesel powered backup ID fan will take over th,e system.
Response:
A. Check the indicator lights to see if the Il) fan air
blower is running. If it is, check the motor starter
contact for correct wiring and operation.
B.
C.
Check for blown fuses and/ or tripped overload heaters
and replace/reset as necessary.
Check for fouled fan impellers.
D. Check motor starter for correct operation.
E. Check wiring to motor and replace if necessary. @mm~~
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822 NEOSHO AVENUE
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Page 5.18
F. Repair/replace motor as necessary.
Alarms which cause auto feed cutoff to the RK:
Quench Backup Thermocouple In Use
If the main thermocouple in the quench temperature
controller fails, then the temperature will be monitored from
a backup TIC wired to the PLC.
Response:
A. Go to the APCE operational panel and check the
temperature reading on the quench temperature
controller. If the controller displays the message
"Input 1 failure", then check the wiring of the
thermocouple to the instrument and repair/replace as
necessary. If there is no problem with the wiring,
then the thermocouple must be replaced.
B. . Verify that the quench temperature controller
instrument reading matches the temperature on the
quench temperature indicator controller (TIC)
faceplate on the monitoring system computer. If they
do not match, check the communications wiring for
the Honeywell controllers and repair/replace as
necessary.
C. If communications wiring is found to be ok, replace
instrument with spare and recheck (A) and (B). If
instrument works, then have original instrument
repaired/replaced.
CO (7% 0,) Rolling Average ID-HI
This alarm occurs when the rolling average of CO emissions
( corrected to 7 % 0,) exceeds the alarm setpoint.
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Page 5.19
Response:
A. Increase the excess air controller setpoint and observe
results. If problem is not corrected, a detailed
analysis will have to be performed to find cause of
the problem.
Quench Temperature HI-HI
This alarm occurs when the temperature in the quench
exceeds the HI-HI setpoint on the quench temperature
controller.
Response:
A. Verify the temperature at the instrument i.s not out
of range. If it is, the backup TIC should be in use
and the primary TIC must be replaced.
Alarms which do not cutoff feed to APCE but do cause
component shutdowns:
Caustic Tank Level Low
This alarm occurs when the level of caustic is below the LO-
LO float switch in the tank. This alarm will cause the
caustic pump to stop until the tank is refilled.
Response:
A.
B.
Check the level indication on the tank to verify that
the level is low. If it is low, then manually refill
the tank.
If the level is not low, then check the ope:ration of
the low level float switch at the bottom of the tank.
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Page 5.20
Mixing Tank Level Low
This alarm occurs when the level of caustic mix is below the
LO-LO float switch in the tank. This alarm will cause the
caustic mixing pump to stop until the tank is refilled.
Response:
A.
B.
C.
Visually inspect the level of the tank to verify that
the level is low. If it is not, then check the operation
of the low level float switch and replace as necessary.
If the tank level is low, then make sure that the
caustic pump (which refills this tank) is operating
correctly.
Make sure all manual inlet valves to the tank are in
their correct positions and that the pH controller is
functioning correct! y.
Effluent Tank Level Low
This alarm occurs when the level of the effluent tank is
below the LO-LO float switch in the tank. This alarm will
cause the effluent pumps to stop until the tank level rises
above the LO-LO level.
Response:
A.
B.
Visually inspect the tank level to verify that it is low.
If it is not low, check the operation of the low level
float switch and replace if defective.
If the tank level is low, then check the scrubber
system for clogged nozzles and the contact chambers
for leaks.
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Page 5.21
Compressor #1 Trouble
This alarm occurs when compressor # 1 is not operating
correctly. This alarm will cause compressor # l to shut
down.
Response:
A. When compressor #1 has trouble, the process can
continue at a reduced rate if compressor #2 is
operating.
B. Have a qualified serviceman inspect the compressor
and repair/replace as necessary.
Compressor #2 Trouble
This alarm occurs when compressor #2 is not operating
correctly. This alarm will cause compressor #2 to shut
down.
Response:
A.
B.
When compressor #2 has trouble, the process can
continue at a reduced rate if compressor #1 is
operating.
Have a qualified serviceman inspect the compressor
and repair/replace as necessary.
5.2.4 RK Non-Interlocking Alarms
822 NEOSHO AVENUE
0 Cross-Over Duct Temperature High
This alarm occurs when the temperature in the crosi.over duct
to the SCC exceeds a preset high value.
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Page 5.22
Response:
A. Oleclc the thermocouple for proper operation and replaoe
if defective.
B. Check the setpoints of the RK temperature controller
and adjust if necessary.
Ash Discharge Temperature High
This alarm occurs when the temperature of the ash discharge
exceeds a preset high value.
Response:
A. Check the thermocouple for proper operation and replaoe
if defective.
Chamber Temperature Low Deviation
This alarm occurs when the actual chamber temperature drops
below the temperature setpoint by a preset value.
Response:
A.
B.
Check the deviation amount for the temperature on
the RK Alarm Setpoint screen and adjust if necessary.
Check the combustion system to insure proper operation.
5.2.5 SCC Non-Interlocking Alarms
822 NEOSHO AVENUE
0 Pilot Burner Off
This alarm occurs when the UV flame detector does not sense
the presence of a flame.
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Page 5.23
Response:
A.
B.
C.
Check to see if flame is present.
If flame is detected, check for defective UV detector
and replace as necessary.
Check for defective UV flame relay and replace as
necessary.
APCE Duct O, Low
This alarm occurs when the oxygen detected by the oxygen
sensor in the APCE duct is below the low oxygen setpoint
of the oxygen analyzer.
Response:
A. Increase the excess air flow by raising the setpoint
of the excess air controller in auto mode.
5.2.6 APCE Non-Interlocking Alarms
822 NEOSHO AVENUE
0 Scrubber Fan Off
This alarm occurs when the scrubber fan is no longer running.
Response:
A. Check the indicator lights to see if the scrubber fan
is running. If not, restart fan.
B. Check for blown fuses and/or tripped overload heaters
and replace/reset as necessary.
C. Check for fouled fan impeller.
D. Check motor starter for correct operation.
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Page 5.24 I
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E. Check wiring to motor and replace if necessary. I F. Repair/replace motor as necessary.
0 Caustic Pump Off I
This alarm occurs when the caustic pump feeding the mixing I tank is no longer running.
Response: I A. Check the indicator lights to see if the caustic pump
is running. If not, try to restart pump. I
B. Check for blown fuses and/or tripped overload heaters
and replace/ reset as necessary. I
C. Check motor starter for correct operation.
D. Check wiring to motor and replace if necessary. I
E. Repair /replace motor as necessary. I
0 Caustic Mix Pump Off
This alarm occurs when the caustic mixing pump is no longer I
running.
Response: I
A. Check the indicator lights to see if the caustic mix I pump is running. If not, try to restart pump.
B. Check for blown fuses and/or tripped overload heaters I and replace/reset as necessary.
C. Check for fouled pump impeller. I
D. Check motor starter for correct operation.
E. Check wiring to motor and replace if necessary. I
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I F. Repair/replace motor as necessary.
I 0 Effluent Pump #1 Off
I This alarm occurs when effluent pump #1 is not running.
Response:
I A. Check the indicator lights to see if the efflw!nt pump
#1 is running. If not, try to restart pump.
I B. If pump will not restart, then switch over to the backup
effluent pump #2.
I C. Check for blown fuses and/or tripped overload heaters
on the stopped pump and replace/reset as necessary.
I D. Check for fouled pump impeller.
I E. Check motor starter for correct operation.
F. Check wiring to motor and replace if nect:ssary.
I G. Repair/replace motor as necessary.
I 0 Effluent Pump #2 Off
This alarm occurs when effluent pump #2 is not running.
I Response:
I A. Check the indicator lights to see if the effluent pump
#2 is running. If not, try to restart pump.
I B. If pump will not restart, then switch over to the primary
effluent pump #1.
I C. Check for blown fuses and/or tripped overload heaters
on the stopped pump and replace/reset as necessary.
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822 NEOSHO AVENUE
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Page 5.26
D. Check for fouled pump impeller.
E.
F.
Check motor starter for correct operation.
Check wiring to motor and replace if necessary.
G. Repair/replace motor as necessary.
Emergency Quench Water Low Flow
This alarm occurs when the quench water flow provided by
the emergency water pump drops below a preset minimum
value.
Response:
A.
B.
C.
Visually inspect the diesel engine and pump for proper
operation.
Look for leaks or restrictions in the piping leading
up to the emergency quench nozzle.
Look for clogs in the ncrzz1e itself and oorrect as necessary.
D. If no problems can be found, then check the operation
of the emergency quench flow switch.
Quench Nozzle #1 Water Flow LO-LO
This alarm occurs when the water flow at the quench nozzle
#I drops below a preset minimum value.
Response:
A. Check for defective flow sensor and repair/replace
as necessary.
B. Check for defective flow transmitter and repair/replace
as necessary.
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C. Check for clogged nozzles and correct if detected.
I D. Check the incoming water supply flow and pressure.
I 0 Quench Nozzle #2 Water Flow LO-LO
This alarm occurs when the water flow at the quench nozzle
I #2 drops below a preset minimum value.
Response:
I A. Check for defective flow sensor and repair/replace
as necessary.
I B. Check for defective flow transmitter and repair/replace
as necessary.
I C. Check for clogged nozzles and correct if detected.
I D. Check the incoming water supply flow and pressure.
0 Entrainment Separator Stage 1 Water Flow LO-LO
I This alann indicates the water flow in the entrainmeni: separator
stage 1 nozzle has dropped below a preset minimum value.
I Response:
I A. Check for defective flow sensor and repair/replace
as necessary.
I B. Check for defective flow transmitter and repair/replace
as necessary.
I C. Check for clogged nozzles and correct if detected.
D. Check the incoming water supply flow and pressure.
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822 NEOSHO AVENUE
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Page 5.28
Entrainment Separator Stage 2 Water Flow LO-LO
1bis alarm indicates the water flow in the entrainment separator
stage 2 nozzle has dropped below a preset minimum value.
Response:
A. Check for defective flow sensor and repair/replace
as necessary.
B. Check for defective flow transmitter and repair/replace
as necessary.
C. Check for clogged nozzles and correct if detected.
D. Check the incoming water supply flow and pressure.
Entrainment Separator Stage 3 Water Flow LO-LO
1bis alarm indicates the water flow in the entrainment separator
stage 3 nozzle has dropped below a preset minimum value.
Response:
A.
B.
C.
D.
Check for defective flow sensor and repair/replace
as necessary.
Check for defective flow transmitter and repair/replace
as necessary.
Check for clogged nozzles and correct if detected.
Check the incoming water supply flow and pressure.
o Scrubber Nozzle I Caustic Mix Flow LO-LO
This alarm occurs if the caustic mix flow through nozzle 1
drops below a preset minimum value.
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I Response:
I· A. Check for defective flow sensor and repair/replace
as necessary.
I B. Check for defective flow transmitter and repair/replace
as necessary.
I C. Check for clogged nozzles and correct if detected.
D. Check the operation of the caustic mixing pump and
I correct if necessary.
0 Scrubber Nozzle 2 Caustic Mix Flow LO-LO
I This alarm occurs if the caustic mix flow through nozzle 2
drops below a preset minimum value.
I Response:
I A. Check for defective flow sensor and repair/replace
as necessary.
I B. Check for defective flow transmitter and repair/replace
as necessary.
I C. Check for clogged nozzles and correct if detected.
D. Check the operation of the caustic mixing pump and
I correct if necessary.
0 Scrubber Nozzle 3 Caustic Mix Flow LO-LO
I This alarm occurs if the caustic mix flow through nozzle 3
drops below a preset minimum value.
I Response:
I A. Check for defective flow sensor and repair/replace
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Page 5.30 I
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B. Check for defective flow transmitter and repair/replace I as necessary.
C. Check for clogged nozzles and correct if detected. ·I
D. Check the operation of the caustic mixing pump and I correct if necessary.
0 Scrubber Nozzle 4 Caustic Mix Flow LO-LO I This alarm occurs if the caustic mix flow through nozzle 4
drops below a preset minimum value. I Response:
A. Check for defective flow sensor and repair/replace I as necessary.
B. Check for defective flow transmitter and repair/replace I as necessary.
C. Check for clogged nozzles and correct if detected. I
D. Check the operation of the caustic mixing pump and I correct if necessary.
0 Scrubber Nozzle 5 Caustic Mix Flow LO-LO I This alarm occurs if the caustic mix flow through nozzle 5
drops below a preset minimum value. I
Response:
A. Check for defective flow sensor and repair/replace I
as necessary.
B. Check for defective flow transmitter and repair/replace I
as necessary.
C. Check for clogged nozzles and correct if detected. ·I
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I D. Check the operation of the caustic mixing pump and
correct if necessary.
I· 0 Wash Ring Water Flow LO-LO
I This alarm occurs when the flow sensor on the wash ring piping
senses a flow less than a preset minimum.
I Response:
A. Check for defective flow sensor and repair/replace
I as necessary.
B. Check for defective flow transmitter and repair/replace
I as necessary.
C. Check for clogged nozzles and correct if detected.
I D. Check the incoming water supply flow and pressure.
I 0 System Draft Pressure Low
This alarm occurs when the system draft pressure :;ensed by
I the ID fan speed controller drops below the low levd setpoint
of the controller (pressure becomes positive).
I Response:
A. Check the ID fan for proper operation.
I B. Check the setpoint of the ID fan speed controller and
adjust as required.
I 0 pH HI-LO Deviation
I This alarm occurs when the pH level sensed by the pH controller
rises above or falls below predetermined alarm sc::tpoints in
the controller.
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Page 5.32
Response:
A.
B.
c.
If the situation is not self-correcting, then check the
pH probe and replace as necessary.
Check the operation of the caustic dosing solenoid
valve operated by the pH controller for correct operation
and adjust/repair as necessary.
Check for proper tuning of the pH controller and make
adjustments as necessary.
Quench Nozzle #1 Air Pressure LO-LO
This alarm occurs when the air pressure to quench nozzle
#1 drops below a preset minimum value.
Response:
A. Verify that both air COilipleswfS are functioning oomially.
B. Check the operation of the air pressure switch(s) and
repair/replace as necessary.
Quench Nozzle #2 Air Pressure LO-LO
This alarm occurs when the air pressure to quench nozzle
#2 drops below a preset minimum value.
Response:
A. Verify that both air compres.us are functioning oomially.
B. Check the operation of the air pressure switch(s) and
repair/replace as necessary.
Scrubber Nozzle #1 Air Pressure LO-LO
This alarm occurs when the air pressure to scrubber nozzle
# 1 drops below a preset minimum value.
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I Response:
I A. Verify that bOOl air oonq:xtsSJts are functiooing nonnally.
B. Check the operation of the air pressure switch(s) and
I repair/replace as necessary.
0 Scrubber Nozzle #2 Air Pressure LO-LO
I This alarm occurs when the air pressure to scrubber nozzle
#2 drops below a preset minimum value.
I Response:
I A. Verify that bOOl ail OOliqJitsSJiS are functiooing nonnally.
B. Check the operation of the air pressure switch(s) and
I repair/replace as necessary.
0 Scrubber Nozzle #3 Air Pressure LO-LO
I This alarm occurs when the air pressure to scrubber nozzle
#3 drops below a preset minimum value.
I Response:
I A. Verify that bOOl ah 00tlqJ1eS&J1s are functiooing nonnally.
B. Check the operation of the air pressure swit,:h(s) and
I repair/replace as necessary.
0 Scrubber Nozzle #4 Air Pressure LO-LO
I This alarm occurs when the air pressure to scrubb<!r nozzle
#4 drops below a preset minimum value.
I Response:
I A. Verify that bOOl ail 00t1q:xesoo1S are functiooing nonnally.
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Page 5.34
Check the operation of the air pressure switch(s) and
repair/replace as necessary.
Scrubber Nozzle #5 Air Pressure LO-LO
This alarm occurs when the air pressure to scrubber nozzle
#5 drops below a preset minimum value.
Response:
A. Verify tha1 lxxh air ullUP,:tsWIS are functiooing nonnally.
B. Check the operation of the air pressure switch(s) and
repair/replace as necessary.
Entrainment Separator Differential Pressure HI-HI
This alarm occurs when the pressure drop across the entrainment
separator increases past a preset maximum value.
Response:
A. Check the chevrons and/or filters in the entrainment
separator and clean/replace as necessary.
System Air Flow LO-LO
This alarm occurs when the air flow provided by the compressors
drops below a preset minimum value.
Response:
A. Check that both air compressors are operating nonnally.
B. Check the air lines for kinks or other restrictions and
repair/replace as necessary.
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I 0 Make-Up Pressure Low
I This alarm occurs when the city water pressure drops below
a certain preset minimum value.
I Response:
A. Check the make-up water pressure manually at the
I inlet and verify the low pressure condition.
B. Check the operation of the low pressure switch and
I repair/replace as necessary.
0 Stack CO, HI-HI
I This alarm occurs when the emissions of CO, from the stack
have increased beyond the preset maximum value,.
I: Response:
I A. Increase the setpoint of the excess air controllers.
0 Stack Temperature HI-HI
I This alarm occurs when the temperature of the stack emissions
has increased beyond the preset maximum value.
I Response:
I A. Verify correct operation of all APCE water and air
flows.
I' B. Check the stack temperature thermocouple and replace
if found defective.
I 0 Stack Velocity HI-HI
This alarms occurs when the velocity of the exhaust gases
I from the stack exceeds a preset maximum value.
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Response:
A. Check the operation of the stack velocity probe.
B. Check for high system draft.
C. Check for increased scrubber air pressure.
Fan Dampers not in Position
This alarm occurs when the main ID fan and backup ID fan
dampers are not in their proper relative positions as indicated
by the position limit switches.
Response:
A.
B.
Visually inspect the damper mechanism to determine
the position of the dampers. The primary and backup
dampers should be opposites of each other (i.e. primary
open-backup closed). Adjust manually as necessary.
QlOCk tre damper in,itioo switches and adjust as neressary.
Caustic Tank Temp LO
This alarm occurs when the caustic tank temperature drops
below a preset minimum value.
Response:
A. Inspect the heaters and verify correct operation.
B. Check the temperature controlling device on the heaters
and verify correct operation.
Caustic Mix Tank Temp m
This alarm occurs when the tank temperature has risen past
the maximum allowable value.
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5.2.8
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Page 5.37
Response:
A. Verify the tank temperature is actually high.
B.
C.
am the temperature setting oo the axitrolling instrument
If it is set too high, try reducing it and check to see
if problem corrects itself.
Check that the temperature controlling instrnment is
functioning correctly.
RK Warn Alarms
To be determined
SCC Warn Alarms
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Combustion Chamber Temperature m-LO Deviation
This alarm~ when the temperature sensed by the o)mbustion
chamber temperature controller rises above or falls below
the setpoint by a pre-determined amount.
Response:
A. If alarm is not self-correcting or occurs continuously,
then check alarm setpoint screen to see the deviation
alarm setpoint and adjust if necessary.
Combustion Chamber Temperature High
This alarm occurs when the combustion chamber temperature
is awroochmg the high temperature seqrint 00 the overternperature
instrument.
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Response:
A. Om: the mixing sectioo tanperature oo the SCC graphic
overview screen and comime to the temperature indicated
on the combustion chamber overtemp controller. If
the temperature on the graphic screen is much greater,
then the thenncxxJuple has fuilal and nee;ls to be repla::ed.
APCE Duct O, LO
This alarm occurs when the oxygen level sensed by the oxygen
analyzer approaches a preset minimum value.
Response:
A. Increase the amount of excess air by raising the setpoint
of the excess air controller in the auto mode.
APCE Duct O, High
This alarm occurs when the oxygen level sensed by the oxygen
analyzer rises above a preset maximum value.
Response:
A. Decrease the amount of excess air in the system by
reducing the setpoint of the excess air controller in
auto mode.
APCE Warn Alarms
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I 0 Quench Temp Low
This alarm occurs when the temperature in the quench has
dropped below a preset minimum value. I
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I Response:
I A. If processing liquid waste in the secondary c:hamber,
an increase in the liquid waste setpoint will ,:ause the
temperature to increase. If liquid waste processing
I is not taking place, then this alarm is normal and can
be ignored.
I 0 Quench Temp High
This alarm occurs when the quench temperature is approaching
I a preset maximum value.
Response:
I A. Check the quench nozzle flows and pres.sure, for correct
operation and adjust/replace as necessary.
I 0 Effluent pH Low
I This alarm occurs when the effluent pH is approaching a preset
minimum value.
I Response:
A. Verify all nozzle flows and air pressures.
I B. Check pH probe and instrument for correct operation.
I C. Check the operation of the caustic dosing solenoid
valve operated by the pH controller and adjust/ repair
as necessary.
I 0 Stack Velocity High
I This warning indicates that the velocity of the exhaust gasses
is approaching the preset high limit.
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Response:
A. Check the setpoint of the pressure controller and adjust
if necessary to decrease the speed of the ID fan.
Stack CO, High
This alarm occurs when the CO, concentration in the stack
exhaust gas exceeds a preset high value.
Response:
A. If the problem does not correct itself, then increase
the setpoint of the ex= air rontrolle.r to provide additional
combustion air.
Stack CO (7% 0,) High
This alarm occurs when the stack CO emissions, corrected
to 7 % oxygen, exceeds a preset high value.
Response:
A. If the problem does not correct itself, then increase
the setpoint of the ex= air rontroller to provide additional
combustion air.
Stack CO (7% 0,) Rolling Average High
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This alarm occurs when the stack CO emissions, corrected I
to 7% oxygen, approaches a preset high value.
Response:
A. If the problem does not correct itself, then increase
the setpoint of the ex= air rontroller to provide additional
combustion air.
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I 0 Emergency Quench Water Low Flow
I This alarm occurs when the quench water flow provided by
the emergency water pump approaches a preset minimum value.
I Response:
A. Visually inspect the diesel engine and pump for proper
I operation.
B. Look for leaks or restrictions in the piping leading
I, up to the emergency quench nozzle.
C. Look fur dogs in the oozz.le itself and correct as necessary.
I D. If no problems can be found, then check the operation
of the emergency quench flow switch.
I 0 Quench Nozzle #1 Water Flow Low
I This alarm occurs when the water flow at the quen~h nozzle
#1 approaches a preset minimum value.
I Response:
A. Check for defective flow sensor and repa;ir/replace
I as necessary.
B. Check for defective flow transmitter and repllir/replace
I as necessary.
C. Check for clogged nozzles and correct if detected.
I D. Check the incoming water supply flow and pressure.
I 0 Quench Nozzle #2 Water Flow Low
This alarm occurs when the water flow at the quench nozzle
I #2 approaches a preset minimum value.
Response:
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Page 5.42
A. Check for defective flow sensor and repair/replace
as necessary.
B. Check for defective flow transmitter and repair/replace
as necessary.
C. Check for clogged nozzles and correct if detected.
D. Check the incoming water supply flow and pressure.
Entrainment Separator Stage l Water Flow Low
This alarm indicates the water flow in the entrainment separator
stage 1 nozzle has dropped below a preset minimum value.
Response:
A. Check for defective flow sensor and repair/replace
as necessary.
B.
C.
D.
Check for defective flow transmitter and repair/replace
as necessary.
Check for clogged nozzles and correct if detected.
Check the incoming water supply flow and pressure.
o Entrainment Separator Stage 2 Water Flow Low
This alarm indicates the water flow in the entrainment separator
stage 2 nozzle has dropped below a preset minimum value.
Response:
A. Check for defective flow sensor and repair/replace
as necessary.
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I
I B. Check for defective flow transmitter and repair/replace
as necessary.
I C. Check for clogged nozzles and correct if detected.
I D. Check the incoming water supply flow and pressure.
0 Entrainment Separator Stage 3 Water Flow Low
I This alann indicates the water flow in the entrainment :,eparator
stage 3 nozzle has dropped below a preset minimum value.
I Response:
I A. Check for defective flow sensor and repair/replace
as necessary.
I B. Check for defective flow transmitter and repair/replace
as necessary.
I C. Check for clogged nozzles and correct if detected.
D. Check the incoming water supply flow and pressure.
I 0 Scrubber Nozzle 1 Caustic Mix Flow Low
I This alarm occurs if the caustic mix flow through nozzle 1
approaches a preset minimum value.
I Response:
A. Check for defective flow sensor and repair/replace
I as necessary.
B. Check for defective flow transmitter and repair/replace
I as necessary.
C. Check for clogged nozzles and correct if df:tected.
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Page 5.44
Check the operation of the caustic mixing pump and
correct if necessary.
Scrubber Nozzle 2 Caustic Mix Flow Low
This alarm occurs if the caustic mix flow through nozzle 2
approaches a preset minimum value.
Response:
A. Check for defective flow sensor and repair/replace
as necessary.
B.
C.
D.
Check for defective flow transmitter and repair/replace
as necessary.
Check for clogged nozzles and correct if detected.
Check the operation of the caustic mixing pump and
correct if necessary.
Scrubber Nozzle 3 Caustic Mix Flow Low
This alarm occurs if the caustic mix flow through nozzle 3
approaches a preset minimum value.
Response:
A. Check for defective flow sensor and repair/replace
as necessary.
B. Check for defective flow transmitter and repair/replace
as necessary.
C. Check for clogged nozzles and correct if detected.
D. Check the operation of the caustic mixing pump and
correct if necessary.
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I 0 Scrubber Nozzle 4 Caustic Mix Flow Low
I This alarm occurs if the caustic mix flow through nozzle 4
approaches a preset minimum value.
I Response:
A. Check for defective flow sensor and repair/replace
I as necessary.
B. Check for defective flow transmitter and repair/replace
I as necessary.
C. Check for clogged nozzles and correct if detected.
I D. Check the operation of the caustic mixing pump and
correct if necessary.
I 0 Scrubber Nozzle 5 Caustic Mix Flow Low
I This alarm occurs if the caustic mix flow through nozzle 5
approaches a preset minimum value.
I Response:
A. Check for defective flow sensor and repair/replace
I as necessary.
B. Check for defective flow transmitter and repair/replace
I as necessary.
C. Check for clogged nozzles and correct if detected.
I D. Check the operation of the caustic mixing pump and
correct if necessary.
I 0 Wash Ring Water Flow Low
I This alarm occurs when the flow sensor on the wash ring piping
senses a flow less than a preset minimum.
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Page 5.46
Response:
A. Check for defective flow sensor and repair/replace
as necessary.
B. Check for defective flow transmitter and repair/replace
as necessary.
C. Check for clogged nozzles and correct if detected.
D. Check the incoming water supply flow and pressure.
Quench Nozzle #1 Air Pressure Low
This alarm occurs when the air pressure to quench nozzle
#1 approaches a preset minimum value.
Response:
A.
B.
Verify that both air compressors are functioning
normally.
Check the operation of the air pressure switch(s) and
repair/replace as necessary.
Quench Nozzle #2 Air Pressure Low
This alarm occurs when the air pressure to quench nozzle
#2 approaches a preset minimum value.
Response:
A.
B.
Verify that both air compressors are functioning
normally.
Check the operation of the air pressure switch(s) and
repair/replace as necessary.
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Scrubber Nozzle #1 Air Pressure Low
This alarm occurs when the air pressure to scrubter nozzle
#1 approaches a preset minimum value.
Response:
A.
B.
Verify that both air compressors are functioning
normally.
Check the operation of the air pressure switch(s) and
repair/replace as necessary.
Scrubber Nozzle #2 Air Pressure Low
This alarm occurs when the air pressure to scrubter nozzle
#2 approaches a preset minimum value.
Response:
A. Verify that both air compressors are functioning
normally.
B. Check the operation of the air pressure swit:ch(s) and
repair/replace as necessary.
Scrubber Nozzle #3 Air Pressure Low
This alarm occurs when the air pressure to scrubter nozzle
#3 approaches a preset minimum value.
Response:
A.
B.
Verify that bah ai.i rompn::SSOIS are fimctioning nonnally.
Check the operation of the air pressure swi1tch(s) and
repair/replace as necessary.
ill Will ~U
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0 Scrubber Nozzle #4 Air Pressure Low I
This alarm occurs when the air pressure to scrubber nozzle I #4 approaches a preset minimum value.
Response: I A. Verify lhat bcxh air COiilptesootS are functioning nonnally.
B. Check the operation of the air pressure switch(s) and I repair/replace as necessary.
0 Scrubber Nozzle #S Air Pressure Low I
This alarm occurs when the air pressure to scrubber nozzle I #S approaches a preset minimum value.
Response: I
A. Verify lhat bcxh air compresoors are functioning nonnally.
B. Check the operation of the air pressure switch(s) and I
repair/replace as necessary.
0 Entrainment Separator Differential Pressure HI-HI I
This alann occurs when the pres.sure drop across the entrainment I separator approaches a preset maximum value.
Response: I
A. Check the chevrons and/or filters in the entrainment
separator and clean/ replace as necessary. I
0 System Air Flow Low
This alann occurs when the air flow provided by the compres.sors I
approaches a preset minimum value.
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I Response:
I A. Check that both air compre5.SOTS are operating nonnally.
B. Check the air lines for kinks or other restric:tions and
I repair/replace as necessary.
0 System Draft Pressure Low
I This alarm occurs when the system draft pressure sensed by
the ID fan speed controller approaches the low level setpoint
I of the controller (pressure becomes positive).
Response:
I A. Check the ID fan for proper operation.
I B. Check the setpoint of the ID fan speed controller and
adjust as required.
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6.0 QUALTIY ASSURANCFJQUALTIY CONTROL (QA/QC) PROCEDURES
The QA program requires the calibration of all sampling and analytical apparatus, where
applicable, and the use of control samples and replicate analyses where feasible. Detailed
analytical QA/QC procedures are presented in Appendix A of this document.
6.1 SAMPLING APPARATUS
The sampling equipment will be calibrated according to USEP A procedures spt:cified in
APTD 0576; 40 CPR 60, Appendix A; and manufacturers' specifications.
6.1.1 Dry Gas Meter and Orifice Meter
6.1.2
The dry eas meters for all sampling trains will be calibrated against a
standard wet test meter which has been calibrated against a spirome ter. The
meters will be adjusted so that the measured gas volumes are within 1
percent of proof (i.e., Y factors are between 0.99 and 1.01).
Thermocouples
The type K thermocouples in the meter control box, heated sample box
impinger umbilical connector, as well as the thermocouple attach,:xt to the
822 NEOSHO AVENUE
6.1.3
Page 6.2
probe will be calibrated against a NBS traceable mercury-in-glass
thermometer at three different temperatures over the range anticipated for
the tests.
Pitot Tube
The • S • type pi tot tubes will be designed to meet geometric configurations
as defined in USEPA Method 2.
6.2 QUALITY CONTROL SAMPLES
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The following are descriptions of the QC samples which will be used. A more detailed I
description is presented in Appendix A.
6.2. l Blank Samples
6.2.2
Blanks will be run, as required, on chromatographic solvents, sorbent,
particulate filters, scrubber water, etc., as indicated in Table I.
Field Biased Blanks
Field biased blanks, or blank samples which have been exposed to field and
sampling r,0nditions to assess possible contamination from the field, will
be collected as indicated in Table 4.1.
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6.2.3
Page 6.3
Duplicate Samples
Duplicate samples will be collected for all solid and liquid process streams
(feeds). The duplicate samples from a single test run will be fortified
with an appropriate spiking material. The analyses of these spiked samples
will provide information regarding the precision and accuracy of these
measurements.
6.3 SORBENT MEDIA QUALITY
The XAD-2 and Tenax sorbents used in the exhaust-gas sample collection systems will
be subjected to rigorous pretreatment in the laboratory prior to release for test sampling
purposes. The recommended pretreatment procedures include sequential extrac:tion with
an organic solvent to rcluce soluble organic contamination to acceptable levels. The
requisite resin pretreatment procedures and guidelines for evaluating resin quality are
contained in EPA IERL,RTP Procedures Manual: Level I Environmental Assessment
(Second Edition), EPA-600/7-78-201 and in the sampling protocols described for
Modified Method 5 and for Method 0030, SW-846. These pretreatment methods are
described in Appendix A.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FA:< [phone]
Page 6.4
6.4 SAMPLE TRANSPORT AND CUSTODY
All samples will be placed in a secure designated repository at the work area as soon as
possible after collection.· One person from the sampling field crew will be in charge of
the sample repository throughout the sampling period. This person will be responsible
for repository security at all times.
Samples will be shipped to the analytical laboratory by the designated person responsible
for sample security. Upon receipt at the laboratory, the samples will be logged into the
laboratory system and given a Hoechst Celanese, Shelby project identification number.
All samples will be inspected for damage, integrity of chain-of-custody, and leakage from
liquid sample bottles. Written records of sample analysis will be maintained. Analyzed
samples will be retained until a final report of the sampling program is issued and
accepted. Field and laboratory custody procedures are summarized in the following
sections.
6.5 FIELD CUSTODY PROCEDURES
In addition to Hoechst Celanese, Shelby project identification labels or tags, chain-of-
custody seals will be used on samples collected by test personnel. These self-sticking
seals will be placed across the sample container cover/lid in such a way that the container
cannot be opened without breaking the seal.
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The condition of the seal will be noted in the Sample Master Log to document whether
any tampering has occurred after the sample was collected.
The chain-of-custody of a sample will be initiated and maintained as follows:
0 A sample will be collected and labeled and the volume will be marked on
appropriate samples.
o The sample identification/description will be recorded on the chain--of-
custody (yOC) record.
'
o All samples will be accounted for, packed, and sent to the laboratory.
The Sample Master Log maintained at the Hoechst Celanese, Shelby site will contain the
following information:
0
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Project Sample Number.
Sample description (Sample type, location of sampling, time of sampling,
etc.).
Analyses requested.
Condition:of sample when received and shipped.
Any special handling or analysis instructions.
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Page 6.6
6.6 LABORATORY CUSTODY PROCEDURES
Upon receipt at the laboratory, the samples and the chains-of-custody will be turned over
to the sample manager, who will:
0 Log the s.,mple into a master laboratory log.
o Note the condition and the container type.
0
0
Assign and affix a laboratory control number to the sample container.
After any necessary subdivision of the samples, the samples will be stored
by the laboratory under appropriate conditions until they are analyzed.
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7.0 ANALYTICAL PROCEDURES
Analysis for the Principal Organic Hazardous Constituents (POHCs) will be performed
on the feeds, incinerator ash, scrubber liquor and stack gas. Detailed analytical
procedures are provided in references cited in this document. All analyses will b,~ carried
out in accordance with USEPA approved methods where applicable. QA/QC procedures
I
specified in the USEPA methods will be used as guidelines for the analyses of the Hoechst
Celanese, Shelby samples. This includes the addition of method blanks and duplicate
analyses, where applicable. Surrogate compounds will also be added to monitor the
efficiency of sample extraction and recovery in the GC/MS analyses.
A summary of the specific analytical protocols to be used in the program is given in Table
4.3. Additional information is presented in Appendix A.
7.1 PRESAMPLING ACT!VfTIES
The first phase of the comprehensive sampling program will involve the preparation of
sorbent material and evaluation of high purity reagents to be used as sampling train rinses
and impinger solutions. Information on specific procedures, such as those for preparing
solvent resins, are presented in Appendix A.
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Page 7.2
7.2 SAMPLE PREPARATION
Upon receipt of the coller.ted samples, the laboratory will initiate appropriate preparations
for specific constituent analyses.
Procedures for sample preparation and the methods used for the subsequent analyses are
as follows:
7. 2.1 Stabilized GRU Feed
For analy~is of the semi volatile organics, a nominal 10 gram aliquot of the
feed sample will be taken for extraction. It will be extracted for at least
16 hours in a Soxhlet extractor. The resulting extract will be dried over
anhydrous sodium sulfate and reduced using a Kudema-Danish evaporator.
7.2.2 Analysis of Volatile POHCs in Feed Samples
Analysis for POHCs in the solid feed to the incineration system will be
performed by Method 5030, SW-846 (purge and trap); more specifically,
these sam;iles will initially be handled using the protocol described in
Section 7.3.3.2 of Method 5030, which requires solution or extraction of
the sample with methanol.
Analysis cf the volatiles will be by GC/MS, Method 8240, SW-846.
[ID[IBfil~LI
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7.2.3
7.2.4
7.2.5
Page 7.3
Processed Material
A nominal IO-gram aliquot of each processed material sample (ash) will
be spiked with the same surrogate used for the feed samples. The sample
will be extracted for at least I 6 hours with methylene chloride. The
resulting extract will be dried over anhydrous sodium sulfate and
concentrated using Kudema-Danish evaporators to facilitate lower sample
detection limits.
Scrubber Effiuent
A I-liter aliquot of each of the effluent samples will be extracted according
to SW-846 Method 3510 or Method 3520. The resulting extract will be
dried over anhydrous sodium sulfate and concentrated using Kuderna-
Danish evaporators. Internal standards will then be added prior to GC/MS
analyses.
Exhaust Gas
The exhaust gas MM5 and Method 0030 sampling trains contain various
components that need to be individually prepared and composited into one
integrated ·sample prior to organic analysis. The components include the
resin from the sorbent trap, probe rinses, condensate water, and particulate
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Page 7.4
filter trap. The sample preparation procedures are outlined in the SW-
846 procedures for sampling exhaust gas. Additional information is
presented in Appendix A.
7.3 ANALYTICAL METHODS
Methods to be used for organic and other analyses are specified in Table 4.4. The
following special instructions will also apply.
7.3.l Gravimetric Determinations of Particulate Matter -Method 5
Particulate matter in the probe rinse and filter samples will be determined
according to the method discussed in the Federal Register 40 CFR 60,
Appendix B, Reference Method 5.
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8.0 DA TE REDUCTION AND REPORTING
8.1 DATA REDUCTION
Data reduction, validation, and reporting will be conducted according to EPA guidelines
for permit applications and sampling plans. In addition, data from the program and
subsequent analyses will be reduced to provide results appropriate to characterize each of
the process streams from the incineration unit as provided below:
o Feed
Concentrations of POHCs (ppm by weight)
Ethylene Glycol
o Processed material
Concentrations of POHCs (ppm by weight)
TCLP Metal only (ppm)
o Scrubber effluent
Concentration of POHCs (ppm by weight)
Total Organic Carbon
Total Chlorides
o Stack gas
Concentra_tion of POHCs (lbs/hr)
Concentration of HCI (lbs/hr)
Concentration of particulate (gr/dscf)
Concentration of oxygen and carbon dioxide (continuous,percem)
Concentration of carbon monoxide (ppm)
Concentration of NOx (continuous,ppm)
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX[phone]
Page 8.2
o Exhaust Gas
Concentration of oxygen (continuous percent)
8.2 DATA REPORTING
The objective of the incineration system monitoring and control system is to ensure that
the various process operating conditions are within the appropriate range for effective
incineration of the waste, and to provide a means to terminate waste feed in the event that
any of the normal process operating conditions deviate appreciably from design set-points.
The computer control system that monitors and controls the operating system will collect
and store data necessary for generating all reports and summaries.
Table 8.1 shows one format for data reporting of sampling program results. The report
will include information for process data, pollution control system operating data, GRU
material, processed feed, product streams and emissions.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
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I TABLE 8.1
I SAMPLING AND MONITORING RESULTS SUMMARY
Test 1 Test 2 Test 3
I Date
Ti me test began
I Time test ended
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Primary Chamber Operating Parameters:
Waste feed rate (lb/hr)
POHC concentration (mg/kg)
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POHC feed rate (kg/h)
Supplemental fuel (scf/hr)
Electricity (kw)
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Average combustion air flow (ACFM)
Waste residence time (min)
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Secondary Chamber Operating Parameters:
Natural gas flow ( cfh)
Average combustion air flow (ACFM)
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Average calculated residence time (sec)*
Total thermal load (10 x 6 Btu/h)
I Average oxygen(%)
Average carbon dioxide ( % )
Average carbon monoxide (ppm)
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Combustion efficiency ( % ) ,
Average scrubber water flow (gpm)
I Average scrubber water pH
Average venturi water flow (gpm)
Average venturi pressure drop ("we)
I Particulate/HCl emissions:
Total sample time (min)
I Total sample volume (dscm)
Stack gas flow rate (dscm/min)
Particulate concentration (gridsct)**
I Chlorides (lbs/hr)
HCI removal(%)
I
@IB~~~ I
I 822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
POHC emissions:
Total sample time (min)
Total sample volume (dscf)
POHC feed rate (g/min)
POHC output rate (g/min)
POHC DRE(%)
* Calculated from stack gas volumetric measurements
** Corrected to 7 percent oxygen
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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APPENDIX A
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1.0 INTROQUCTION
The purpose of this burn is to obtain data necessary to demonstrate that the incinerator
proposed for the on-site destruction of the hazardous waste can adequately mee1t RCRA
standards ( 40 CFR Part 270.62);
Performance data needed at this time relate to the destruction of the RCRA desi~ated
substances. The RCRA regulations address the measurement of incinerator stack em1Ssions
as the primary performance criterion. The required destruction and removal efficiency
(DRE) achieved by an incineration system under RCRA is determined by the emission rate of
hazardous materials in the incinerator stack versus the concentration of hazardous materials
in the waste to be incinerated.
The current state-of-the-art incinerator operation is such that very low levels of contaminants
emitted from incinerator stacks cannot be measured on a continuous basis; such
measurements require specialized stack sampling apparatus and sensitive analytical
laboratory instruments. Conversely, parameters necessary for monitoring and controlling
incinerator operation (temperatures and the concentrations of oxygen, carbon monoxide,
carbon dioxide, etc.) can be measured continuously by conventional monitoring equipment
One purpose of a trial burn is to establish a correlation between those parameters that are
used for control of the incinerator and those parameters that relate to the stack emis;ion rate
of the contaminants being processed. The purpose is to establish that, when the incin.erator is
being routinely operated and continuously monitored (for example, during the field
demonstration) and the monitored parameters are held within specific operation ranges,
materials fed to the system for destruction (at the same or lesser rates than those of the trial
burn) will not emit to the environment contaminants at levels greater than those measured by
the stack sampling required during the trial burn.
As noted above, the calculation of DRE for each specific contaminant involves only stack
monitoring data and feed rate data. The trial burn performance measurements thus
concentrate on the extent to which toxic substances are pre-processed in the kiln, destroyed by
the secondary combustion chamber (SCC), and subsequently released to the environment
from the stack. Other data will also be taken during the burn, such as contaminant level in
the ash, scrubber solids, baghouse solids, and scrubber water. However, this information does
not relate to the calculation of DRE or to the assessment of the trial burn performan,:e of the
incinerator relative to emissions to the environment.
1.1 Trial Burn Scope
The DRE will be based on the concentration of a surrogate compound, naphthalene to be
added to the waste feed. One or more "mini burns" may be performed prior to the required
test to fine tune the performance of the incinerator. Along with these Principal Organic
Hazardous Constituents (POHCs), stack gas sampling and/or analysis will be performed for
metals, oxides of nitrogen (NOx), hydrochloric acid (HO), and particulate matter. Process
samples will be analyzed for EP ToXIcity and reactivity as well as POHCs of concern.
The trial burn samples will require the following trains:
Multiple Metals
Modified Method 5
Method5
-for Antimony
-for Naphthalene
-Particulate and Ha
2.0 PROJECT ORGANIZATION AND RESPONSIBILITY
The project organization for the sampling program is presented in Figure 2.1. The quality
assurance (QA) and quality control (QC) functions have been organized to allow independent
review of project activities, while providin~ on-site QC coordination by the person most
knowledgeable of the sampling/analysis activities.
The objectives of the quality control efforts for this program are to assess and to document
the precision, accuracy, and adequacy of the process and emission data developed during
sampling and analysis.
The QA Coordinator for the project is Dr. Fred Fowler. While Dr. Fowler coordinates the
development and execution of the QA activities for the field testing effort, he will also be
responsible for reviewing the QA Project Plan, evaluating the internal QC program, and
documenting the results of QNQC activities.
As Project Director for the sampling effort, Mr. J. C. Zuzolo will be responsible for
irnplementin~ the project-specific system of quality control activities. He will schedule all on-
site QC activities, establish on-site sampling/analysis protocols, and coordinate record keeping
and data review and validation.
Mr. Zuzolo is ultimately responsible for the overall technical effort. That responsibility
includes the timely, cost-effective execution of all project activities. He will also coordinate
preparation of the final report.
The analytical task leader, Mr. R. Taylor, will be resl'onsible for the off-site analytical effort.
His responsibilities include obtaining valid analytical data for all project samples and
adhering to quality control requirements specified in the analytical methods. All sample
analysis as _presented will be performed at YORK's laboratory facility. His duties will also
include reVJewing all results of sample analyses, calibrations, blanks, duplicate analyses, and
analytical system performance checks.
The Program Manager, Mr. A E. Rubenstein, has final responsibility for completing this
program in accordance with the program objectives and within schedule and budget
constraints.
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TASK i, S!TE
J .• ZUZOLO
TASK 1 :
PROJECT
A.
VI SIT
Figure 2 .1
PROJEC':: ORGA.'HZATION
GDC
PROJECT OFFICER
TORK
PIIOJECT NAUGEII
AIITHUII RUBEN STE IM
PIIOJECT D !RECTOR
JOSEPH ZUZOLO
I
TASK 3: MOBILIZATION
CRAIG DOUGLAS
.. ,.; , .... , .. ,.J
CH·AIILES FO\ILEII
I
TASK 5: ANAL TS IS
ROBERT TAYLOR
QUALITY ASSURANCE TASI'.. 4: SA"PLIIIG TA.SJ:. 6: DATA
PLAN PREPARATIQM
REDUCTION/REPORTING
RUBENSTEIN J. ZUZOLO Robert Ta.yl or
3.0 DATA QUALITY OBJECTIVES
The objectives of the quality assurance plan for this project are two-fold. First, the plan
provides the mechanism for ongoing control and evaluation of measurement data quality
throughout the course of the project. Second, audit results and quality control <lata will
ultimately be used to define data quality for the various measurement parameters in terms
of both rrecision and accuracy. These data quality estimates will, in turn, be used to define
the !eve of the uncertainty associated with the measured emission concentration values.
All data will be calculated and reported in units consistent with standard EPA and industry
practice. Method detection limits (MDL's) are listed in Table 3-1 for organics and Table
3-2 for metals. Table 3-1 lists all organic analytes to be determined in this study. The
suitability of any extraction method to be used in conjunction with a specific analyte is
given or referenced in Appendix IX (FR 25942-53, July 9, 1987).
Accuracy and precision objectives for analytes are based on results for matrix spikes and
matrix spike duplicate (MS/MSD) analyses. The matrix spike compounds and recovery
criteria specified in EPA Contract Laboratory Program (CLP) are given for volatile and
semi-volatile organics as well as metals. Precision objectives for analyses are based on
matrix spike duplicates. Data quality objective for the sampling parameters associated with
this project are presented in Table 3-3. Data quality objectives for analytical parameters
are presented in Table 3-4.
No data quality objectives for total dissolved solids, total suspended solids, ash ultimate
analysis, higher heating value, and pH are presented because these are system parameters
to be monitored and are not criticaf measurements.
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TABLE 3-1. SUMMARY OF DETECTION LIMITS FOR ORGANICS
Contaminant
Volatiles (Method 8240)
Acetonitrile
Acrolein
Acrylonitrile
Benzene
Bromodichloromethane
Bromomethane
Carbon disulfide
Carbon tetrachloride
Chlorobenzene
Chlorodibromomethane
Chloroethane
Chloroform
Chloromethane
2-Chloro-1,3-butadiene
3-Chloropropene
1,2-Dibromo-3-chloropropane
1,2-Dibromoethane
Dibromomethane
Dichlorodifluoromethane
1,1-Dichloroethane
1,2-Dichloroethylene
1, 1-Dichloroethylene
trans-1,2-Dichloroethane
trans-1,4-Dichloro-2-butene
1,2-Dichloropropane
trans-1,3-Dichloropropene
cis-1,3-Dichloropropene
Ethyl methacrylate
Iodomethane
Methyl ethyl ketone
Methyl methacrylate
Methylene chloride
Ethylene Oxide
Xylene
1, 1, 1,2-Tetrachloroethane
1, 1,2,2-Tetrachloroethane
Tetrachloroethene
Toluene
Tribromomethane
Method
Detection Limit
(ug/1..)
200
500
10
2
2
2
10
2
2
2
2
2
2
50
2
2
2
2
2
2
2
2
2
50
5
5
5
2
2
10
2
50
1000
10
2
2
2
2
2
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TABLE 3-1. (Continued) I
Method I Contaminant Detection Limit
(ug/L)
Volatiles (Method 8240) ( continued) I 1,1,1-Trichloroethane 2
1,1,2-Trichloroethane 2
Trichloroethene 2 I Trichlorofluormethane 2
1,2,3-Trichloropropane 50
Vinyl chloride 2 I Ethylbenzene ·2
Vinyl Acetate 10
Styrene 2
Acetone 50 I Methyl isobutyl ketone 10
2-Hexanone 50
Propanenitrile 500 I
Semivolatiles (Method 8270)
I Acenaphtalene 2
Acenaphthene 10 Acetophenone 10 I 2-Acetylaminofluorene 1000
4-Arninobiphenyl .200
Aniline 20
I Anthracene 10
Aramite C
Benzo( a)anthracene 10 Benzenethiol C I Benzidine 1000 "'11-10
Benzo uoranthrene 20 I Benzo · perylene 20
Benzo )Yuoranthrene 20
KBenzoquinone 1000
enzoic acid 500 I B-aJcl alcohol 50
2 oroethyl vinr ether 1000
4-Chloro~yl p enyl ether 50 I Dibenzo 2
Dibenz( a,h )pyrene 10
Bis(2-chloroethoxy)ethane 10
I
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TABLE 3-1. (Continued)
Contaminant
Semivolatiles (Method 8270) (Continued)
Bis~2-chloroethyl)ether
Bis 2-chloroisopropyl)ether
Bis 2-ethylhexyl)phthalate
4-Bromophenyl phenyl ether
Butylbenzylphthalate
2-sec-Butyl-4,6-dinitrophenol
p-Cltloroaniline
Chlorobenzilate
p-Chloro-m-cresol
~-Cltloronaphthalene
2-Chlorophenol
3-Chloropropionitrile
Chrysene
ortho-Cresol
para-Cresol
Dibenz( a,h )anthracene
Dibenzo( a,e )pyrene
Dibenzo( a,i)pyrene
m-Dichlorobenzene
o-Dichlorobenzene
p-Dichlorobenzene
3,3 '-Dichlorobenzidine
2,4-Dichlorophenol
2,6-Dichlorophenol
Diethylphthalate
3,3'-Dimethoxybenzidine
p-Dimethylaminoazobenzene
3,3'-Dimethylbenzidine
2,4-Dimethylphenol
Dimethyphthalate
Di-n-butylphthalate
1,2-Dichlorobenzene
1,3-Dichlorobenzene
1,4-Dichlorobenzene
7, 12-dimethylbenz( a )anthracene
2,2-Dimethylphenethyamine
Isophorone
Methyl methanesulfonate
2-methylnaphthalene
1,4-Dinitrobenzene
Method
Detection Limit
(ug/L)
10
10
10
10
10
C
100
C
10
10
10
C
10
10
10
10
C
C
10
10
10
20
10
10
10
10000
200
10000
10
10
10
2
2
2
5
C
C
20
2
100
[ID 00 ill~ TI
TABLE 3-1. (Continued)
Contaminant
Semivolatiles (Method 8270) ( continued)
4,6-Dinitro-o-cresol
2,4-Dinitrophenol
2,4-Dinitrotoluene
2,6-Dinitrotoluene
Di-n-octylphthalate
Di-n-propylnitrosoarnine
Diphenyfamine/Diphenylnitrosarnine
1,2-Diphenylhydrazine
Fluoranthene
Fluorene
Hexachlorobenzene
Hexachlorobutadiene
Hexachlorocyclopentadiene
Hexachloroethane
Hexachlorophene ·
Hexachloropropene
Ideno(l,2,3-cd)pyrene
Isosafrole
Methapyrilene
3-Methylcholanthrene
4,4'-Methylenebis(2-Chloroaniline
Naphthoquinone
1,4-Naphthoquinone
1-Naphthylarnine
2-Naphthylarnine
p-Nitroaniline
4-Nitrophenol
N-Nitrosodi-n-butylarnine
N-Nitrosodiethylarnine
N-Nitrosodimethylamine
N-Nitrosomethylethylamine
Pyridine
N-Nitrosodiphenylamine
2-Nitrophenol
4-Nitroaniline
3-Nitroaniline
2-Nitroaniline
N-Nitrosomorpholine
N-Nitrosopiperidine
N-Nitrosopyrrolidine
Method
Detection Limit
(ug/L)
50
50
10
10
10
20
10
10
10
10
10
10
10
10
20000
10
10
100
C
100
200
10
100
100
100
50
10
50
100
100
100
20
10
10
10
10
10
200
200
200
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TABLE 3-1. (Continued)
Contaminant
Semivolatiles (Method 8240) ( continued)
5-Nitro-o-toluidine
Pentachlorobenzene
Pentachloroethane
Pentachloronitrobenzene
Pentachlorophenol
Phencetin
Phenanthrene
Phenol
2-Picoline
Pronamide
Pyrene
Resorcinol
Safrole
1,2,4,5-Tetrachlorobenzene
2,3,4,6-Tetrachlorophenol
1,2,4-Trichlorobenzene
2,4,5-Trichlorophenol
2,4,6-Trichlorophenol
Tris(2,3-dibromopropyl)phosphate
Method
Detection Limit
(ug/L)
200
10
10
100
50
100
10
10
100
100
10
1000
100
10
100
10
50
10
nd
a MDL's are given for groundwater. Practical quantitation limits for fe1:d, ash
and gas samples are dependent ueon the matrix and sampling conditions and
may be higher than the MD L's gwen by a factor of 10-10,000. Actual l\1DL's
used will be included in the final report.
c Detection limit not given, standard unavailable.
nd Not Determined.
[ID IB ffi ~ 'TI
TABLE 3-2. SUMMARY OF MEIBOD DETECTION LIMITS FOR METALS
Method Detection
Analyte Analysis Type Limit (mg/L)
Silver ICPES 0.009
Arsenic GFASS 0.003
Barium ICPES 0.009
Beryllium ICPES 0.001
Cadmium ICPES 0.003
Chromium ICPES 0.010
Copper ICPES 0.010
Mercury CVAAS 0.002
Nickel ICPES 0.020
Lead ICPES 0.050
Antimony ICPES 0.06
Selenium GFAAS 0.005
Thallium GFAAS 0.003
Vanadium ICPES 0.020
Zinc ICPES 0.006
ICPES -Inductively Couples Plasma Spectroscopy.
CV AAS -Cold Vapor Atomic Absorption Spectroscopy.
GFAAS -Graphite Furnace Atomic Absorption Spectroscopy.
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I TABLE 3-3. SUMMARY OF ESTIMATED PRECISION, ACCURACY, AND DATA
CAPTURE OBJECTIVES
I Data
Parameter (Method) Pre!;i~ion Accuracy Capture
I Volatile Ori:anics (Flue Gas -3Q%b 50% 90%
Solid/Liquid)
I Semi-Volatile OrFianics (Flue Gas -3Q%b 50%-S 90%
MM5 and So id/Liquid)
I Particulate Matter (Flue Gas -
Method 5)
11%d 10o/c9 90%
I Flue Gas -VelocityNolurnetric 6%d 10o/c9 95%
Flow Rate (Methods 1 and 2)
I Flue Gas -Fixed Gases/Molecular 10%' 20o/6 90%
Weight (Method 3)
Flue Gas -Moisture (Method 4) 2Q%d 10o/c9 90%
I Flue Gas 02 (Continuous Emission 20%' 20% 90%
Monitoring System)
I Flue Gas NOx (Continuous Emission
Monitoring System)
20%' 20% 90%
I Flue Gas CO (Continuous Emission 20%f 20% 90%
Monitoring System)
I Flue Gas CO2 (Continuous Emission 20%' 20o/6 90%
Monitoring System)
Flue Gas THC (Continuous Emission 20%' 25% 90%
I Monitoring System)
Flue Gas HO (Continuous Emission 20%f 25% 90%
I Monitoring System
Chlorine (Solid/Liquid) 2Q%b 10% 90%
I Metals (Flue Gas and Solid/Liquid) 2Q%b 15% 90%
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a Valid data percentage of total tests conducted.
b Relative percerit difference for duplicate analysis, where:
RPD = Maximum Value -Minimum Value x 100%
(Maximum Value+ Minimum Value)/2
c Relative error (%) based on recovery of matrix spike analytes native to each
analytical method matrix, where:
% = Measured Value -Spiked Value x 100%
Spiked Value
d Precision and accuracy estimate based on results of EPA collaborative tests
e Relative error (%) for audit analyses, where:
% = Measured Value -Theoretical Value x 100%
Theoretical Value
f Coefficient of variation (CV) for daily analyses for control sample prior to and
after daily testing, where:
CV = Standard Deviation x 100%
Mean
g Phenols accuracy may fall outside this range; see Table 3-4
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TABLE3-4. PRECISION, ACCURACY, AND COMPLETENESS OBJECTIVES
FOR ANALYSES OF VOIATILE AND SEMIVOIATILE ORGANIC
ANALYSES
Precisionb Accuracyc Completenessd
Critical Measurement (%) (%) (%)
Volatile Organics
(SW-846 Method 8240)
1,1-Dichloroethene 20 61-145 95
Trichloroethene 20 71-120 95
Chlorobenzene 20 75-130 95
Toluene 20 76-125 95
Benzene 20 76-127 95
Semi-volatile Ojanics
(SW-846 Metho 8270)
1,2,4-Trichlorobenzene 20 39-98 95
Acenaphthene 20 46-118 95
2,4-Dinitrotoluene 20 24-96 95
mene 20 26-127 95
Nitroso-di-n-propylamine 20 41-116 95
1,4-Dichlorobenzene 20 36-97 95
Pentachlorophenol 20 9-103 95
Phenol 20 12-89 95
2-Chlorophenol 20 27-123 95
4-Chloro-3-methylphenol 20 23-97 95
4-Nitrophenol 20 10-80 95
Metals (Methods 6010 20 75-125 95
and 7000 series)
a Accuracy objectives based on matrix spike ecovery limits specified in EIP A CLP
Statement of Work for Organic Analyses, September, 1986.
b Difference between matrix spike duplicate recoveries. The RPD for sample
matrix spike duplicate analyses must be 20% for analyte concentrations greater
than 200 ppb; 100% for analyte concentrations less than 200 ppb.
c Percent recovery for matrix spikes.
d Valid data, expressed as a percentage for possible measurement data.
The QNQC program focus will be upon controlling measurement error within these
estimated limits of measurement uncertainty. It should be noted that these are e:,timates
which are, in most cases, described in the methods and represent the range of results which
can be expected from these methods based on actual field sampling results and laboratory-
based QNQC studies. It is therefore reasonable to expect that the measuremeDit errors
associated with this project will be within the estimates shown on Table 3-3.
In the event that ongoing QA/QC procedures reveal that a measurement's error has
exceeded these estimated limits, the source of the excessive error will be immediately
identified and corrective action taken, as described in Section 10. If data fall outside the
acceptable range of precision and accuracy, even after corrective action has been taken,
those data points will be flagged in the final reports; the precision and accuracy for the
measurement will be reported as determined using the actual data. Additionally, if
possible, alternative procedures ( either samplin& or analytical) mar. be considered and
recommended to the client. Any changes or additions would necessarily be agreed to by all
parties before implementation. .
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4.0 SAMPLING INFORMATION
This section describes in detail the sampling methods and procedures to be used dw:ing the
incinerator demonstration test for collection of samples of the stack gas, liquid, and solid
samples. Process data will be collected during the test burn. At present time, this data
concerning incinerator operation is not detailed in this section since the final incinerator
plants are not complete. ·
4.1 Sampling Locations
This subsection presents a brief description of each location where samples will be
collected. The streams which will be sampled are:
1. Stack Gas;
2. Waste Feed;
3. Incinerator Ash;
4. Scrubber Liquids;
5. Scrubber Solids;
4.2 Sampling Procedures
This section describes in detail the sampling methods and procedures to be used by YORK
du.ring the incinerator demonstration test for collection of samples of the stack gas and
liquid and solid samples. Process data will also be collected by YORK personnel.
4.2.1 EPAMethod5
The stack gas and secondary chamber offgas will be sampled for measurement of
particulate matter, volumetric flow rate and moisture. The Method 5 sampling train is
shown in Figure 4-1.
Based on the Method 5 technique, a sample of particulate-laden flue gas is wilhdrawn
isokinetically using a gooseneck nozzle and beat-traced, glass-lined probe. The pruticulate
matter is collected on a glass fiber filter maintained at a temperature in the range of 248
25 F. The particulate mass is determined gravimetrically from the residues collected on the
filter and in the probe and associated glassware prior to the filter. After the filter, the flue
gas enters a chilled impinger tram where condensate is collected for moisture
determination of the flue gas (EPA Method 4). A pump and d~ gas meter are used to
control and monitor the gas flow rate. The data sheet shown in Figure 4-2 will be used to
record sampling data.
Du.ring collection of EPA Method 5 samples, S-o/Pe pitot measurements are taken in the
flue gas duct to determine the isokinetic samplmg rate. The&itot differential pressure
measurements, along with the flue gas composition (CO2, 2, N2, H2O) and cross-
sectional area of the duct, are also used to determine the volumetric flue gas flow rate.
---
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At the end of the samplin~ period, the nozzle, probe liner, and glassware preceding the
filter housing are rinsed with acetone and deionized water to remove particulate matter.
The resulting wash is evaporated and the mass of particulate residue is determined
gravimetrically. The glass fiber filter is removed from the filter holder, desiccated for 24
hours, and weighed to determine the mass of particulate on the filter. The total mass of
particulate present on the filter and in the probe wash is then divided by the total volume
of gas sampled to determine the particulate loading.
The impingers used during particulate sampling are weighed before and after sampling to
determme the moisture content of the flue gas. .
The sampling for the particulate test run will be at least one hour in duration with a
minimum of 30 dry standard cubic feet of stack gas collected. The average sampling rate
for each run will be within 10% of 100% isokinetic conditions. Reference Method 5
analytical procedures will be strictly adhered to in the determination of particulate
emissions.
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4.2.2 Modified Method 5 Sampling Train -SW846 Method 0010
The Modified Method 5 (MMS) sampling train will be used accordin~ to procedures
outlined in SW846 Method 0010 to measure naphthalene and semivolatiles. Ilte MM5
train includes a cartridge of XAD-2 resin to capture hydrocarbons that pass through the
particulate filter. Sample gas is cooled in a water-cooled condenser prior to encolUiltering
the XAD. The following sections describe each component in the proposed MM5
sampling train.
4.2.2.1 Sampling Train Description
A schematic of a typical MM5 sampling train is shown in Figure 4-3. Flue gas is pulled
from the stack through a stainless steel nozzle and glass probe. Particulate matter is
removed from the gas stream by means of a filter housed in a glass filter holder maintained
at 248 +/-25 F. (All components will be thoroughly cleaned with hexane prior to UlSe.) The
gas passes through a condenser and into a sorbent trap for removal of organic constituents.
A chilled impinger train is used to remove water from the flue gas and a dry gas meter is
used to measure the sample gas flow. Sealing greases will not be used on the sample train.
4.2.2.2 XAD Preparation
Cleanup of the XAD-2 resin will be conducted according to the Environmental Standards
Workshop protocol. Hexane will be used as the final solvent for preparation of the resin
and the fluidized bed technique will be used to dry the resin. The final solvent rinses will
be analyzed for residuals prior to packing the traps. Care will be taken to ensure that the
resin is kept at temperatures below 120 F before and after sample collection to prevent
resin decomposition. The sorbent tube will be charged with 20 to 30 grams of the
precleaned resin. The period of time between resin precleaning and use in the field! will be
minimized and will not be allowed to exceed 14 days.
4.2.23 Glassware Preparation
All glass parts of the MM5 sample train including the sorbent tube, will be predeaned
prior to sampling according to the procedure listed below. Cleaned glassware will be
capped with precleaned foil or glass plugs until sample train assembly in th,: field.
Following sample recovery, the glassware may be reused at the same sampling location.
1.
2.
3.
4.
5.
6.
Soak all glassware in hot soapy water (Alconox) 50 C or higher
H20 rinse (X3)a.
Distilled/deionized H20 rinse (X3)a.
Bake at 450 F for 2 hours.
1:1 v/v methanol/methylene chloride rinse (X3)a, (Pestidde grade).
Cap glassware with clean glass plugs or rinsed aluminum foil:
a (X3) = three times
I
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4.2.2.4 Sample Train Operation
The sample train will be operated according to the protocol. Special attention will be
given to the following QC checks:
1.
2.
3.
4.
5.
The entire sample train will be leak tested to ensure that leakage does not
exceed the lesser of
b
a) 4 percent of the average sampling rate
) 0.02 cfm
The probe exit temperature will be maintained above 248 F, and the filter
compartment will be maintained at 248 25 F during sampling.
Gas entering the sorbent module will be maintained at or below 68 F.
Isokinetic sampling will be maintained within 10 percent of 100.
Stored resin will be kept below 120 F at all times.
If a sample train leak is found after testing has begun, the following procedure will be
implemented:
4.2.25
1.
2.
3
4.
The field team leader will be immediately notified of the problem.
The location and quantity of the leak in the sample train will be identified.
Based on the location and quantity of the leak, the portion of the samfling
run completed at the time of the leak and the projected impact o the
problem on the particular sample and the overall test effort, the team leader
will decide whether to abort or continue the test run.
All occurrences of sample train leaks and the corrective action taken will be
noted on the data sheet and documented in the daily logbook.
Sample Recovery
Recovery of the MM5 samples and assembly of the sample trains will be conduct,ed in an
environment free from uncontrolled dust, such as a lab or vehicle if a lab is not available.
Access to this area will be limited to only those individuals involved in the 1recovery
process.
Sample containers from a typical MM5 test run will include those shown below. All
sam1;>le containers containing water should be extracted for analysis by the desiw:iated lab
within 7 to 14 days after sample collection. It should be noted that dependmg on the
particulate loading and/or the flue gas moisture content, the actual number of containers
from each sample run may vary.
Container/Component
1. Component Number 1 Filter(s)
2.
3.
4.
5.
6.
7.
8.
Component Number 2 Rinses of nozzle, probe, transfer line and front half
of filter holder
Component Number 3 Rinses of backhalf of filter holder, condenser, and
knockout
Component Number 4 Knockout contents
Component Number 5 First, second, and third impinger contents
Component Number 6 First, second, and third impinger rinses
Component Number 7 XAD-2s resin
Component Number 8 Silica Gel
The solvent to be used for rinsing the nozzle, probe, filter holder and cyclone is 1:1 v/v
methanol/methylene chloride.
4.2.2.6 Field Blanks
Field blanks consist of three portions of a sample train (impingers/sorbent trap, filter
holder and probe) which are assembled at the location as though to collect a sample, but
gas is not pulled through the train. The train is then disassembled (into three portions) and
returned to the laboratory for recovery using the same procedure used to recover actual
samples. The field blank is obtained using a train that has previously been used to collect
at least one actual sample from the test site. Blanks of each solvent lot used at the test site
are also saved for potential analysis.
4.23 Multiple Metals Sampling Train
Particulate and gaseous metals as emissions are withdrawn isokinetically from the stack
and collected on a filter and in a set of impingers contain absorbing solutions of the
following:
Hydrogen Peroxide;
Ammonium Sulfate;
Silver Nitrate and
Nitric Acid.
The sampling train is similar to the Method 5 train, and consists of a probe nozzle, probe
line, {litot tube, differential pressure gauge, filter holder, filter heating system, and
metenng system. For the purpose of this train, the train probe liner will be constructed of
borosilicate or quartz glass tubing.
The impingers connected in series with leak free non-contaminated fittings will contain a
known volume of the absorbing solutions.
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Preparation and collection of the sample will follow the procedures iiven in Method 5.
Recovery of the sample will follow Method 5 guidelines with the followmg exception:
All rinses of the probe nozzle, probe liner, and front half glassware will be
done with 0.1 N HNO3. All rinses of the impingers will be made with 0.1 N
HNO3.
Due to the large quantity ofliquids involved, the collected impinger sample
will be placed m several containers.
Blanks will be taken of all absorbing solutions and of the fiber filter used. A minimum of
200 ml of each of the absorbing solutions will be retained during the field test prngram.
Sample analysis will follow procedures detailed in SW 846, Chapter Three -Metallic
Analytes. Specific methods presented in Section 3.3 of this document contains :,pecific
atomic absorption procedures for inorganic analytes.
4.2.4 Continuous Emission Monitors (CEMs)
CEMs will be used during the demonstration test to monitor the concentrations of CO,
CO2, NOx, HQ in the stack gas.
A stainless steel probe will be inserted at the stack gas sampling location. Gas will be
withdrawn and transported via heat-traced (at 300 F) Teflon sample line to the
instrumentation area.
Gas will first enter a conditioning system having a series of short stemmed imping.ers ( as
condensers) immersed in an ice bath. After the conditioning system, P.articulate matter
and mist will be removed by a glass fiber filter. After filtration, the gas will be further dried
using a Perma-Pure dryer which utilizes a water vapor permeable membrane.
The gas will be drawn by a Teflon coated diaphragm pump located between the filter and
the Perma-Pure dryer. Flue gas for the seven instruments will be drawn from a manifold
downstream of the pump.
A brief description of each CEM instrument is provided below.
Carbon Monoxide - A Beckman Model analyzer, or equivalent, will be used to
measure CO co ncentration in the stack gas. This instrument is a non-dispersive
infrared (NDIR) analyzer which measures the concentration of CO by infrared
absorption at a characteristic wavelength.
Carbon Dioxide -To measure the CO2 concentration in the stack gas, a Beckman
Model, or equivalent, non-dispersive infrared (NDIR) analyzer will be used. This
instrument measures the concentration of CO2 by infrared absorption at a
characteristic wavelength.
Oxygen - A Taylor Model 540A oxygen analyzer, or equivalent, will be used to
determine the 02 concentration of the stack gas. The Taylor 540A measures
oxygen concentrations on the basis of the strong paramagnetic properties of 02
compared to other compounds present in combustion gases. In the presence of a
magnetic field, 02 molecules become temporary magnets. The Taylor 540A
determines the sample gas 02 concentration by detecting the displacement 1:orque
of <he-p~ 1"I body m th< p,~~re of, m,gn,i;, fi<l@IB ~ ~~
4.25
Nitrogen Oxides (NOx) - A TECO Model 10 analyzer, or equivalent, will be used to
measure the concentration of NOx present in the stack gas and primary furnace
offgas. This instrument determines NOx concentrations by converting all nitrogen
oxides present in the sample gas to nitric oxide and then reactin$ the nitric oxide
with ozone. The reaction produces a chemiluminescence proportional to the NOx
concentration in the sample gas. The chemiluminescence IS measured using a high
sensitivity photomultiplier. The instrument has the capability to measure NO, NOx
and N02 by difference.
Solid and Liquid Sampling Procedures
Sampling procedures which will be used to collect samples from solid and liquid sgearns
are described in this section.
Sample containers for the solid and liquid samples must be organic free and sealed prior to
receipt in the field. All sample bottles used for solid and liquid samples will be amber glass
with Teflon cap liners, cleaned to EPA protocols.
Each sample bottle that will be used to store samples for organic analysis will be pre-
cleaned using the following procedure:
4.25.1
Oeaned initially with a phosphate-free soap;
Rinsed three times with taP. water-
Rinsed three times with deionized water; Rinsed with nitric acid·
Rinsed three times with deionized water;
Rinsed with methY,lene chloride;
Baked in an oven for 6 hours at 200 C;
Allowed to cool and then capped.
Solid Sampling Procedures
Samples of the solid waste feed, furnace ash, scrubber solids, and baghouse will be
collected using a scoop, trier or dipper, as specified in USEPA Methods S007, S006, and
S002 of "Sampling and Analysis Methods for Hazardous Waste Combustion," February,
1984. Furnace ash, scrubber and baghouse solids will be collected throughout each test
period. Approximately 1,000 g of sample will be composited for each tesL A uniform
amount of the solid waste feed will be collected every 30 minutes and placed in a sealed
container. For each test, at least 2,500 g will be collected, and the total sample will be used
for subsequent analysis.
4.25.2 Liquid Sampling Procedures
Scrubber make-up water samples will be collected using the dipper and tap sampling
procedure specified in USEP A Method S002 and S004, "Sampling and AnalysIS Methods
for Hazardous Waste Combustion," February, 1984.
4.2.6 Calibration Procedures
Information is presented in this section pertaining to the calibration of sampling
equipmenL Included are descriptions of each procedure or references to applicable
standard operating procedures, the frequency of calibrations, and the calibration standards
to be used. Calibration frequency of the field sampling equipment is presented in Table 4-1.
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4.2.6.1 Sampling Equipment Calibration Procedures
An important function in maintaining data quality is the checkout and calibration for the
source sampling equipment. Using referenced procedures, the equipment will be c.~ibrated
prior to field sampling at the YORK laboratories and the results will be properly
documented and retained. If a referenced calibration technique for a particular piece of
apparatus is not available, then state-of-the-art techniques are used. A discussion of the
procedures used to calibrate this equipment is presented below.
4.2.6.2 S-Type Pitot Tube Calibration
The EPA has specified guidelines concerning the construction and geometry of an
acceptable S-Type pi tot tube. If the specified design and construction guidelines ar,: met, a
pitot tube coefficient of 0.84 can be used. Information related to the design and
construction of the S-type pitot tube is presented in detail in Section 3.1.1 of EPA
document 600/4-77-027b. Only S-type pitot tubes meeting the required EPA specifications
will be used during this project. Pnor to the field sampling, the pitot tubes will be
inspected and documented as meeting EPA specifications.
4.2.63 Sampling Nozzle Calibration
EPA Method 5 prescribes the use of stainless steel gooseneck nozzles for isokinetic
particulate sampling. Calculation of the isokinetic sarnplin& rate requires that th,: cross-
sectional area of the samplin& nozzle be accurately and prec1Sely known. All nozzles used
for the EPA Method 5 particulate sampling and Modified Method 5 sampling will be
thorou&hly cleaned, visually inspected, and calibrated according to the procedure outlined
in Sectmn 3.4.2 of EPA document 600/4-77-027b. According to this procedur<~ three
measurements of the inside diameter of the nozzle will be made on different diameters.
Using a Vernier caliper, measurements will be made to the nearest 0.001 inch. Nozi:les will
be considered acceptable if the difference between any two measurements is less than 0.004
inches.
TABIE 4-1 CALIBRATION FREQUENCY OF FIELD SAMPLING EQUIPMENT
Sampling
Equipment
S-Type Pitot Tube
Sample Nozzle
Calibration
Before Sampling Daily
* * * * Differential Pressure Gaie
Tem&erature Measuring evices
Dry as Meters
~~ical Balance * * * *
4.2.6.4 Differential Pressure Gauge Calibration
Frequency
After Sampling
*
*
*
If any, Magnehelic gauges are to be used during this project to measure differential; and
static pressures. They will be calibrated using Section 3.1.2 of EPA document 60~/4-77-
027b. This technique requires that pressure readings of the Magnehelic be compared
directly to that of a gauge oil manometer. The Magnehelic gauges will be calibrated prior
to field sampling and checked at a single representative value following the field sampfing.
4.2.65 Temperature Measuring Device Calibration
During source sampling, accurate temperature measurements are required. Thermocouple
temperature sensors will be calibrated using the procedure described in section 3.4.2 of
EPA document 600/4-77-027b. Each temperature sensor will be calibrated at a minimum
of three points over the anticipated range of use (if possible) against a NBS traceable
merclll)'-in-glass thermometer. All sensors will be calibrated prior to field sampling.
4.2.6.6 Dry Gas Meter Calibration
Dry gas meters (DGMs) will be used in the Modified Method 5, and Method 5 trains to
momtor the sampling rate and to measure the sample volume. All dry gas meters will be
calibrated ( documented correction factor at standard conditions) just prior to the
departure of the equipment to the field. A post-test calibration check will be performed as
soon as possible after the equipment has been returned to YORK. The pre and post test
calibrations should agree within 5 percent.
The dry gas meters to be used will be calibrated using the calibration system illustrated in
Figure 4-4. Using the procedure outlined in Section 3.3.2 of EPA document 600/4-77-
237b, a positive pressure leak check of the system will be performed prior to calibration.
To perform the leak check, the system is placed under approximately ten inches of water
pressure and a gauge oil manometer is used to determine if a pressure decrease can be
detected over a one minute period. If leaks are detected, they will be eliminated before
actual calibrations are performed.
To calibrate a dry gas meter, the pump will be allowed to run for 15 minutes after the
sampling console is assembled and leak checked. Once the pump and dry gas meter are
warmed up, the valve on the console is adjusted to obtain the desired flow rate. After 10
minutes, the valve is closed and a final set of data is recorded. A duplicate calibration is
then performed at the same flow rate. If necessary, additional calibrations are conducted
until the calibration results (Yi) vary by no more than 2 percent The average Yi is then
calculated and recorded on the face of the DGM console.
During this project, Rockwell dry gas meters will be used during the Modified Method 5
and Method 5 tests.
4.2.6.7 Analytical Balance Calibration
During the field measurement program, the analytical balances will be calibrated over the
expected range of use with standard weights (NBS Class S traceable) on a daily basis.
Measured values must agree within +/-.1 mg.
4.2.6.8 Sample Custody
Sample custody procedures for this program are based on EPA recommended procedures.
Since samples will be analyzed off-site, at YORK's permanent laboratory facilities, the
custody procedures discussed below will emphasize careful documentation of monitoring,
sample collection, and field analytical data and the use of chain-of-custody records for
samples being transported.
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The field sampling leader will be responsible for ensuring the proper custody and
documentation procedures are followed for the field sampling and field analytical efforts.
He will be assisted in this effort by the sampling personnel involved in sample recovery.
All sampling data, including sampling times, locations, and any specific considerations
associated with sample acquisition will be recorded on preforrnatted data sheets.
Followin& sample coflection, all samples will be logged into a master logbook (bound
notebook) and given a unique alphanumeric identification number. Any specific sample
preservation, storage, or on-siteanalysis information will also be noted. Sample labels and
chain-of-custody seals will be completed and affJXed to the sample contamer. Finally,
chain-of-custody forms will be completed by any personnel invofved in the handling of
samples.
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5.0 LABO RA TORY PROCEDURES/CALIBRATIONS/QUALITY CONTROL
Samples of solid waste feed, scrubber solids, scrubber liquids, furnace ash, and liquids and
solids from flue gas sampling, will be analyzed for parameters as specified in Table 5-1.
The analytical scheme is discussed briefly below. Descriptions of the analytical methods
are presented in the following sections.
5.1 Analytical Quality Control Procedures
For each measurement parameter, internal QC procedures are designed to control and
assess the performance of the analytical system. The procedures include adherence to
accepted laboratory rrocedures in accordance with the specified analytical protocols, the
use of quality contro charts, and adherence to acceptance criteria for internal QC :;ample
analyses. A control chart consists of a graphical chart with the vertical scale plotted in
units of the test result and the horizontal scale in units of time or sequence of results. The
upper and lower control limits shown on the chart are used as criteria for action or for
judging the significance of variations between duplicate samples. Daily precision and
accuracy data will be plotted by means of these quality control charts to determine if valid,
questionable, or invalid data are being generated from day to day.
Internal QC procedures are described in the following sections for each analytical method.
They are designed to ensure that the analytical systems remain properly calibrated, free
from contamination, and in control. Analyses may not proceed until specific acceptance
criteria for calibration, control sample recovery, and blank sample analyses ar,: meL
Measurement accuracy for project samples will be determined from matrix spike
recoveries. If a matrix spike recovery is unacceptable, a control sample will be analyzed to
determine whether the error is due to a problem with the analytical system or due to
matrix effects. If the problem is related to the analytical system, tlie cause of error will be
corrected before analyses proceed; analyses will be repeated to the last acceptable control
sample. When matrix spike recovery data indicate that accuracy objectives cannot be met
due to matrix interferences, the data will be flagged and the Project Director will be
advised. The feasibility of alternate methods of quantitation ( e.g., the method of standard
additions) as a means of mitigating the matrix effects will be investigated with the clic:nL
Duplicate matrix spikes will be performed at a rate of one set per twenty samples,
minimum, or at least one set per matrix.
Acceptance criteria for control sample analyses and drift checks will also be used to control
analytical variability, although precISion estlIDates will be based on duplicate matrix :;pikes.
Control sample recoveries will be required to repeat within specified fimits or analyses will
not proceed. If duplicate analysis results do not agree within the specified acceptance
criteria, a third value will be obtained to improve the estimate for precision for that
parameter. ·
In addition to controlling the quality of data during production, internal QC sample test
results will be used to provide estimates of precision and accuracy which will be used in the
evaluation and interpretation of project data.
Table 5-1
Pa.ramecer
pH
Chloride
Ulcimace
Ash, Moiscure
HHV
Densit:y
TOC
Solids (TSS, TDS)
Parriculace Macrer
Moisture
Mecals
Uquid Dissolved
Solids
Preservacion Requ.iremencs and Holding Times foe Samples
Preservacion &
Storage Requiremencs
None
None
None
None
None
4"C; pH <2 (H2S0,)
4•c
· None
None
Filcer, pH <2 (HN03)
None
Maximum Holding
Time (days)
6 Hours
28
None
None
None
None
28
7
None
None
6 Monchs"
6 Monchs•
Volacile and Semi-Volacile Organics
8240
8270
VOST
•
b
4"C, Dark, Inverred 14
4•c
4•c
14(excracc), 40(analyze)
14-42b
Excepc for Mercury, which is 28 days.
Analysis will be done as quickly as possible.
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5.2 V-PP+lO Analysis
V-PP+ 10 analysis will be conducted on several types of samples including solid and'. liquid
phase samples. The solid and liquid incinerator samples include:
5.2.1
Feed;
Furnace Ash;
Scrubber Solids;
Scrubber Liquids;
Liquid and Solid Sample Analysis for V-PP+ 10
Liquid and solid samples will be analyzed by scanning gas chromatography/mass
spectrometry (GC/MS) following SW-846 Method 8240, Third Edition, November 1986.
Analyte identification and quantitation will be performed using response factors and
retention times, relative to the closest eluting of three internal standards, generated from a
five point calibration curve. The three internal standards are:
Bromochloromethane;
1,4-Difluorobenzene; and
Chlorobenzene-d5.
5.2.1.1 Calibration
The mass spectrometer will be tuned daily to give an acceptable spectrum for
bromoflurobenzene (BFB). Relative ion abundance cnteria for BFB are shown in Table 5-
2
TABLE 5-2 BFB* KEY ION ABUNDANCE CRI1ERIA
Mass
50
75
95
96
173
174
175
176
177
Ion Abundance Criteria
15 to 40% of mass 95
30 to 60% of mass 95
Base Peak, 100% Relative Abundance
5 to 9% of mass 95
Less than 2% of mass 174
Greater than 50% of mass 95
5 to 9% of mass 174
Greater than 95% but less than 101 % of mass 174
5 to 9 % of mass 176
• BFB is 4-bromofluorobenzene
System performance will be verified initially and after every 12 hours to ensure a minimum
average response factor of 03 (0.25 for bromoform) for the following system perfonnance
check compounds (SPCCs):
Chloromethane;
1, 1-Dichloroethane;
Bromoform;
1, 1,2,2-Tetrachloroethane and
Chlorobenzene.
A five 8oint calibration, used for generating response factors, will be performed initially
using 1 , 20, 50, 100, and 200 ug/L standards. As a check on linearity, the relative standard
deviation (RSD) must be less than 30 percent for the five response factors calculated for
each of the following calibration check compounds (CCCs):
1,1-Dichloroethene;
Chloroform;
1,2-Dichloropropane;
Toluene;
Ethylbenzene; and
Vinyl chloride.
A continuing ( every 12 hours) calibration check will be performed, following the system
performance check, using the CCCs listed above. A single concentration of each CCC will
be analyzed and a response factor calculated. The single point RF for each CCC must be
within 25 percent of the average five point RF. OthefWISe, a new five point calibration
must be generated.
53 SY-PP+ 10 Analysis
SY-PP+ 10 analysis will be conducted on all sampled streams including:
53.1
Solid Waste Feed;
Furnace Ash;
Scrubber Solids;
Scrubber Liquids and
Stack Gases.
Stack Gas and Primary Furnace Offgas Analysis for SY-PP+ 10 Analysis
SY-PP+ 10 analysis for surrogates and semi-volatile organic com_p~~ds will be performed
on the stack gas samples collected using MM5. The solid (XAJJ-2 resin) and liquid
samples ( aqueous condensate) will be prepared for analysis and then analyzed for
senuvolatile constituents usin& the procedures outlined in SW-846, ''Test Methods for
Evaluating Solid Waste,"and m the EPA publication, "Methods for Organic Chemical
Analysis of Municipal and Industrial Waste Water." The SV-PP+lO in the stack gas and
primary furnace offgas samples will be analyzed using the procedures specified in the Third
Edition of SW-846 Method 8270. . .·.
The MM5 agueous condensates will be extracted using SW-846 Method 3520, which is a
continuous liquid-liquid extraction. The XAD-2 resin and filter catch of the Modified
Method train will be extracted by Soxhlet extraction in accordance with SW-846 Method
3540. Extracts will be concentrated for analysis using a Kedema-Danish concentration
with Snyder columns. The resulting organic extract samples will be diluted in an
appropnate solvent as necessary to be within the calibration range of the instrument.
[ID [lli ill ~ 1J
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Quantitation will be performed using six internal retention time standards used for
quantitation are:
Dichlorobenzene-d4;
Naphthalene-dB;
Acenaphthene-d 10;
Phenanthrene-dlO;
Chrysene-dl2;and
Perylene-d12.
Target analyte determination will be determined from both retention times and by
matching three major ions from the mass spectrum of GC eluent to those in th◄: mass
spectral library. A standard solution containing analytes from the target list will be used to
generate the mass spectral library.
53.1.1 Calibration
The mass spectrometer will be tuned daily to give an acceptable spectrum for DFI'PP.
DFI'PP ion abundance criteria are shown in Table 5-3.
System performance will be verified initially and after every 12 hours to ensure a minimum
average response factor of 0.050 for the following system performance check compounds
(SPCCs).
N-nitroso-di-n-propylamine;
Hexachlorocyclopentadiene;
2,4-Dichlorophenol; and
4-Nitrophenol.
A five point calibration, used for _generating response factors, will be performed initially
using 10, 20, 50, 100, and 200 ug/L standards. Specific ion response factors for Method
8270 calibration check compounds must be less than 30 percent RDS over the range
calibrated. The CCCs are:
Hexachlorobutadiene;
Acenaphthene;
2,4,6-Trichlorophenol and
Naphthalene
Benzo(a) pyrene
A continuing (every 12 hours) calibration check will be performed following the i;ystem
performance check using the CCCs listed above. A single concentration of each CCC will
be analyzed and a response factor calculated. The single point RF for each CCC must be
within 30 percent of the average five point RF. Otherwise, a new five point calibration
must be generated.
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TABLE 5-3. DFfPP KEY IONS AND ION ABUNDANCE CRITERIAa
Mass Ion Abundance Criteria
51
68
70
127
197
198
199
275
365
441
442
443
30 to 60% of mass 198
Less than 2% of mass 69
Less than 2% of mass 69
40 to 60% of mass 198
Less than 1 % of mass 198
Base peak, 100% relative abundance
5 -9% of mass 198
10 -30% of mass 198
Greater than 1 % of mass 198
Present but less than mass 443
Greater than 40% of mass 198
17 to 23% of mass 442
a Eichelberger, J.W.; LE. Harris; and W.L Budde.
Reference compound to calibrate ion abundance in gas
chromatography/mass spectrometry. Analytical Chemistry,
47:995, 1975.
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6.0 DATA REDUCTION, VALIDATION AND REPORTING
6.1 Calculations
The overall data reduction, validation and reporting flow scheme for this project is
presented in Figure 6-1. Detail of the data reduction, validation and reporting are
discussed in the remainder of this section.
The following section detail the calculations which will be performed for data reduction.
6.1.1 Particulate Mass Emission Calculation
The mass emission rate (gains per dscf) will be determined for total particulates b~!Sed on
EPA Method 5 as follows:
Cs= (Mn) (0.001) (15.43) / (Vd),
where:Cs= concentration of particulates in the flue gas at dry standardconclitions
Mn
Vd
0.001
15.43
(grains/dscf);
= mass of particles collected (mg);
= dry gas volume sampled at standard conditions ( dscf);
= conversion of milligrams to grams; and
= conversion of grams to grains.
[ID [fil ffi ~ Li
Figure 6-1 Data Reduction, Validation and Reporting Flow Scheme
!
PARTICULATE
KASS
10% AUOIT
OF DATA
FIELD CATA COLLECTION
(Field Supervisor)
•
"10 MAJOR" PEAk'.S,
PROXIKATE/lJLTIKATE
CL, ASH, OENSITY
!
DATA REVIEII -(QA/QC Officer)
l
DATA REOUCTIOH -(Project Manager)
I
REPORTING
(Project Manager)
INCINERATOR PROCESS CATA
(GUC Personnel)
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6.1.2 Particulate Mass Emission Correction
The particulate mass emission will be corrected to 7 percent oxygen in the stack gas as
follows:
where:
Csc = Csx 14
(21-Y)
Csc = Corrected Particulate Mass Emissions
Cs = Particulate Mass Emission
Y = Measured oxygen concentration in the stack gas 011 a dry
basis ( expressed as percentage)
6.1.3 Scrubber Efficiency
Scrubber efficiency (SE), used to determine chloride species removal, will be calcul~.ted as
follows:
6.1.4
SE = Clin -Clout x 100%
Clin
where: Clin = mass feed rate of chlorine entering the incinerator;and
Clout = mass emission rate of chlorine ( as hydrogen chloride )in the
scrubber exhaust prior to emission to the atmosphere.
Stack Gas Volumetric F1ow Rate
The stack gas volumetric flow rate will be determined for two bases. The velocity of the
stack gases based on EPA Method 2 will be calculated as:
Vs = 85.49 CP P (Ts)(P)
(Ps)(Mw)
where: Pilot tube constant = 85.49 ft/sec (lb/lb-mole )(in. Hg)
( R)(in. H20)
Vs = p =
Ts =
Ps = Mw = Cp =
velocity of the flue gas (ft/sec);
average differential pressure measured by S-type pitot (in. H20);
absolute gas temperature in duct ( R);
absolute duct pressure (in. Hg);
wet gas molecular weight (lb/lb-mole); and
~~ p;~ oo=ruoo racto, (••rn& ~ ~ ~
6.1.5 Stack Gas Volumetric Flow Rate Calculation · Actual Conditions
The volumetric flow rate of the stack gases based on EPA Method 2 will be calculated as:
Qac = 60 (Vs) (A),
where: Qac = actual volumetric flow rate (acfm); Vs = velocity of the flue gas (ft/sec); A = cross-sectional area of the duct (ft2); and 60 = conversion from seconds to minutes.
6.1.6 Stack Gas Volumetric Flow Rate Calculation· Dry Standard Conditions
The volumetric flow rate of the stack gases at dry standard conditions based on EPA Method 2 will be calculated as:
where:
Qsd = (1 · Bw) (Qac) (528/Ts) (Ps/29.92),
Qsd = dry volumetric flow rate at standard conditions (dscfm); Qac = actual volumetric flow rate (acfm); Bw = moisture fraction;
528 = standard temperature ( R);
Ts = average gas temperature in duct ( R); 29.92 = standard pressure (in. Hg); and Ps = absolute duct pressure (in. Hg).
6.1.7 CO, CO2, and 02 Concentration Calculations
Response factors (RF) for the continuous monitors will be calculated from the single point RF check and the mstrument zero value as follows: ·
RF = Cstd
(%IR)std • (%IR)zero
Using this response factor, the sample concentration will be calculated using the following equation:
Csmpl = [(%IR)smpl · (%IR)zero] x RF,
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where:
RF
Cstd
Csmpl
(%IR)std
?%IR?zero %IR smpl
=
=
=
=
=
=
response factor or calibration factor for the parameter calibrated,
CO, CO2, 02, or NOx;
certified concentration of the parameter in the calibration gas;
sample concentration;
instrument response to standard;
!115trument response to zero gas; and
instrument response to sample.
6.1.8 Waste Feed Rate
The concentration of antimony, volatiles, semi-volatiles and other metals will be reported
in units of microwarns per gram for the waste feed solids. These values will be reported
for each composite sample for each run. The total mass rate of the individual compounds
fed to the incinerator during each burn will be calculated from these concentrations and
the process operation data for the amount of each feed material fed to the incinerator
during each burn.
6.1.9 Solids/Liquids Analysis Calculations
The concentration of antimony, volatiles, semi-volatiles and other metals will be reported
in units of microgram per liter for the liquid samples and in units of microgram per gram
for the solid samples for each test.
6.1.10 Mass Balance
The concentration of chlorine in the waste feed, liquids, solid samP.les and stack gas
emissions will be determined. Mass balances for the compounds will be evaluated as
follows:
Win + Ain = SGout + Lout + Sout
where:
Win =
Ain =
SGout=
Lout =
Sout =
compound in waste feed in;
compound in auxiliary fuel in;
compound in stack emissions;
compound in liquids out; and
compound in solid samples out
6.1.11 Percent Destruction and Removal Efficiency (DRE)
The DRE for each principal hazardous constituent in the hazardous waste will be
calculated as follows:
DRE= [(Win-Wout)/Win] x 100
[ID 00 ffi ~ U
where:
6.2
Win = mass feed rate of the compound or element of interest in the
waste stream fed to the incinerator; and
Wout = mass emission rate of the compound or element of interest in the
stack prior to release to the atmosphere.
DATA VALIDATION
All measurement data will be validated based upon representative process conditions
during sampling or testing, acceptable sample collection and testing procedures,
consistency with e"£ected and/or other results and adherence to prescribed QC procedures.
Any suspect data will be flagged and identified with respect to the nature of the problem.
63 REPORTING
Reporting responsibilities for this project are shown in Table 6-2.
In addition to calculating and reporting the information listed in this section, incinerator
operational data (supplied by GDC personnel) will be included in a report on the results of
the trial bum. Analytical results will be summarized and included in the data analysis
report.
YORK will evaluate the results of the demonstration test for completeness and
representativeness and will _perform the calculations for chlorine removal, particulate
matter concentrations, emission rates and other required data. A report of the results of
the trial bum will be submitted to GDC after completion of sampling. Data and results
interpretation will be presented as necessary in the report. The report will also detail
sampling and analytical procedures used.
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I Task
I Quality Assurance
Project Plan
Site·S~ecific
I Data umrnaries
Final Report
I Outline
Draft Final Report
I Final Report
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Table 6-2 Summary of Data Reduction, Review and Validation
of Reporting Responsibilities
Data
Reduction
Field Team
Members
C. Douglas
Personnel Responsibilities
Data Review
· and Validation
C. Douglas
J. Zuzolo
J. Zuzolo
J. Zuzolo
Reporting:
J. Zuzolo
J. Zuzolo
J. Zuzolo
A Rubenstein
A Rubenstein
Final
Review
F. Fowler
F. Fowler
7.0 INTERNAL QUALITY CONTROL CHECKS
Specific QC procedures will be followed to ensure the continuous production of useful and
valid data throughout the course of the GDC incinerator trial burn. The QC checks and
procedures described in this section represent an integral part of the overall sampling and
analytical scheme. Strict adherence to prescribed procedures is quite often the most
apphcable QC check. A discussion of both the sampling and analytical QC checks that will
be utilized during this program is presented below.
Prior to actual sampling on site, all of the applicable sampling equipment will be
thoroughly checked to ensure that each component is clean and operable. Each of the
equipment calibration data forms will be reviewed to ensure the QC objectives have been
met. Each component of the various sampling systems will be carefully/ackaged for
shipment Upon arrival on site, the equipment will be unloaded, inspecte for possible
damage and then assembled for use. Method-specific QC procedures follow.
7.1 Sampling Quality Control Procedures for Methods 2 through 5 and Modified
Method 5; and Metals
Samples for semivolatile organics analyses will be collected according to SW 846 Method
0010 (Modified Method 5) protocol. Total particulate mass and metals concentrations in
the stack gas and secondary chamber off gas will be determined using EPA Method 5.
Quality control for sampling will focus on the following as appropriate for the individual
samphng trains.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Prior to sampling, each MMS/MS filter will be placed in a labeled, individual
precleaned glass or plastic petri dish.
Assembly and recovery of the sample trains will be performed in an
environment free from uncontrolled dust
Each sampling train will be visually inspected for proper assembly before
use.
All sampling data and calculations will be recorded on preformatted data
sheets.
Prior to sampling, calculations will be made to determine the proper size
nozzle required to attain isokinetic sampling.
The sampling nozzle will be visually inspected before and after each run for
damage.
The S-type pitot tube will be visually inspected before and after each run for
damage.
Each leg of the S-type pitot tube will be leak-checked before and after each
run.
The oil manometer to be used to indicate the differential pressure (P) across
the S-type pitot tube will be leveled and zeroed.
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7.2
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
The temperature measurement system will be visually checked for damage
and checked for operability by measuring the ambient temperature: prior to
each traverse.
During sampling, the roll and pitch axis of the S-type pilot tube and the
sampling nozzle will be properly maintained.
The entire sampling train will be leak-checked before and after each run. If
the sampling train is moved from one sampling port to another during a run,
the train will be leak-checked before and after the move.
Additional leak checks will be performed if the sampling time exC(:eds four
hours.
The filter and sorbent trap will be maintained at the proper temperature
throughout the test run.
Ice will be maintained in the sampling train ice baths throughout each run.
Dry gas meter readings, velocity bead differential pressure (P) and meter
orifice (H) readings, temperature readings and pump vacuum readings will
be properfy made during sampling at each traverse point (An exan1ple data
sheet is provided in Appendix D.)
Isokinetic sampling will be maintained within + 10%
In weighing the filters, both prior to and after sampling, repeat weighings will
be performed at least six hours after the initial weighings. Repeat weighings
must agree within +0.5 mg to be considered acceptable.
Mass blank determinations (particulate determinations) will be performed
on each lot of methylene chloride/ methanol rinse solution. Blank residues
must be <0.01 mg/g or 0.001 % of the blank weight
Each irnpinger will be weighed to the nearest 0.2 gram before a1Dd after
sampling.
Any unusual conditions or occurrences will be noted during each run on the
appropriate data form.
The field sampling team leader will review sampling data sheets daily during
testing. ·
The Method 3 sampling probe will be stainless steel and equipped with a
filter (glass wool plug) to remove particulate matter.
The Method 3 sampling train will be purged prior to sample collection.
The Method 3 sampling port will be properly sealed to prevent air in-
leakage.
73
2.
3.
4.
All containers used for collection of bulk samples and all sampling equipment will expose the sample material to only glass, Teflon or stainless
steer surfaces.
Only amber or opaque containers will be used.
The method of sample collection will be documented.
All bulk samples will be thoroughly mixed before sample analysis.
CEM Quality Control Procedures
During the testing program, CEM: operation will include the following general QC procedures.
1. All calibration standards will be certified standards (+2% analytical accuracy).
2. All CEM calibration data, QC data and maintenance operations will be recorded in bound laboratory notebooks or on pre-formatted data sheets.
3. CEMs data will be collected using a computerized data acquisition system and/or strip chart recorders.
In addition to these general QC considerations, CEM drift checks for all analyzers will be performed routinely to ensure that the monitoring data remain within precision and accuracy limits specified in the performance specifications. Each day calibration gas will be introduced to each monitor. Drift will be defined as the difference between the monitor value and the actual concentration of the standard, expressed as a percentage of the calibration gas value.
Drift checks will be performed prior to any calibration or zero adjustmenL For the 02 and CO2 monitors, the acceptance limit is 05% 02 or CO2 (absolute). The acceptance limit for the CO, NOx, and HCI monitors is +5% (full scale) drift. ·
7.4 Quality Control for Fixed Gas Analysis
Fixed gas analfsis for molecular weight determination will be based on EPA Method 3. Quality contra procedures will include two or more single point calibration prior to the field_ test activi_ties: _The a~~ce criteria for the single point calibrations will be rephcate analysJS within <5% (CV). ·
Each day, each monitor will be challenged with a mid-range ( 40-60%) certified gas. ~eference to these gases will define accuracy and serve as a daily audit for each instrumenL
7 5 Quality Control Procedures for GC/MS Analysis of Volatiles
Internal quality control checks on the GC/MS analysis will consist of daily tuning of the mass spectrometer, anai>:sis of GC column performance standards, calibration checks, and analysJS of surrogate spikes for extraction efficiency. A multipoint calibration curve and
respo= fuctm rn, the =po~ds of U>te«st will be de,olop<d. @[2 [fj ~ u
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7 5.1 Instrument Calibration and Tuning
Mass calibration of the GC/MS instrument will be demonstrated daily with
perfluorotributylamine (PFfBA) prior to tuning the instrument to the criteria for
bromofluorobenzene (BFB).
75.2 System Performance
System P,erformance will be verified initially to ensure a minimum average respon:se factor
of 03 (0.25 for bromoform) for the following system performance check compounds
(SPCCs):
Chloromethane;
1,1-Dichloroethane;
Bromoform;
1, 1,2,2-Tetrachloroethane and
Chlorobenzene.
The above criteria will be demonstrated every 12 hours for the duration of the analyses.
753 Analyte Calibration
The initial five point calibration of 10, 20, 50, 100, and 200 ug/L standards, used for
generating response factors, must demonstrate a percent relative standard deviation
(%RSD) of less than 30 for all calibration check compounds (CCCs) shown below:
1,1-Dichloroethene;
Chloroform;
1,2-Dichloropropene;
Toluene;
Ethylbenzeneand
Vinyl chloride.
This criterion will also be demonstrated every 12 hours for the duration of the analyses for
the 8240 analyses.
7.5.4 Surrogate Recovery
To monitor purging and trapping efficiency, each sample will be spiked with three surrogates before analysis. The compounds are listed below:
l,2-Dicloroethane-d4;
Toluene-dB; and
Bromofluorobenzene.
7.5.5 Blanks
Daily extraction blanks will be analyzed to check for background contamination.
7.5.6 Duplicate Matrix Spike analyses
A sample from each matrix type will be used to perform duplicate matrix spike analyses. Duplicate aliquots will be spiked with 125 ng each of the following volatile compounds:
.hl-Dichloroethene;
1 richloroethene;
Chlorobenzene;
Toluene and
Benzene
7.5.7 Internal Standard
All volatile measurements will utilize the internal standard method of quantitation. The internal standards to be used are bromochloromethane, 1,4-difluorobenzene, and chylorobenzene-d5.
7.6 Quality Control Procedures for GC/MS Analysis Semivolatiles
7.6.1 Instrument Tuning and Calibration
All semivolatile extracts will be analyzed using the procedures outlined in SW-846 Method 8270, third edition, without significant modification. The mass spectrometer used for these analyses will be tuned daily using PFfBA The stability of this tune will be verified by demonstrating an acceptable spectrum of decafluorotriphenylphos_phene (DFI'PP) daily ( or every 12 liours ). Chromatograehy will be verified by examimng the peak shape of benzidine and pentachlorophenol daily.
7.6.2 System Performance
System performance will be verified daily, beginning with the 5-point calibration, by demonstrating that system performance check compounds (SPCCs) have response factors greater than 0.05 using the mid level calibration standard. These SPCCs are:
N-Nitrosodi-n-propylarnine;
Hexachlorocyclopentadine;
2,4-Dichlorophenol; and
4-Nitrophenol.
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7.63 Continuing Analyte Calibration
A 5-point calibrations will be generated before beginning this work using Appendix IX
standards at 10, 20, 50, 100, and 200 ugtmL concentrations. Specific ion response factors
for the calibration check compounds must have less than 30% relative standard deviation
over the range calibrated. These calibration check compounds (CCCs) are:
Hexachlorobutadiene;
Acenaphthene;
2,4,6-Trichlorophenol;
Naphthalene
Benzo(a)pyrene.
These CCCs will be reanalyzed every 12 hours to verify that the response factor remain
with 30% of that generated from the average of the 5 point standard.
7.6.4 Surrogate Recoveries
Surrogate recoveries for the semivolatile extraction surrogates will be determined for all
blanks and samples.
7 .6.5 Blanks
At least one extraction blank will be generated for each sample seL Fair Toxic
Characteristic Leaching Procedures (TCLP) samples, a leachate and reagent blank. will be
generated and analyzed with the samples. .
7.6.6 Duplicate Matrix Spike Analyses
A sample from each matrix type will be used to perform duplicate matrix spike analyses.
Samples will be spiked prior to extraction with a mixture containing the following:
1,2,4-Trichlorobenzene;
Acenaphthene;
2,4-Dinitrotoluene;
Pyrene;
1,4-Dichlorobenzene;
N-nitrosodi-n-propylamine;
Pentachlorophenol;
Phenol;
2-Chlorophenol;
4-Chloro-3-methyl phenol, and
4-Nitrophenol
This analysis gives a measure of both accuracy and precision of the method.
[ID 00 ill ~ TI
7.6.7 Internal Standards
All semivolatile measurements will utilize the internal standard method of quantitation. The internal standards to be used are:
1,4-Dichlorobenzene-d4;
Napthalene-d8;
Acenaphthene-dlO;
Phenanthrene-dlO;
Cluysene-dl2; and
Perylene-dl2.
7.7 Metals Analyses
7.7.1 Instrument Calibration
All samples will be analyzed according to the procedures outlined in tbe appropriate methods listed in Section 5. Calibration of all instrumentation will be performed daily witb freshly prepared standards.
7.7.2 System .Performance
System performance will be verified immediately after calibration witb a calibration verification standard prepared from a different source from the calibration standards. An NBS or EPA Quality Assurance sample will be used for this purpose when applicable. This standard is tben analyzed at 10% intervals throughout the analysis and at the end of tbe analytical run, to verily system control. .
7.73 Blanks
Calibration of DI water blanks will be analyzed at a frequency of 10% to check for system contamination. Preparation blanks, aliquots of deionized water that are taken through tbe digestion/extraction process as though they were a sample, will be prepared at a frequency of one per batch digested/extracted or one per twenty samples, whichever is greater.
7.7.4 ICP Interference Check Sample
An ICP Interference Check Sample will be analyzed at the be$inning, middle and end of the run throughout most of tbe project. The results must be within the 80-120% recovery control limits set by the EPA .
7.7.5 Duplicate Matrix Spike Analysis
A duplicate matrix spike sample will be analyzed once during the project. The relative percent difference should be within 20 percenL
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8.0 PERFORMANCE AND SYSTEM AUDITS
No performance or systems audits are planned as an integral aspect of this pro gr am to be
performed by YORK. YORK will cooperate with any and all regulatory agencies involved
with this program with Agen9' requested performance and[or systems audits. Any
performance and/or systems audits requested will be coordinated through Dr. Fred Fowler
of YORK.
9.0 DATA QUALITY INDICATORS
The QC analyses conducted during the testing program are designed to provide a
quantitative assessment of the measurement system data. The tow aspects of data quality
which are of primary concern are precision and accuracy. Accuracy reflects the degree to
which the measured value reeresents the actual or "true" value for a given parameter and
includes elements of both bias and precision. Precision is a measure of the variability
associated with the measurement system. The completeness of the data will be e:valuated
based upon the valid data percentage of the total tests conducted.
9.1 Precision
Precision by the definition presented in the EPA Quality Assurance Handbook for Air
Pollution Measurement Systems. Volume I: Principles (EPA-600/976-005) is "a measure
of mutual at1reement among individual measurements of the same property, usually under
prescn"bed similar conditions."
Quality control procedures, such as control sample analyses and reelicate analyses,
represent the primary mechanism for evaluating measurement data variability or precision.
Replicate analyses will be used to define analytical replicability, while results for ireplicate
samples may be used to define the total variability (replicability) of the sampling/analytical
system as a whole.
Precision of the measurement data for this program will be based upon replicate analyses
(replicability) and control sample analyses (repeatability). Where there are only two data
pomts ( e.g., replicate or repeat analysis), variability will be expressed in terms of the
relative percent difference (RPD). The RPO is defined as:
RPD = Maximum Value -Minimum Value x 100%
(Maximum Value+ Minimum Value)/2
and is commonly used to express variability between duplicate measurements because it is
easily calculated and measurement distnbution is always normal for duplicate results.
For data sets greater than two eoints, the Coefficient of Variation (CV) is more commonly
used. It is defined by the equation:
CV = Standard Deviation x 100%
Mean
Both terms are independent of the error (accuracy) of the analyses and reflect only the degree to which the measurements agree with one another, not the degree to which they agree with the "true" value for the parameter measured. To facilitate comparison of variability for data sets of two and more, the two quantitates for two data points are related by:
% RPO = (2) x (% CV)
9.2 Accuracy
Accuracy is the agreement between a measurement value and a theoretical value. Accuracy will be expressed as the relative error (% RE) where:
% = Measured Value -Theoretical Value x 100%
Theoretical Value
This accuracy estimate includes error due to both imprecision and bias.
The analytical systems will also be checked routinely for system accuracy in the absence of matrix effects. The following equation will be used to calculate matrix spike recovery:
% Recovery (spike) = Css -Cus x 100
Csa
where:
Css = Analyte concentration in spiked sample;
Cus = Analyte concentration in W1Spiked sample; and
Csa = Analyte concentration added to the sample.
If matrix spike error exceeds the specified acceptance criteria, a QC check sample ( analyte spiked in DI water) will be analyzed to determine whether the error was due to matrix interferences or to an assignable cause of error in the analytical system itself. Data which are not within the acceptance criteria for matrix spikes will be flagged.
Daily control sample analyses represent one mechanism for controlling measurement system error. Typically, repeated measurements are made of the parameter of interest for the same control sample or for additional samples at different levels, and the average error is calculated. This error value represents an estimate of measurement bias or systematic error, although it is often simply referred to as "accuracy." The significance of the bias estimate may be evaluated usmg confidence intervals. An approximate 95% confidence interval for the mean error (bias) can be calculated using:
Mean (X) t .025, (n-1) Standard Deviation
n
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where n is the number of measurements used to compute the average and standard deviation and t .025, (n-1) is a table statistical value (0.025 confidence level, n-1 degrees of freedom, when n is greater than 10, t approaches 2.0).
As an example, for a particular set of nine measurements, assume an overall mean of 20 ppm is reported, and the standard deviation of these data is 10 ppm. Also, assume that the true concentration is 30 ppm. For these measurements, the 95% confidence interval is:
20 2.3 .ill
9
or 20 7.7
which is the interval (12,28). Since this interval does not include the true value, 30 ppm, a conclusion of bias is Justified. The ma~itude of this bias is between 2 and 18 ppm. The uncertainty in the estunate is due to variability arising from random error.
Daily control samples analyses will be used to assess measurement bias. The average degree of agreement between measured values and actual values for control samples provides a fong-term, or average estimate, of measurement bias as well as precision (repeatability).
9.3 Completeness
Measurement data completeness is a measure of the extent to which the data base resulting from a measurement effort fulfills objectives for the amount of data required. For this program, completeness will be defined as the valid data percentage of the total tests planned. As previously shown in Table 3-1, this valid data percentage will be 90% for all tests.
10.0 CORRECTIVE ACTION
During the course of the GDC incinerator testing program, it will be the responsibility of the field supervisor and the sampling team members to see that all measurement procedures are followed as specified, and that measurement data meet the prcscnl>ed acceptance criteria. In the event a problem arises, it is imperative that prompt action be taken to correct the problem(s). A fully assembled spare MM5 sampling train will be maintained on site for emergency deployment in the event of a sampler malfunction.
The field team supervisor will initiate corrective action in the event of QC results which exceed acceptability limits. Corrective action may be initiated by the QA coordinator based upon QC data or audit results. The corrective action scheme IS shown in the form of a flow chart in Figure 10-1. ·
FIGURE 10-1 CORRECTIVE AC7ION FLO~ SCHE~E
Notify ProjectH
[Problem Identified
Notify Testing Supervisor
I 1
1Per1onn Initial
I 1
Evaluation
Fonrulate
Solution Man.ager Yes I
I
Modification of Prescribed ProceoJt"es
Required for Resolution of Problem? INo
I '---,-----'
I T
1
'
Major Modification -Yes
Required?
' 1
'
Notify Testfog
Su;,ervisor
' 1 . '
Review Problem and· ,..
FoM!Lllate Solution
' 1
' Scope of \Jori:. Mod• !Tes!
iffcation Required?
i ' ' 1
' I Il?f?lement SolutiOl"I
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' ! ?robl cm Resolved?
1
[ssue In-house
Problem R~rt
Reevaluate
Problem
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T No
'
tify Testing
SUperviscr hNo
QA/QC Offfcer
Approval 7
l·res
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I No
I
Notify Project Manager
1
I~lement SOlutfon
1
Problem
No Resolved?
1
'
Record in
Daily Lo;
' 1
B
End
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11.0 QUALlTY ASSURANCE REPORTING
Effective management of a field sampling and analytical effort requires timely assessment
and review of field activities. This will require effective interaction and feedback between
the field team leader, the project manager and the QA officer.
During the incinerator test, the field supervisor will submit a verbal QC daily report to the
YORK QC officer. This report will address the following:
Summary of activities and general program status;
Summary of corrective action activities;
Assessment of summary of data completeness; and
Summary of any significant QNQC problems and recommended and/or
implemented solutions not included above.
The project final report will include a separate QNQC section which addresses QNQC
aspects of the project.
Problems requiring swift resolution will be brought to the immediate attentio1a of the
project manager via the corrective action scheme d1Scussed in Section 10.0.
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12.0 (Intentionally Deleted) I
13.0 PROJECT SAFETY
A primary objective of the testing activity is that it be performed in a safe and prudent I manner. The site is a controlled, limited access facility. YORK will comply with the facility's safety program. However, in order to minimize any risks, the YORK team will be 1 equipped for emergency situations likely to occur.
The following discussion contains information regarding general safety procedures and site-specific safety considerations. · I
13.1 General Safety Procedures
The safety procedures and protective equipment required on site will vary according to the I type of activity in progress and one's proximity to the sampling area. The On-site Safety Officer will serve as safety coordinator and wilf decide the types of protective equipment to be used and the delineation of safety zones on the job site. I
13.2 Safety Zones
Safety zones will be established according to the exposure levels encountered. It is anticipated that Level One, Level 1\vo, and Level Three wnes will be required at this work site. The following three-level exposure system will be used:
Level One -The exposure level is very low hazard associated with site activities. Low hazard area requires little or no safety equipment.
Level 1\vo -An exposure level exists which requires intermediate precautions. Hazard potential is defined and safety equipment is required.
Level Three -An extreme exposure level exists, and strict safety precautions are required. This exposure level is considered life-threatening.
133 Safety Equipment
Equipment will be available to _protect each worker from Level 1\vo and Level Three exposure. In addition, the followmg equipment will be available on site:
Ear protection;
Emergency eye washes; and
First aid supplies.
13.4 Safety Training
Prior to .the initiation of on-site work, the On-site Safety Officer will conduct a safety meeting. The meeting will inform the project personnel of the potential and real hazards present, instill in them the necessity for safety precautions and develop their understanding of proper safety measures. Instruction as to the use of various safety equipment and procedures will be given if necessary. Also, a contingency plan for emergency situations will be discussed. In addition, YORK personnel will have completed a safety course in compliance with 29 CFR 19.10.
135 Site-Specific Safety Procedures
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YORK personnel will comply strictly with all the safety requirements of the facility,
particularly with respect to hard hats, steel-toed boots, eye protection and long-sleeved
shirts.
Chemical exposure may be minimized by the use of protective clothing, respirators
equi_pped with acid/organic canisters, disposable gloves and Tyvek suits when working in
the unmediate vicinity of the high level sources. The necessity of these measure:S will be
decided by the GDC and On-site Safety Officer. Gloves will be worn when handling sludge
and liquid samples and filling sampling containers.
14.0 QUALITY ASSURANCE PROGRAM
14.1.0 Introduction
14.2.0
14.2.1
14.2.2
14.23
14.2.4
143.0
14.4.0
The Analytical Laboratory of York Research Consultants (YRC) performs 21 variety o( analytical services for a wide range of customers which represents many varying specifications and requirements. The QNQC program was developed to ensure that a high standard of performance would be consistently applied to these serviles.
These services are performed by trained analysts. The technical reports include the analytical results, analytical methods, and a thorough discus siollll of the subject material, as required by the customer.
Quality assurance is monitored on a continuing basis by the Quality Control Coordinator or his designate from the Quality Assurance Department (QAD). The QAD reports directly to YRC management. This permits complete independence in overall program review and direct access to YRC management.
Definitions
Quality Assurance Policy Manual -Quality control procedures which state the official Quality Assurance and Quafity Control procedures for all activities which could directly or indirectly influence data quality.
Standard Operating Procedures (SOP's) -Standard documents used to define the guidelines and/or procedures to be followed in the various operations of the laboratory. These may be general in nature or project specific.
Project Quality Assurance Plan -A formalized document which will be initiated when a project requires YRC/QAD approved project plans. The plans ma:y supercede QNQC policy programs and procedures. Customer specifications and regulations will be the basis of a project QA program plan and for project specil'ic operating procedures.
Regulations, Standards, and Guidelines -Those requirements on which basic ana project specific QA activities are based.
Quality Assurance Policy
York Research Consultants is committed to providing services which meet clients needs, satisfy regulatory requirements, and utilize state of the art technology. YRC policy is to conduct all projects in a timely, efficient, and consistent manner so as to provide customers with consistent and reliable services. The quality assurance pro,gram is to ensure that all data generated and reported is accurate, precise, scientifically valid, and legally defensible.
Responsibility
The responsibility and authority for establishing, coordinating, and implementing the quality assurance program has been delegated to the QAD. The Quality Control Coordmator reports directly to the YRC n•= of Res=<h ~, O,,,clopmeot ®
116
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14.5.0
14.6.0
14.6.1
14.6.2
14.6.2.1
Quality Assurance Program
The Quality Assurance Program for the Analytical Division of YRC is
designed to encompass the basic principles as set forth in Good Laboratory
Practices Regulations (Part 58 of Federal Register).
In the event of a conflict between the Laboratory QA program and Pro~ect
QA r,rogram, the Project QA program shall take precedence as will Project
SOPs.
QA Program Requirements
The Laboratory's quality assurance program is designed to ensure QA
compliance to customers specifications of all applicable projects.
Responsibility
14.6.1.1 The Laboratory Director and/or Project Manager shall:
14.6.1.1.1 Identify, compile, and write the SOP.
14.6.1.1.2 Make pertinent SOP's available to the appropriate stllff and in
the appropriate areas.
14.6.1.1.3 Monitor and assure compliance with the SOP.
14.6.1.2 The Quality Assurance Officer shaIJ:
14.6.1.2.1 Coordinate SOP preparation.
14.6.1.2.2 Coordinate review/revision of SOP's.
14.6.1.2.3 Verify conformance (via inspections of audits).
14.6.1.2.4 Direct or supervise the following:
-Reproduce and issuing controlled copies of SOP's.
-Retaining current and superseded copies of the SO P's and LQPP's.
Maintenance of inspection records.
Format Criteria for SOP's and LQPP's
These shalJ be written in a standardized format as follows:
14.6.2.1.1 First Page:
Code identification number
Revision number (Original to be denoted as "O")
Date of issue (i.e. effective date)
-Page number and total number of pages (page ___ of" __ _,)
Title
14.63
14.6.4
14.65
14.6.2.1.2 Subsequent pages:
Code identification number
Revision number
Date of issue
Page number and total number of pages
14.6.2.1.3 Additional requirement for Laboratory Quality Manual:
Table of Contents
Revision summary page
Each page revised m a specific manual
Revision will denote manual revision in upper right comer above the code number.
14.6.2.2 MSOP's (method SOP's) shall be formatted in the following sequence:
Summary
Application
Apparatus & Chemicals
Calibration
Sample Handling & Storage
Procedure
Calculations
Quality Control
References
NOTE: MSOP's will be maintained under separate covers, but will be required to follow the same procedure as for "Controlled Copies."
LQPP's and SOP's shall be written in such terms as to be complete, concise, and easily understood by the user.
Equipment SOP's may omit detailed instructions by referring to portions of the equipment manual. The manual is to be referenced and is to be in the work area where the equipment is located. LQPP-1
As a minimum, there shall be LQPP's covering the following:
Quality Assurance Poli':)'.
Staff Or$anization/Qualifications/fraining
QA ReVIew and Audit of Records
Reagent Labeling, Storing and Testing Documentation
QA Record Storage and Retention Time
Inspection/Audits
Non-conformance and Corrective Action Analysis of QC Samples
Analytical Procedures
Data Verification and Reports
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14.6.6 As a minimum, there shall be Analytical Laboratory Standard Operating
Procedures (ALSOP) covering the following:
Facility Security
Visitors
Temperature Monitoring of Refrigerated Storage Areas
Water Purification System Monitoring
Instrument Operation, Calibration, and Maintenance
Preparation of Sample Containers
Reagent Procurement, Receipt, and Storage
Sample Receipt and Log-in
Sample Storage
Sample Chain of Custody
Glassware Oeanup
Calibration of Measuring Equipment
Standards Preparation and tracking System
Sample Analysis and Tracking
Data Recording, Assembly, and Storage
Sample Disposal
Safety Manual
14.6.7 If forms are referenced, refer to them by title and form number and by what
other identification they have been given in the text. (Example: Figure 3 or
Exhibit "C", etc.). Sample forms should have "SAMPLE" marked on them.
14. 7.0 Responsibility for Compliance
14.7.1 General QA Compliance
14.7.2
14.7.1.1 The Analytical Laboratory staff shall:
Conduct their respective tasks and responsibilities in accordance with
generally acce)?ted good laboratory practices and the established
laboratory quality assurance program.
Update staff credentials as changes occur.
14.7.1.2 At least annually, unless otherwise required by specific contract
requirements, the QAD shall:
Assist in implementing and monitoring QNQC programs.
Review and initial UP,date of QA-related policies and procedur,es.
Inspect project-specific archives. .
Report the results of inspection to Lab management and YRC
Management
Proposal Compliance
14.7.2.1 For proposals that, in the opinion of YRC Management, require a
QNQC plan, the QAD shall:
Review the program requirements.
If required, assist in the preparation/revision of the proposed program
and QNQC plan.
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14.73
14.8.0
I
Project Compliance
14.73.1 For projects requiring approved QNQC plans, the QAD shall:
Review the project proposal for adequacy of the QNQC plan. I Coordinate the ereparation of QNQC plans.
Conduct inspections of audits.
Prepare and submit the results of inspections and/or audits to Laboratory I Director, Project Manager, and YRC Management
Corrective Action
Problems that are determined by or referred to the QAD shall be reviewed by the QAD, the Lab Director, and the Group Leader, who shall then initiate the appropriate corrective action. Refer to LQPP-9.
14.9.0 Regulation/Guidelines
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14.9.1
14.9.2
14.93
14.9.4
14.95
General guidelines used in generating the overall Laboratory program are:
Good Laboratory Practice Regulations for Non-Qinical Laboratory Studies, FDA, FR 43, 59986, Dec. 22, 1978. Amendment FR 45, 24865, Apr. 11, 1980.
Toxic Substances Control Act: Good Laboratory Practices Standards, EPA FR 48, 53922, November 29, 1983.
Interim Guidelines and Specifications for Preparing Quality Assurance Project Plans, QAMS-005/80/ December 29, 1980.
YRC Facility Quality Assurance Policy Manual
Good Laboratory Practice Regulations for Non-Oinical Laboratory Studies, FDA, FR 43, 59986, Dec. 22, 1978. Amendment FR 45, 24865, Apr. 11, 1980.
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15.0
15.1
15.2
15.2.1
15.2.2
153.0
153.1
STAFF QUAUFICATIONS
Introduction
This standard Laboratory Quality Program Procedure (LQPP) provides general
information on qualifications and training of staff personnel, and for
documenting the staff qualifications.
Requirement
Personnel shall be qualified to perform assigned work. Staff who do not possess
specific experience by prior training or background shall be trained before
assignment to projects requiring that experience.
Staff resumes and/or curriculum vitae shall be updated at least annually.
Responsibility
The Laboratory Director is responsible for:
-Initiating the preparation and/or updating of all resumes and/or curriculum
vitae.
-Ensuring that department staff resumes and qualification and training
documentation are current, complete, and provided to QAD.
-Defining job descriptions, determining the extent of training reguired and the
training methods, and documenting successful completion of traming.
NOTE: This does not preclude any policies of requirements of the Personnel Office, but as a
minimum is in addition to requirements of the Personnel Office.
153.2 The QAD shall maintain current summaries of the various job descriptions,
experience, and pertinent training of staff relating to projects which require YRC
Managemenl/QAD approved program plans or projects conducted under
regulations.
15.4.0
15.4.1
Training Methods
Training methods may include the following:
Trainin,g courses offered by an accredited university, technical school,
professional associations, seminars, instrument manufacturer or YRC.
15.4.2 On-the-job training, consisting of:
15.4.2.1 Instruction on the general theory and operation of a task.
15.4.2.2 Observation of the trainee performing the task by an experienced person.
15.4.23 Performance of the task by the trainee under close supervision.
15.4.2.4 Semi-independent performance of tasks by the trainee using check samples or
equivalent.
15.5.0 Documentation Procedures
To cover projects requiring QAD review of staff credentials:
15.5.1 Staff members shall send copies of certificates, diplomas, or evidence of training
courses, etc. to Lab Director who shall in turn be responsible for providing
information to the QAD.
15.5.2 For on-the-job training:
15.5.2.1 The job instructor shall prepare documentation to include:
Names of the trainee(s) and instructor(s)
Date(s) of instruction
Detailed instruction procedure (if applicable). As a
minimum, an outline of training covered.
Results of the proficiency exam (if applicable).
15.5.2.2
15.5.3
15.6.0
The Laboratory Director shall sign the memo, signifying that the trainee(s) are
now prepared for the specific task(s) assigned. A copy of the documentation shall
be sent to QAD.
QAD shall follow through on documentation recording/filing procedure.
Corrective Action
Problems shall be referred to the Laboratory Director who shall then take the
appropriate corrective action.
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16.0
16.1.0
16.2.0
16.2.1
16.22
163.0
16.4.0
16.4.l
16.4.2
DOCUMENTATION PROCEDURES
Introduction
This standard Laboratory Quality Program Procedure (LQPP) provide:s general
guidelines on documentation procedures.
Responsibility
The Laboratory Director and Group Leader are responsible for training the staff
and for enforcing this LQPP. .
The Quality Assurance Department (QAD) is responsible for verifying
compliance (via inspections) and maintainmg inspection records.
Corrective Action
Problems shall be referred to the Laboratory Director and/or Group Leader who
shall then take the appropriate corrective action.
Documentation Procedures
Project documentation requirements which supersede or supplement current
pohcy shall be communicated by the Laboratory Director and/or Group Leader
to project staff. In such cases, project SOP's are required.
It should be noted that "raw data" are any original observation project records,
or exact copies thereof, necessary for the reconstruction and evaluation of a
reporL
Validation
For a project subject to a QAD audit, project staff who enter, review, correct, or
add project information of original data shall print and sign their names and date
entry accordingly.
Laboratory Notebooks
All staff who enter or review entries in the notebook shall print and sign their
names and write their initials on the signature page at the front of the notebook.
Thereafter, initials may be used in place of signatures.
16.4.2.1 Record all entries legibly in permanent, preferably black, ink.
16.4.2.2 Record information in chronological order, preferably on the day the work is
performed.
16.4.23 Complete the information blocks at the top and bottom of each page. The
Group Leader or designee shall frequently review entries, initial and datt: the
bottom of each page of "raw data".
16.4.2.4 Enter information directly into the notebook unless conditions do not pe:rmit
such entry. Discuss "restricted-access" procedures with supervisor.
ill CTJffi~TI
16.4.2.5
16.4.2.6
16.4.2.7
16.4.2.8
16.4.3
16.4.3.1
16.43.2
16.433
16.43.4
Include all data, obseivations, calculations, notes and pertinent
procedures. Include sufficient detail that a co-worker could continue the work.
Record all activities regardless of outcome. Record unusual obseivations or
unexplained results, and if possible, add an explanation. Describe results that
may warrant future investigation. Include new ideas, concepts, or applications of
an idea. •
Document All deviations from standard operating procedures (SOP's) and
include reason.
Fully identify loose sheets or e9uipment printouts as applicable if they are
attached to notebook pages. (See 'Equipment Printouts" on following pages.)
CORRECTIONS/ADDffiONS: Draw a single line through the incorrect entry
so that the original entry remains legible. Add the correct entry then explain,
initial, and date the correction. New information may be added to the onginal
page if initialed and dated. Erasures are NOT allowed.
Equipment Printouts
Input (if computerized) or record legibly, in permanent ink, the following
information on each printout:
-Project identification (i.e. job number Date work was performed
Other pertinent information ( analyst, sample number, instrument parameters,
etc.)
Sign or initial and date each printout or the cover sheet of printout sets.
Where applicable, cross reference the printout or cover sheet to the applicable
lab notebook (book number and page number).
CORRECTIONS/ADDffiONS:
16.43.4.1 Manual Changes: See Laboratory Notebooks section.
16.43.4.2
16.4.4
Automated Changes:
a. Keep the original entry intact in the system. If possible, do not transfer the
origmal entry to a new position (to avoid transfer errors).
b. Code the original entry to show it has been superseded.
c. Input the correct entry so that it is traceable to a person. Date and explain the
correction. Use traceable codes when possible.
QA.Records
All QAD records shall be maintained by the QAD.
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17.0
17.1.0
17.2.0
173.0
173.1
173.1.1
173.1.2
173.13
173.1.4
173.2
1733
17.4.0
17.4.1
17.4.2
17.4.2.1
QAD INSPECTIONS AND AUDITS
Introduction
This standard Laboratory Quality Program Procedure (LQPP) provides general
information on inspections/audits conducted or directed by Quality Assurance
Department (QAD). In some instances, the QAD may request assistance in an
inspection/audit by a Quality Control Coordinator (QCC).
Definition
Quality Control Coordinator: Someone considered by the Quality Assurance
Manager and YRC Management to be qualified to perform a particular field or
laboratory audit who is temporarily assigned to the QAD. This may be a
member of YRC, of the Division, or an outside source.
Department Compliance
To assure laboratory QC/QA compliance, the QAD shall:
Periodically conduct general inspections/audits of:
Laboratory Facilities: These shall be maintained in accordance with the policies
of the Analytical Lab as well as I&C applicable safety policies, and the Good
Laboratory Practices Act (GLP).
Equipment: Equipment used on projects for sampling and/or analysis shall have
standard operating procedures, use logs, and calibration and/or maintenance
records in accordance with LQPP3.
Methods and Practices: Methods and practices shall be in accordance with the
Quality Assurance Manual for the Analytical Lab unless superseded by specific
project requirements in which case YRC Management/QAD apjproval is
required.
Records: Records shall be documented and retained in accordance with LQPPS
andLQPP6.
Prepare and submit the results to YRC Management, Noting problems and
recommended actions.
Maintain the written and signed records of inspection/audits.
Project Compliance
For projects requiring YRC Management/QAD approved QA plans and
procedures, the QAD shall conduct or direct inspections and/or audits specific to
the projecL These shall include but not be limited to facilities, equipment,
methods and practices, procedures, records and QA program plans specific to the
project
For projects conducted under EPA regulations, the QAD shall also:
As a minimum, inspect each critical phase of a study as follows:
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Studies lasting 6 months or more--every 3 months
Studies lasting Jess than 6 months--sufficiently to adequately ensure
study/program integrity
To determine that no SOP deviations were made without proper authorization
and documentation.
17.4.2.2 Prepare and submit the results to Group Leader and Laboratory Director as well
as YRC Management.
17.4.23 Maintain the written and signed records of each. inspection.
17.4.2.4 Prel?are and sign a statement to be included with the final report which specifies
the mspection date(s) and the date(s) of reports to YRC Management.
17.4.25 Review the final report to assure that report accurately reflects methods, SOP'S,
and the results of the raw data.
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18.0
18.1.0
18.2.0
18.2.1
18.2.1.1
18.2.1.2
18.2.2
18.2.2.1
QA REVIEW AND AUDIT OF REPORTS
Introduction
This standard Laboratory Quality Program Procedure (LQPP) provides specific
information for Quality Assurance Department (QAD) reviews or audits of
reports.
Responsibility
The QAD shall review or audit reports when:
Reguired by a specific projects requirements, regulations, or by department
policy, or upon request of YRC Management
Laboratory Director or Group Leader specifically requests a review or audit
The Laboratory Director and/or Group Leader are responsible for:
A, two-level technical review of a report prior to a QAD review/audit
NOTE: Technical review shall be documented to include signature and dates of the review
attached directly to the applicable report.
18.2.2.2 Ensuring that the QAD receives all reports required to be reviewed or audited.
183.0 Corrective Action
Problems shall be referred to the Laboratory Director and/or Group Leader who
shall then takefmitiate appropriate corrective action ...
18.4.0 Guidelines
18.4.1 Items generally include in a review or audit (by both the technical group and
QAD), but not limited to, are:
18.4.1.1 Darity.
18.4.1.2 Accuracy of the description of results: reported data in any form (figures, tables,
graphs, etc.) must reflect the raw data.
18.4.13 Completeness and accuracy of any instrumental parameters.
18.4.1.4 Random checks for computational errors.
18.4.2 Additional items which may be included in an audit are:
18.4.2.1 Examination of the study files.
18.4.2.2 Documentation procedures.
18.4.23 Data calculation procedures.
18.4.2.4 Internal quality control procedures. rn rn & ~ u
18.4.3 Additional items required in a report of an EPA related project are:
18.4.3.1 Study initiation and completion dates.
18.4.3.2 Clear statement of objectives.
18.4.3.3 Description of methods, procedures, and test system used. The methods, etc.
must be consistent with the Project's program requirements. Any change must be
documented and justified. (Refer to LQPP-5 for procedure.)
18.4.3.4 Adequate identification of the test/control substance.
18.4.3.5 Stability of the test/control substance under study conditions.
18.4.3.6
18.4.3.7
18.4.3.8
18.4.3.9
Description of all circumstances that may have affected quality or integrity of the
data.
The name of the Group Leader and the names of other analysts and/or
professionals and all supervisory personnel involved with the project.
Final reports shall also include:
-Signature by the Group Leader
-Indication of review by YRC Management
-QAD Statement
Any corrections to final report must specify the portion of the fmal report being
amended and must be signed by Group Leader, YRC Management, and QAD.
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19.0
19.1.0
19.2.0
19.3.0
19.3.1
19.3.1.1
19.3.1.2
19.3.2
19.3.2.1
19.3.2.2
CORRECTIVE ACTION PROCEDURES
Introduction
This standard Laboratory Quality Program Procedure (LQPP) provides i~eneral
information on corrective action procedures, and is based on the princip .es of
YRC.
Background
A quality assurance system must be sensitive and responsive in. detecting
problems and unusual project activities and provide a timely, systematic
mechanism to rectify the situation. Three types of systems are described below:
On-the-spot, Closed-loop, and Quality control sample corrective procedures.
Corrective Action Procedures
On-the-spot corrective action usually applies to spontaneous, generally non-
recurring problems, such am an instrument malfunction. Recurrin;~ quality
assurance problems may require closed-loop corrective action involVJng YRC
ManagemenL
Deviations from established procedures, program plan, or customer's regulations
reported by QAD shall be immediately communicated to the Group Leader and
Laboratory Director for corrective act10n.
On-the-spot Corrective Action Procedure
Any staff member who detects/suspects nonconforrnance to previously
established criteria or erocedure in equipment, instruments, data, methods, etc.
shall immediately notify the appropriate Group Leader and/or u1boratory
Director. In many cases, the staff member will be able to correct the problem.
When a situation results in a change in data reported, a corrected report shall be
prepared or reported to the Laboratory Director who shall then forward
corrected copy following routine distribution of the original reporL
The corrected report shall then be attached to the top of the original ;report so
that sample analytical data is complete and accurate.
If a large quantity of data is affected, or if any of the analyses conducted during
the suspect period where of a critical nature, or if the program involv,:d is one
which requires documented corrective action, the closed-loop corrective action
procedure is to be followed. ·
□osed-loop Corrective Action Procedure
Any staff member who detects a recurring or unresolved quality assuranc:e
problem shall advise the Laboratory Director and QAD.
The QAD shall contact the Laboratory Director and Group Leader if a~•plicable,
and prepare and route a Corrective Action Request (CAR), and advise r'RC
Management by copy of the CAR.
19.3.2.3
19.3.2.4
19.3.2.5
19.3.2.6
19.3.2.7
19.3.3
19.3.3.1
As determined appropriate, the staff member, Group Leader, Laboratory
Director, QAD and YRC Management shall consult to determine appropriate
corrective action plan and report same on CAR.
The corrective action shall be initiated, documented and results forwarded to
QAD.
QAD shall investigate to verify resolution.
The QAD shall close the CAR or plan for follow up if determined necessary
before CAR may be e-0nsidered closed.
If the e-0rrective action was unsuccessful, above procedure is to be repeated.
Quality Control Sample Corrective Procedure
The followin,g procedure is to be applied when unacceptable results are obtained
in the analys1S of quality control samples. The steps are to be done in sequence.
If at any step the problem is corrected the sequence can be terminated.
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19.3.3.1.1 The analyst shall inform Laboratory Director/Group Leader, and Quality
1 Assurance department that the above situation has occurred.
19.3.3.1.2 Raw data, equations, and calculations used are to be validated and e-0rrected.
19.3.3.1.3 Calibration ( of irlStrurnent is to be tested with check standard.
19.3.3.1.4 Quality control samples are to be reanalyzed. All samples run in e-0njunction
with an out-of control QC sample (s) will be rerun. Example: All samples
analyzed after an in C-Ontrol blank, spike, or duplicate and before one that proves
to be out-of-control will be reanalyzed.
19.3.3.15 Instrument is to be shut down for complete calibration, cleaning, tuning, aligning,
etc. as ree-0mmended by manufacturer.
19.3.3.1.6 Customer is to be notified of problem and given an estimate of delay.
19.3.3.1.7 After restarting irlStrurnent, double the frequency of quality e-0ntrol samples
analyzed until correction is validated.
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20.0 CUSTOMER OR REGUIATING AGENCY AUDITS
20.1.0 Inuoduction
20.2.0
20.2.1
20.2.2
20.23
20.2.4
20.2.5
203.0
203.1
203.1.1
This standard Laboratory Quality Program Procedure (LQPP) provides general
information on the procedures for customer and/or their regulating agency's
inspections/audits of projects conducted under EPA regulations.
YRC Policy
It is the policy of YRC to permit inspections and audits by customers and/or their
regulating agency when such is understood to be part of the order/conuact
Unless waived or otherwise stipulated by conuact, advance notice of at least two
weeks is required.
Inspection/audits shall be conducted during normal business hours.
The confidentiality of a client's identity and data shall be maintained at all times.
Requests by regulatory agencies to inspect specific project data shall be honored
only after written permission of the customer is obtained.
Inspectors shall comply with YRC regulations governing visitors.
When inspecting facilities, inspectors shall comply with YRC and project
operation and safety procedures.
Inspection/Audit Procedures
Initial Contact/Preliminary Procedures: Regulatory agencies may or may not give
advance notice to arrange an inspection date. ThJS shall be dependent upon
the customer's program requirements as stipulated by conuact. (When not
stipulated by conuact, advance notice is required.)
ppon ini~ial customer/regulatory contact, YRC shall obtain the following
information:
• Desired inspection date(s) and alternative date(s)
Name of the inspector(s)
Type of inspection to be conducted (surveillance and/or directed • see
"definitions" above)
• Project(s) to be examined
-Request that an inspection/audit plan be forwarded to the Group Lead,:r or
QAD prior to the date of the audit
203. 1.2 It shall be the responsibility of the YRC individual contacted to advise the
affected departments/personnel. As a minimum this shall includ<: YRC
Management, Conuacts, Laboratory Directory and/or Group Leader, and QAD.
203.13 The QAD shall prepare for the inspection as follows:
203.13.1 Coordinate and verify that all affected personnel have been informed.
20.3.1.3.2 Have a room reserved for the inspectors. The room shall be secure, quiet, and
contain the necessary chairs and tables.
20.3.1.3.3 If a project's program is to be inspected (i.e. a review of the data and records),
the QAD shall: .
20.3.2
-Assure that customer's permission in writing, has been obtained
Assure that all study and QA records are available and retrievable
-Coordinate with Laboratory Director and Group Leader and associated
technical support staff and explain inspection procedures that may be expected
and encourage a courteous, cooperative spirit.
Inspection Procedure
20.3.2.1 Upon arrival of the inspectors in the lobby, the QAD shall greet the inspectors
and escort them to the Conference Room where YRC Management and affected
personnel will meet for:
-Greeting and introduction of the inspectors
-Verifying of inspectors credentials
-Initial preinspection conference
20.3.2.2 The inspectors shall:
-Describe the purpose of their visit
List the studies to be examined
-State the approximate length of the inspection
Give an approximate date/time for the exit debriefing and discussion of
findings
203.23 The QAD shall:
-Escort the ins1;>ectors of the reserved room
Request definition of the inspection plan (i.e. what records and areas/facilities
will be examined)
-Request the time plan
Accommodate the request of the inspectors, when possible Resolve any
scheduling problem
-Explain the YRC visitor policy
203.2.4 When inspectin~ the Analytical Lab facilities, the QAD and/or Group Leader
shall escort the mspectors at all times.
203.2.5 Interviews of staff members by the inspectors should be carried out in the
presence of the QAD. If this is not possible, the staff member shall report the
substance of the interview to the QAD, or to the Laboratory Director and/or
Group Leader who shall in turn advise the QAD.
203.2.6 If documents are requested by the inspectors, the QAD shall deliver them to the
reserved inspection room, then shall:
203.2.6.1 Maintain a record of all paperwork inspected
203.2.6.2 Maintain control of all documents in the inspector's office
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I 20.3.2.6.3 If copies of the documents are requested, the QAD shall:
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-Provide two copies, one for the inspectors and one for QAD
Stamp copies of documents considered to be proprietary (SOP's etc.) with an
appropriate stamp .
-Have the inspectors sign and date one copy and countersign the one retained
by the QAD.
2033 Post-Inspection Procedure
203.3.1 At the conclusion of the inspection, the inspectors shall arrange for a deb:riefing
meeting. YRC Management, QAD, Group Leader, and Laboratory Director
shall meet with the inspectors.
20.33.2 At the debriefing:
The inspectors shall submit a listing of any adverse findings. YRC Management
shall discuss any differing opinion and attempt to clarify the inspectors
perception or observations. Management may also at the conclusion, offer to
explam what Management considers to be erroneous observations.
203.4 Staff Debriefmg: The QAD shall conduct a debriefing for the technical/support
staff involved.
203.5 Records: The QAD shall maintain a complete record of the inspection,
including:
-Data inspected
Facilities/areas visited
-Staff interviewed
-Copies of records taken and receipts for them
-Any other pertinent information
21.0
21.1.0
21.2.0
ANALYSIS OF QUALITY CONTROL SAMPLES
Introduction
This LQPP discusses samples which are routinely added to the normal laboratory
sample routine to demonstrate that the laboratory is operating within prescribed
requirements for accuracy and precision. Quality control samples are of known
content and concentration (with the exception of field blanks) so that accuracy
and precision can be determined and control charts can be prepared. Evaluation
of these data are discussed in LQPP-13.
Types of Quality Control Samples
21.2.1 Field Blank (Trip Blank) Analyses
21.2.2
21.2.3
Volatile organic samples are susceptible to contaminating by diffusion of organic
contaminants through the teflon-faced silicone rubber septum of the sample vial;
therefore, field blanks shall be analyzed to monitor for possible sample
contamination during shipment Field blanks will be prel?ared by filling two
VOA vials with organic-free water and shipping the blanks with the field kit Field
blanks accompany the sample bottles through collection and shipment to the
laboratory and are stored with the samples. One field blank analysis shall be
performed for each matrix and batch of samples, but no less than one for every
20 samples. Following the analyses, if the field blanks, depending upon the
analyses, if the field blanks indicate possible contamination of the samples,
depending upon the nature and extent of the contamination, the samples may he
corrected for the field blank concentration or the sources resamples. Results of
Ekl.!1 blank analyses should be maintained with the corresponding sample
analytical data in the project file.
Reagent Blank Analyses
A reagent blank is a volume of deionized, distilled laboratory water for water
samples, or a purified laboratory water for water samJ?les, or a purified solid
matrix for soil/sediment samples carried through the entrre analytical procedure.
The volume or weight of the blank must be approximately eq_ual to the sample
volume or sample weight processed. A reagent blank verifies that method
interferences caused by contaminants in solvents, reagents, glassware, and other
sample processing hardware are known and minimized. Optimally, a rea~ent
blank should contain no greater than two times (2X) the method detection !unit
for the parameter. A reagent blank is to be analyzed at least once every
operating shift for each matrix. Results or reagent blank analyses should be
maintained with the corresponding analytical data in the project file. .
Duplicate Sample Analysis
Duplicate analyses are performed to evaluate the precision of an analysis.
Results of the duplicate analyses are used to determine the relative percent
difference between reelicate samples. Criteria for evaluating duplicate sample
results are provided m LQPP-13. A duplicate analysis shall be performed
whenever a batch of samples is analyzed. The frequency shall be no less than one
for each matrix and every 20 samples. Duplicate analysis results should be
summarized on the quality control data summary form.
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21.2.4
21.2.5
21.2.6
21.2.7
21.2.8
Check Standard Analyses
Standards and calibration cUIVes are subject to change and can vary from day to
day, so a midpoint standard or check standard shall be analyzed for every 10
s~ples analyzed on an instrument. Analysis of this standard is nee<!ssary to
verity the standard cUIVe and may serve in some cases as sufficient for
calibration. This value should be entered in the instrument calibration log
whenever performed. Check: standard analyses results should be summarized on
the quality control data summary form.
Surrogate Standard Analyses
Surrogate standard determinations should be performed on all samples and
blanks for GC/MS analyses. All samples and blanks are fortified with surrogate
spikinS compounds before puriing or extraction to monitor preparation and
analysJS of samples. Recovenes should meet acceptance cntena which are
established as faboratory results become available. Surrogate standard data
should be summarized on the surrogate standard recovery form.
Matrix Spike Analyses
To evaluate the effect of the sample matrix upon analytical methodology, a
separate aliquot of sample should be spiked with the analyte of inte:rest and
analyzed at feast once every 20 samples for each matrix. The percent recovery
for the respective compound will then be calculated. If the percent recovery
falls outside established quality control limits (75 to 125 percent for most
parameters), the data should be evaluated and the sample reanalyzed if criteria
are not met. Matrix spike results should be summarized on the quality control
data summary sheets.
Blind Replicate Analysis
A blind replicate sample is a duplicate sample which has been introduced as a
separate sample by the Quality Control Coordinator during the log-in process or
pnor to analysis. Evaluation of the replicate is discussed in Section 23. 1his data
JS reported to and summarized by the Quality Control Coordinator.
Verification/Reference Standard
On a quarterly basis, the Quality Control Coordinator should introduce a group
of prepared verification samples, or standard reference materials, into the
analytical testing regime. Results of these data will be summarized, evaluated,
and presented to laboratory management for review and corrective actions, if
appro~riate. The data are• reported to and summarized by the Quality Control
Coordinator.
22.0
22.1.0
22.1.1
22.1.2
22.13
22.1.4
22.1.5
22.2.0
223.0
22.4.0
ANALYTICAL PROCEDURES
Introduction
Analytical procedures for the analysis of samples include the following:
Prescribed method for sample preparation, including observance of stated
sample holding times and necessary extractions, dilutions, etc.
Instrument standardization, including calibration and preventive maintenance.
Analytical techniques to be used in processing the sample.
Prescribed format on prepared data sheets for recording raw data which include:
-Identification of project(s)
Identification of sample number(s)
-Identification of Analyst
Identification of Analyst performing data validation
-Dates for sample analysis and data validation
-Raw data resulting from the analysis with appropriate calibration standards
and blanks.
Method for computation of analytical results, which can be included on the data
sheet.
Documentation
Documentation of the above as an analytical as an analytical procedure is
dependent upon the specific instrumentation and data collectJon and reduction
methods used within the laboratory. Therefore, YRC Analytical Division shall
prepare and maintain as a Laboratory S_pecific Attachment to this manual an
Analytical Laboratory Standard Operatmg Procedures (ALSOP) which included
the above for all analyses performed. The requirements of the Quality
Assurance Policy Manual for activities such as calibration, preventive
maintenance, and quality control sample analysis shall be incorporated into the
laboratory specific manuals as appropriate.
Analytical Methods
Whenever possible, YRC Analytical Division utilizes industry recognized
analytical methods from source documents published by agencies such as the U.
S. Environmental Protection Agency (USEPA), Amencan Public Health .
Association (APHA) , American Society for Testing and Materials (ASTM), and
the National Institute for Occupational Safety and Health (NIOSH).
Methods as they appear in CFR 40 Part 136 lists the analytical methods typically
used throughout YRC Analytical Division.
Variance from Stated Analytical Methods
Analysis will be performed in accordance with the methods cited herein unless
specific project requirements or needs dictate adoption of an alternate method
or modification of the cited methods.
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I If analysis is performed in an alternate manner, the method shall be documented.
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23.0 DATA VERIFICATION AND REVIEW
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23.1.0
23.2.0
23.2.1
23.2.1.1
23.2.1.2
23.21.3
23.2.1.4
23.2.15
23.2.1.6
23.2.1.7
Introduction
Data verification is the steps taken within an analytical laboratory so that
reported results correctly represent the analyses performed. There are two basic
verification activities: .
The processing of quality control sample results to demonstrate that analyses are I
withm laboratory-prescribed bounds for accuracy, precision, and completeness.
Data validation to demonstrate that numerical computation of data IS correct
and that it is correctly reported. This section discusses how data verification is I
performed.
Data review is a procedure to irISure that results of field and quality control
samples are correctly verified and reported. This is conducted by a member of I
the Quality Assurance DepartmenL Review may occur as the data is being
processed by the analyst or being validated by the Group Leader/Supervisor, but
will occur as required by contract/customer when reports of data have been I
prepared for transmission outside the laboratory.
Processing of Quality Control Data
Specific Routine Procedures Used to Assess Data Precision and Accuracy
A reagent and/or method blank is prepared and analyzed with each set of
samples.
Field blanks are analyzed to determine possible sample contamination during
collection and shiement to the laboratory. Field blanks are applicable to volatile
organics analysis (VOA) where volatile contaminants can be mtroduced from
ambient air on site, durmg shipment, and in the laboratory.
A dail:y calibration curve consisting of at least three standards and gL reagent
blank IS prepared for each parameter. If the standard curve is known to be
stable, the standard curve can be verified daily by the analysis of a midpoint
standard.
One sample is to be analyzed in duplicate for each matrix and each batch of
samples, but no less than one for every twenty samples. .
One sample in every batch of samples or for each matrix, but no less than one
every twenty samples is to be spiked at a level to provide a final concentration
equivalent to the original concentration of the sample before dilution and then
analyzed.
A blind replicate, unknown to the Anal:yst, is introduced by the Quality Control
Coordinator at least once monthly. Bhnd replicates are routinely used for the
analysis of metals, water quality parameters, and organics analyses which do not
require separate extractions.
Standard Reference Materials (SRMs) are introduced periodically into the
testing scheme by the Quality Control Coordinator to evaluate the testing
procedure and the Analyst's performance.
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23.2.1.8 A check standard consisting of deionized water spiked with the parameter of
interest is analyzed. Check standards are routinely used for the analysis of
metals, water quality parameters, and some organics parameters.
23.2.1.9 Every sample is · spiked with the appropriate surrogate standards prior to
extraction and analysis for volatile organic compounds, base-neutral, and. acids.
23.2.1.10 International standards are added to all samples for GC/MS analysis prior to
analysis.
23.2.2 When the analyses of a sample set are completed, the results will be reviewed
and evaluated to assess the validity of the data set. Review is based on the
following criteria:
23.2.2.1 Reagent Blank Evaluation -The reagent and/or method blank results are
evaluated for high readings characteristic of background contamination. If high
blank values are observed, laboratory glassware and reagents should be checked
for contamination and the analysis halted until the system can be brought under
control before further sample analysis proceeds. A high background is defined as
a background value sufficient to result in a difference in the sample value, if not
corrected, greater than or equal to smallest significant digit known to b,e true. k
reagent blank should contam no greater than two times (2X) the parameter
detection limit for most parameters.
23.2.2 2
23.2.23
23.2.2.4
Field Blank Evaluation Field blank results are evaluated for high readings similar
to the reagent and/or method blanks descnbed above. If high fidd blank
readings are encountered, the procedure for sample collection, shipment, and
laboratory analysis should be reviewed. If both the reagent and/or method blanks
and the field blanks exhibit significant background contamination, the i;ource of
contamination is probably within the laboratory. In the case of VOA, ambient
air in the laboratory and reagents should be checked as possible sources of
contamination. High field blank readings for other parameters may be due to
contaminated sample bottles or cross-contaminated sample bottles or cross-
contamination due to sample leakage and poorly sealed sample containers.
Calibration Standard Evaluation. The daily calibration curve is evaluated to
determine linearity through its full range, and that sample values are 'l\rithin the
range defmed by the low and high standards. If the curve is not linea:r, sample
values must be corrected for nonlinearity by deriving sample concentrations from
a graph or by using an appropriate algorithm to fit a nqnlinear curve to the
standards.
Replicate Sample Evaluation Duplicate sample analysis for the sample: set is
used to determine the precision of the analytical method for the sample matrix.
The duplicate results are used to calculate the precision as defined by th,e relative
percent difference (RPD). The precision value, RPD, should be plotted on
control charts for the parameter determined. If the precision value exceeds
the warning limit for the given parameter, the appropriate Group Leader or the
QA Coordmator is notified. If the precision value exceeds the contiol limit,
the sample set must be reanalyzed for the parameter in question. Atta:inable
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23.2.2.5
23.2. 2. 6
23.2.2.7
23.2.2.8
23.2.2.9
23.23
23.23.1
precision limits will be specified by the QC Coordinators and updated
periodically following review of data.
Matrix Spike Evaluation. The observed recovery of the spike versus the
theoretical spike recovery is used to calculate accuracy as defined by the percent
recovery. The accuracy value, the percent recovery, may be plotted on a control
chart for the parameter determined. If the accuracy value exceeds the warning
limit for the given parameter, the appropriate Group Leader or the QA
Coordinator is notified. If the accuracy value exceeds the control limit, the
sample set must be reanalyzed for the parameter in question.
Blind Replicate Evaluation. The blind replicate analysis is evaluated in the same
manner as described above for the duplicate sample analysis and is treated as a
duelicate result for purposes of evaluating the precision of the analytical method.
Tius evaluation is performed independently by the QA Coordinator.
Reference Standard Evaluation. Standard Reference Materials analyses are
compared with true values and acceptable ranges. Values outside the acceptable
ranges require corrective action determine the source of error and provide
corrective action. All sample analyses should be halted pending this evaluation.
Following correction of the problem, the Standard Reference Material should be
reanalyzed.
Check Standard Evaluation. The results of check standard analysis are compared
with the true values and the percent recovery of the check standard is calculated.
If correction is required, the check standard should The reanalyzed to
demonstrate that the corrective action has been successful.
Surrogate Standard Evaluation. The results of surrogate standard
determinations are compared with the true values-spiked into the sample matrix
prior to extraction and analysis and the percent recoveries of the surrogate
standards are determined. The percent recoveries recommended as attainable by
USEP A for volatile and semi-volatile organic compounds are followed.
Statistical Evaluation of Quality Control Data
As part of the analytical quality control program, YRC Analytical Division will
determine precision and accuracy for each parameter analyzed. Initially, when
these data are compiled, the evaluation is applied over a broad concentration
range. As more data are accumulated, precision and accuracy determinations
will be updated and criteria developed to define precision and accuracy over
specific concentration ranges.
Evaluation of Data Using Control Charts YRC Analytical Division will apply
precision and accuracy criteria to each parameter that is analyzed. When
analysis of a sample set is completed, the quality control data are reviewed and
evaluated through the use of control charts to validate the data set.
Control charts may be established for all major analytical parameters. A
minimum of ten measurements of precision and accuracy are required before
control limits can be established.
In general, for water samples, control limits of two standard deviations shall be
utifu<d; m,al)'<' of otl><< =pie "1"• '""' a, h""d•~m, oo•m w 'IT
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23.23.2.1
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standard deviations as control limits. Once established, control limits are
updated as additional precision and accuracy data become available by the QA
Coordinator. ·
Evaluation of Analytical Precision
General Considerations To determine the precision of the method and/or
laboratory Analyst, a routine program of rephcate analyses is performed. The
results of the replicate analyses are used to calculate the relative percent
difference (RPD), which is the governing quality control parameter for precision.
The RPD for replicate analyses is defined as 100 times the difference (range) of
each replicate set, divided by the average value (mean) of the replicate set. For
replicate results D and D, the RPD is calculated from Equation 1:
D1-Di
RPO%= ____ X 100%
l/2(D1 + Di) l/2(0
When the RPD is obtained for at least ten replicate pairs, the average RPO
calculated using:
m = mi+ mi+t .... mn
n
where:
m = the RPO of a replicate pair,
m = the average of the RPO Determinations, and
m = the number of RPD determinations.
For data sets greater than two points, the Coefficient of Variation (CV) is
commonly used:
% CV = Standard Deviation x100% Mean
CV -the coefficient of variation of the data set of RPO determinations
When constructing a control chart for a specific parameter, the Warning and
Control Limits are then calculated from the following:
Upper Control Limit = m + 3 CV
Lower Control Limit = m -3 CV
Upper Warning Limit = m + 2 CV
Lower Warning Limit = m - 2 CV
23.2.3.3 A control chart is established by plotting the RPO of each replicate pair on a
graph generated as follows:
23.2.3.3.1 The average of the RPO determinations for the original data set is established as
the midpomt on the Y axis of the graph.
23.2.3.3.2 The Upper Warning and Control Limits calculated above are plotted as solid
horizontal lines across the graph at their respective points on the Y axis above
the mean of the RPO determinations. ·
23.2.3.3.3 The Lower Warning Control Limits calculated above are plotted as solid
horizontal lines across the graph at their respective points on the Y axis below
the mean of the RPO determinations.
23.2.3.3.4 The calculated RPO of each replicate pair is plotted on the graph to determine
whether the RPO is within the Warning and Control Limits of the Control Chart
23.2.3.3.5 If the RPO plots between the Warning and Control Limits, the Group Leader,
LQPP-13 Operations Manager, or QC Coordinator is notified for a dec1Sion as to
how to proceed.
23.2.3.3. If the RPO plots outside the Control Limits, the data set is invalid and the
analysis is stopped until the source of error has been determined and corrective
action taken. Once the error source has been resolved, the data set is reanalyzed.
23.2.3.4 Evaluation of Analytical Accuracy
In addition to the evaluation of analytical precision, YRC Analytical Division
evaluates accuracy.
When a program for evaluation of analytical accuracy is established, the
evaluation is applied over the entire range of SJ?iking concentrations. As more
data are accumulated, the evaluation procedure IS refmed the analytical accuracy
of the method over specific concentration ranges.
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To determine the accuracy of an analytical method and/or the laboratory
Analyst, a J?eriodic program of sample spiking is conducted. The results of I
sample spiking are used to calculate the quality control parameter for accuracy
evaluation, the Percent Recovery (%R).
The % is defined as 100 times the observed concentration, minus the sample I
concentration, divided by the true concentration of the spike.
O;·Os, %R-______ x100%
T;
where:
% R = the Percent Recovery
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Oi = the observed Spiked Sample Concentration
Os= the sample Concentration, and
T; = the True Concentration of the Spike
The True Concentration is calculated from:
T; -Spike Concentration [c] (mg/1) x Vol. of Spike (ml)
Volume of Sample (m ml)+ Volume of Spike (ml)
When the Percent Recovery is obtained for at least ten spiked samples, th.e mean
percent recovery and the standard deviation are calculated using the following
formula:
n
where:
%R = the Mean Percent Recovery,
%Ri = the Percent Recovery of a Single Spiked Sample,
n = the number of results, and
R = Percent Recovery determinations.
For data sets greater than tum points, the Coefficient of Variation (CV) is
commonly used:
% CV -Standard Deviation X 100%
Mean
CV -the coefficient of variation of the data set of Percent Recovery
determinations .
The Warning and Control Limits are then calculated from the following
equations:
Upper Control Limit = %R + 3 CV
Lower Control Limit = %R -3 CV
Lower Control Limit = %R -3 CV
Upper Warning Limit= %R + 2 CV
Lower Warning Limit = %R -2 CV
rnJWffi~'IT
23.23.5 A control chart ( as shown in Figure is generated by plotting the Percent
Recovery data on a graph as follows:
23.23.5.1 The average of the Percent Recovery determinations for the original data set is
established as the midpoint on the Y axis on the graph.
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23.2.3.5.2 The Upper Warning and Control Limits calculated above are plotted as solid 1 horizontal lines across the graph at their respective points on the Y axis above
the mean of the Percent Recovery determinations.
23.2.3.5. The Lower Warning and Control Limits calculated above are plotted as solid I
horizontal lines across the graph at their respective points on the Y axis below
the mean of the Percent Recovery determinations.
23.2.3.5.4 The calculated Percent Recovery of each spiked sample is plotted on the graph
to determine whether the Percent Recovery is within the Warning and Control
Limits of the Control Chart.
23.2.3.5.5 If the Percent Recovery plots between the Warning and Control Limits, the
Group Leader or QA Coordinator is notified for a decision as to how to proceed.
23.23.5.6 If the Percent Recovery plots outside the Control Limits, the data set is invalid
and the analysis is stopped until the source of error has been determined and
corrective action taken. Once the error source has been resolved, the data set is
reanalyzed.
23.2.3.5.7 When an addition ten Percent Recoveries have been determined, the Warning
and Control Limits are recalculated for the entire data set and the Control Chart
for the corresponding parameter is updated.
23.2.3.6 All control charts are maintained by the Quality Control Coordinator in the
QAD.
233.0 Data Validation
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Data validation begins with the processing of data. Data processing can be I
performed by the analyst who obtamed the data or by another analyst Validation
233.1
233.2
continues with checking that the data processing has been done correctly. This
step can be performed by an independent analyst or the Group I
Leader/Supervisor. At this time a member of the Quality Assurance Department
may review the data processing. All those who review or review data processing
(Group Leader or QA) shall indicate this by signature and date on the 1 documents validated or reviewed.
In general, data will be processed by an Analyst in one of the following ways:
• Input of raw data for computer processing
· Duect acquisition and processing of raw data by a computer.
If data are manually processed by an Analyst, all steps in the computation shall
be provided including equations used and the source of input parameters such as
response factors, dilution factors, and calibration constants. The analyst shall
sign (Full signature) and date in ink each page of calculations.
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2333
233.4
23.4.0
23.4.1
For data that are input by an analyst and processed using a computer, a copy of
the input shall be kept and uniquely identified with the project number and other
information as needed. The samples analyzed shall be evident and the input
signed and dated by the analyst
If data are directly acquired from instrumentation and processed, tile analyst
shall verify that the following are correct: project and sample · numbers,
calibration constants and response factors, output parameters such as units, and
numerical values used for detection limits (if a value is reported as li!ss than).
The analyst shall sign and date the resulting output. .
Review of Data Reports
Review of data reports is required to verify that information reported by YRC
Analytical Division corresponds with processed analytical results. Preparation of
the data reports is the responsibility of the Group Leader. Review of a data
report by the Quality Assurance Department is done prior to transmission of the
report from the laboratory, when such review is required by contract/customer.
Those who prepare and review data reports shall indicate such by signature on
the report
24.0
24.1.0
24.1.1
24.1.2
24.13
24.1.4
24.15
24.1.6
24.1.7
24.1.8
DATA REPORTS
Introduction
The format and content of a data report is dependent upon project needs, such
as: whether or not explanatory text is required, client or contract requirements,
and government agency reporting formats. The YRC Quality Assurance
Program does not specify a report format; however, the following are applicable
to data presentation:
The final data presentation shall be checked in accordance with data verification
requirements of LQPP-13 and approved by the Laboratory Director. ·
Data are presented in a tabular format whenever possible.
Data are formatted as an YRC-Analytical Report such as shown on Figure 14.1,
or formatted as an YRC Laboratory memorandum.
Each page of data are identified with the project number. and name, date of
issue, and, if appropriate, client name.
Data presentation includes:
Sample identification number used by the YRC laboratory and/or the sample
identification provided to the laboratory.
Chemical parameters analyzed, reported values, and units of measurement
Detection limit of the analytical procedure if the reported value is less than the
detection limit
Data for a chemical parameter are reported with consistent significant figures for
all samples.
Results of Quality Control sample analysis if appropriate.
Achieved accuracy, precision, and completeness of data if appropriate.
Footnotes referenced to specific data if required to explain reported values.
Data should be transmitted from the laboratory only by the Laboratory Director
or responsible Group Leader.
If explanatory text is not issued with the analytical results; it is recommended
that:
- A letter of transmittal be included for external clients.
- A memorandum be included to augment data for other YRC facilities.
As necessary, the letter of transmittal/memorandum should include:
-Persons receivin~ the data.
Person transmittmg the data.
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-Document if the chain of custody was provided or correct, if any samples were
damaged in shipment, if sample contamers were inaepropriate for analysis, or
if volume provided was inadequate for proper analysIS.
-Brief discussion of samples analyzed and the analytical program.
-Discussion of any apparent data anomalies.
Discussion of any analytical difficulties.
25.0
25.1.0
25.1.1
MONITORING OF REFRIGERATED STORAGE
Introduction
Temperatures of all refrigerated storage areas must be monitored. Calibrated
thermometers must be placed in vials containing glycerin and monitored at least
one each day by a designated person from the field services j1;roup. The
temperature must be recorded in the appropriate notebook and irutialed by the
person recording the temperature. ·
The temperature of all refrigerated areas must remain within a range of 1 degree
C to 10 degrees C. If the temperature falls outside this range, the laboratory
Director, the QC Coordinator, and the field services group leader must take
appropriate corrective action and the affected samples flagged. The analytical
results will contain the following information:
-The date and time the anomaly in temperature was observed.
The approximate period for which the samples have been outside the
temperature window (1 degree C to 10 degrees C).
-Whether samples were maintained at the required temperature range while
corrective action was being instituted.
-Any corrective action taken must be documented in the temperature book.
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26.0
26.1.0
26.2.0
263.0
26.4.0
265.0
26.6.0
GIASSWARE CLEAN UP
Methods of glassware cleaning should be selected according to substamces that
are to be removed and by the analytical protocols required.
Water soluble substances can be washed with hot water and the vessel finally
rinsed with small amounts of deionized water. . Other substances may require
the use of a detergent, organic solvent, chromic acid cleaning solution, nitric acid
or aqua regia.
For trace metal analysis, the glassware shall be rinsed with 1:1 nitric acid-water
mixture. Rinse thoroughly with successive portions of deionized water. Chromic
acid should not be used for cleaning of glassware for trace metal analysis.
Glassware used for phosphate determinations should be thoroughly rinised with
tap water and then deionized water. Detergents containing phosphate:s should
not be used for cleaning.
For ammonia and kjeldahl nitrogen determinations, the glassware must be rinsed
with ammonia-free water.
Glassware used in the determination of trace organic constituents should be
cleaned in the following manner:
-Wash with detergent and water.
-Rinse 3X with warm tap water.
-Soak 15 minutes in chromic acid cleaning solution.
Rinse 3X with warm tap water.
-Rinse 3X with Type I water.
-Rinse 3X with acetone (reagent grade or better).
Rinse IX with the solvent to be used in the sample prep or analytical method.
27.0
27.1.0
27.2.0
27.2.1
27.2.2
27.2.3.
273.0
273.1
27.3.2
2733
273.4
2735
27.4.0
27.4.1
INSTRUMENT OPERATION, CAUBRATION, AND MAINTENANCE
Introduction
This SOP provides general information on instrument operation, calibration, and
maintenance requirements.
Definitions
Equipment: Any nondisposal mechanical and/or electronic device used in the
generation or measurement of data.
Calibration: Adjusting equipment with reference standards to assure that any
measurement performed is quantitatively accurate. The reference
standards should be traceable to primary standards ( e. g. , National Bureau of
Standards or other certified standards). If traceable chemical standards
are not available, standards may be prepared according to the Laboratory's
quality control procedures or the project's requirements.
Maintenance: Oeaning and/or replacing equipment components to assure that
the equipment has been properly and periodically serviced and is in satisfactory
condition.
Requirements
Equipment for the generation, measurement of determination of data shall be
adequately calibrated.
Equipment shall have adequate procedures for operation, calibration,
maintenance, and quality control which shall:
-Be prepared in written form in accordance with LQPP-1.
Be congruent with the manufacturer's recommendations.
-Reflect actual use patterns for the equipment
Establish frequency intervals for the calibration and maintenance particular to
the equipment.
Equipment shall be calibrated and maintained in accordance with the procedures
and schedules detailed in the equipment's SOP.
Calibration and maintenance intervals begin from the date of last calibration of
service.
Equipment maintenance shall be documented and the records retained in
accordance with the logging requirements of the SOP, in the respective equipment file.
Responsibility
The Laboratory Director and/or the Group Leader shall:
-Identify, compile, and write the SOP.
Make pertinent SOP's available to the appropriate staff. (This is to be
ordinated with the QAD.)
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27.4.2
275.0
-Maintain instrument SOP's with the instruments. Operation manuals shall also
be available in the immediate work area.
-Ensure that use logbooks are initiated and maintained in accordance with the
SOP'S.
-Review records for completeness and accuracy which indicates the equipment
is in proper working order.
-Momtor and assure compliance with the SOP.
The Quality Assurance Department shall:
-Coordinate SOP preparation.
-Coordinate review/revision of SOP's
-Reproduce and issue SOP's
Retain current and historical copies of the SOP'S.
-Recall superseded
Maintain distribution list of issued SOP'S copies.
-Verify compliance (via inspections).
Corrective Action
Problems shall be referred to the Laboratory Director and/or Group Leader who
shall then initiate the appropriate corrective action.
28.0 REAGENT PROCUREMENT, LABELING, STORAGE, AND TESTING
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28.1.0 Introduction
28.2.0
28.2.1
28.2.2
28.23
28.2.4
283.0
283.1
283.2
2833
28.4.0
28.4.1
28.4.2
This SOP provides general information regarding reagents and standard! I
solutions for chemical analysis.
Procurement Requirements
All reagents and chemical procurement must be entered into a Reagent and
Chemical Procurement Log when the order is made.
All solvents and chemicals purchased must be at the purity required by the
customer. Reagents for USEPA or for any state agencies must be either
pesticide residue grade or HPLC grade or better. All chemicals used for
calibration standards must be NBS traceable.
All reagents and chemicals received must be dated on receipt by the field services
group.
All reagents or chemicals beyond the expiration date must be discarded. All
groups must maintain an inventory of chemicals and reagents. Form Al.SOP: 9.1
should be used to monitor the expiration date.
Labeling Requirements
Labeling requirements include notations as to expiration date and storage
requirements. When there are additional contract specific requirements they
shall also apply and shall supersede.
Storage shall be in accordance with Good Laboratory Practices, the applicable
SOP, and/or customer requirements.
Testing of standards and solutions will be accomplished as part of routine QC by
the quality control officer. Samples will be taken and submitted as blind samples.
Responsibility
It shall be the responsibility of the Laboratory Director and the group leader to
indoctrinate staff members to these requirements and ensure compliance with
the SOP. .
It shall be the res.eonsibili~ of the QAD to monitor the Laboratory activity
periodically to verify compliance. Problems detected shall be followed up by
request for corrective action to the Director.
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29.0
29.1.0
29.2.0
29.2.1
29.2.2
29.2.3
29.2.4
29.3.0
29.3.1
29.3.2
29.3.3
RECORD RETENTION PROCEDURES
Introduction
This Standard Operating Procedure (AI.SOP) provides general guidelines for
project retention.
Definitions
Laboratory Director: The analytical department director. This person is
responsible for directing the overall activity of the analytical lab and reports
directly to YRC vice-president.
Group Leader: The person designated by YRC management to be responsible
for coordinating and directing a particular program/project. This person is
responsible for producing ancf mamtaining project records until store:d in the
YRC archives.
Raw Data: Any "original" observation project records, or exact copieii thereof,
necessary for the reconstruction and evaluation of a report. Raw data may
include, but is not limited to:
-Hand-written records
-Instrument printouts
-Computer printouts ( direct data input)
Magnetic records
-Photographs
-Transcripts
Exact Copies: Records that are verified as exact copies of raw data ( e. g.
Photocopies, transcripts computer printouts, etc.) by signature and dated.
Chain-of -custoc!y records require the additional statement of "exact c~"
-Transcripts: Exact transferrals of information generally from one m,:dium to
another ( e.g. magnetic records to hand-written or types notes). If a transcript
is verified as accurate by signature and dated, it may be substituted for the
original source.
Archive: An order record storage system.
Project Archive: Data/records maintained under supervision of a Group Leader
until stored via YRC archives.
GLP Archives: A limited access storage area for non-regulated project records
maintained under the direction of the Laboratory Director.
Responsibility
The Laboratory Director and/or Group Leader are responsible for training all
laboratory staff in this AI.SOP.
The Laboratory Director and/or Group Leader are responsible for enforcing this
ALSOP.
The YRC QAD is responsible for maintaining the limited access archives.
@[t]j}J~1]
29.3.4
29.3.5
29.3.6
29.4.0
29.4.1
29.4.2
29.5.0
29.5.1
29.5.2
29.5.3
29.6.0
The Group Leader is responsible for ensuring the retention of all records
associated with a project until final archiving. -
The Grou1;> Leader is responsible for ensuring automatic distribution of reports
and other unportant documents to YRC archives as they are generated.
The QAD is responsible for verifying compliance (via inspections) and
maintaining the applicable inspection records and for final archive storage.
Corrective Action
Problems discovered prior to final archiving shall be referred to the Group
Leader who shall then take the appropriate corrective action. If the Group
Leader is unavailable corrective act10n.
Problems discovered after final archiving are the responsibility of the Group
Leader, Laboratory Director, QAD, and YRC management. Information of this
nature is to be documented and sent to QAD for review and continued
coordination, and to YRC management.
Guidelines
Raw data and records &enerated as a result of, or directly associated with a
project shall be retained m a systematic and logical form.
Project information shall be:
• Accounted for
-Adequately filed for future rapid retrieval
Appropriately indexed
• Stored under the required level of security
Retained at least for the specified retention period.
Project material generated during the course of a project are shown in Table 1 of
this ALSOP.
After project completion, the Laboratory Director and/or Group Leader shall be
responsible to collect and transfer the records to the fmal lab archives.
Retention shall be for a minimum of five years unless otherwise additionally
specified by project requirements or YRC management.
Initial Archiving Procedure
The Group Leader or designee shall:
• Complete the ~ portion of the Record Index form ( copy attached) and
then retain it with the project records.
Prepare file folders according to the categories on the Record Index form, as
appropriate, and begin filing accordingly as soon as project information is
available.
• Ensure that any contract-specific document control requirements for archival
are followed. If an alternate inventory format is required, substitute it for the
Record Index form.
• Maintain project records under the required level of security.
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29.7.0
29.7.4
29.7.5
Final Archiving Procedure
After the final report is written, the Group Leader shall:
-Ensure that all required project records are placed in stora!le o)ntainers
( as minimum storage file boxes) and that extraneous information has been
removed. NOTE: QAD reports are maintained by the QAD and shall NOT
be stored with project records. Copies of QAD results formally submitted to a
client shall, however, be in project reports. .
-Com_plete the Record Index form, sign off at the bottom of the form, and
obtam approval signatures.
-Make sufficient copies of the completed Record Index form to allow for:
-One copy each for file reference of Group Leader, Laboratory Director,
and QAD. Distribute accordingly.
-Two copies for each storage container.
Place one copy of the completed Record Index inside the storage container and
one taped to outside. (If stored in storage file boxes, place on top of the files so
that it will be readily visible when box is opened.) Be sure containers are
numbered as specified on the Record Index.
Transfer stored records to designated archive storage area.
@[JJfi1~U
30.0
30.1.0
30.1.1
30.1.2
30.13
30.2.0
30.2.1
30.2.2
303.0
PROJECT RECORDS TO BE MAINTAINED
Project Administration
Name and role of all project staff members including YRC management.·
External communication ( communication with customer, i.e. correspondence,
telephone conversations, meetings notes, etc.)
Internal communications (field reports, lab memos, etc.)
Background Information
Safety information
Published literature used as a direct source of information
Protocol
303.1 Copies of all protocols and their revisions
303.2
3033
303.4
30.4.0
30.4.1
30.4.2
30.43
30.4.4
30.45
30.4.6
30.4.7
30.4.8
30.4.9
30.4.10
305.0
Work assignments
QA plans
Training programs
Project Data: Including but not limited to:
Sampling and/or survey information
Field and/or laboratory chain-of-custody records
Sampling and/or analysis data
Subcontractor data
Copies of analytical notebooks (case files, EPA Archives)
Sample locations (reference storage location)
Data calculations and tabulations
Computer programs ( or references), revisions, validations, etc.
EPA regulated project records
EPA samples
Reports
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31.0
31.1.0
31.2.0
31.2.1
31.2.2
31.23
31.2.4
313.0
313.1
313.1.1
313.1.2
313.2
313.2.1
313.2.2
SAMPLE CHAIN-OF-CUSTODY
Introduction
The location of all samples within the laboratory must be documented using an
YRC Analytical CHAIN OF CUSTODY form. A facsimile of this form is
appended at the end of this Al.SOP.
Procedure
The YRC Analytical CHAIN OF CUSTODY form is generated by the: sample
management computer when the sample is logged into the laboratory.
The sample custodian will issue a completed form ( date, location, initials) when
the sample is released for analysis. The form is placed in an access file adjacent
to the sample storage area.
Each analyst will enter required information ( date, location, initials) on the form
when removing the sample from or returning the sample to the storage iuea.
Upon completion of analyses for a sample, the YRC Analytical CRt.JN OF
CUSTODY form will be filed in the permanent record of that sample.
Special Requirements
EPA Contract Lab Program (CLP) Samples
The National Enforcement Investigations Center (NEIC) defines custody of a
sample in the following ways:
-It is in your actual possession,
It is in your view after being in your possession,
-It was in your possession and then you locked or sealed it up to prevent
tampering, OR
-It is in a secure area.
Samples sent to YRC by EPA will be accompanied by their own chain-of--custody
record. It is to be completed according to the particular EPA contract
requirements and placed in the permanent file of that sample(s).
External Chain of Custody
Certain samples, other than EPA CLP type, may require external chain-of-
custody when they are to be analyzed for compliance to Federal, State and Local
regulations. These samples require the use of the CHAIN-OF-CUSTODY
RBCORD form, an example of which is included at the end of this Al.SOP.
The CHAIN-OF-CUSTODY RECORD is prepared outside of YRC by a field
representative. The original remains with the field representative, whilc: a copy
accompanies the sample to YRC.
Page I YRC Analytical Chain of Custody
RCVD: 01/07/87 DUE: 01/21/87
Order #87--01--030
Keep: 02/20/87
DASH SAMPLE IDENTIFICATION STORED TESTS
01A SarnDle ID# Shelf# NO TEST
RELEASED BY DATE
TRANSFERRED TO DATE
RECEIVED BY DATE
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32.0
32.1.0
32.2.0
32.3.0
32.4.0
32.5.0
32.6.0
32.7.0
SAMPLE STORAGE AND SECURITY
Samples must be stored protected from light and in locked refrigerators from
time of receipt until extraction or analysis.
Samples will be stored in the original containers unless damaged. Damaged
samples will be disposed of in an appropriate manner after approval from client
Refrigerators for samples from state and federal agencies and customers
specifically requesting security must be locked at all times.
Only the Laboratory Director, Group Leader, and the second shift supe1visor will
have keys to the refrigerators.
Samples and standards must not be stored in the same refrigerator.
All transfers of samples into and out of storage must be documented on the
internal chain-of-custody record (YRC Analytical CHAIN OF CUSTODY
form).
When the analyst removes the sample(s) from storage, the analyst becomes
responsible for the custody of the sample.
00 00 ffi ~ if
33.0
33.1.0
33.1.1
33.1.2
33.1.3
33.1.3.1
33.1.3.2
33.13.3
33.1.3.4
33.1.35
33.1.3.6
33.1.4
33.1.4.1
33.1.4. 2
33.1.4.3
33.1.4.4
SAMPLE RECEIPT AND LOG-IN
Introduction
All samples will be received by the Data Management Off ice or Sample
Custodian.
All deliveries must be made between the hours of 0800 through 1800 Monday
through Friday, and 0800 to 1200 hours on Saturday. There will be no receipt
of samples at any other time than those listed above unless prior arrangements
with the appropnate laboratory personnel have been made.
The designated lab employee must follow the procedures listed below when
receiving samples:
Si~ for shipment after verifying that the number of P.ackages received agrees
with the airbill.
Sign and date the airbill upon receipt of samples.
Fill in date of receipt on Sample Receipt Log (Figure 1.1)
Check the ice chests for the presence, position, and condition of Custody Seals.
Note the condition of the Custody Seals on the Chain-of-CUstody sheets, if
available. Otherwise, note all anomalies on the sample log-in form.
Check the sample tag/label and the sample tag numbers for listing on chain-of-
custody. Note anomalies on the sample log-in form.
Check for presence of any other form or notes on the samples. Note any
additional information on the sample Log-in form.
Procedures when Field Service Group Personnel are not available for sample
receipt
Verify that the number of packages received agree with airbill.
Record the date/time samples were received on Sample Receipt Log (Figure
1.1).
Record on Sample Log-in sheet the presence or absence of the chain-of-custody
records, the presence or absence of air of airbills and/or bills of lading
documenting shipment of samples.
Move the shipping containers to the refrigerated sample storage area.
33.1.4.5 Sign and date the Sample Receipt Log and any chain-of custody to storage.
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SAMPLE LOCATION:
PROJECT SAMPLE LOG-IN FORM
YRC 1AB WORK ORDER NO.:
PROJECT NUMBER: DA TE RECEIVED:
PROJECT NAME: RECEIVED BY:
PROJECT CONTACT: REPORTTO:
SUBMITTED BY: REPORT DATE:
SAMPLE PARAMETERS
IDENTIFICATION (Water and Waste
Comments or Special Instructions:
Figure 1.1
Water)
34.0
34.1.0
34.2.0
34.2.1
34.2.2
34.2.2.1
34.2.2.2
34.2.23
34.2.2.4
34.2.2.5
34.2.2.6
34.2.2.7
PREPARATION OF SAMPLE CONTAINERS
Only new containers will be used for collection of samples to be shipped to the
laboratory for analysis.
Preparation of Volatile Organic Analysis Vials
40ml borosilicate glass vials with teflon-lined silicone rubber septa and screw
caps must be used for collection of samples for volatile organic analysis.
Procedure
Soak vials in detergent solution for approximately 30 minutes.
Scrub vials clean with a brush.
Rinse several times with tap water to remove detergent
Rinse the vials several times with deionized water.
Place vials in an oven at 180 degrees C for one hour to dry and remove any trace
contamination from volatile organic compounds.
Remove vials form oven and allow to cool.
Seal vials with the teflon-lined silicone rubber and screw caps. The teflon-lining
must face the interior of the vial. Store the vials in contamination-free areas
until use.
34.2.2.8 Prior to shipping of the vials, add 3g sodium thiosulfate to the vials.
343.0
343.1
343.2
3.2.1
3.2.2
Preparation of Base, Neutral, Acid and Pesticide Organic Analysis Bottles
One quart or two-quart glass bottles with teflon-lined caps must be used for
sample collection. Only new bottles should be used for sample collection.
Procedure
Soak bottles in detergent solution for approximately 30 minutes.
Scrub bottles clean with a brush.
343.23 Rinse bottles several times with distilled water.
343.2.4 Rinse bottles several times with distilled water.
343.2.5 Rinse bottles with pesticide-grade acetone.
343.2.6 Rinse bottles with pesticide-grade hexane.
343.2. 7 Allow bottles to thoroughly air dry to remove organic solvents, seal and store
until shipping.
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34.3.2.8 Prior to shipping, add IO0g sodium thiosulfate to bottles.
34.4.0 Preparation of Metals Analysis Bottles
34.4.1 250ml or 500ml new polypropylene plastic bottles must be used for sample
collection.
34.4.2 Procedure
34.4.2.1 Soak the bottles in detergent solution for approximately 30 minutes.
34.4.2.2 Scrub the bottles clean with a brush.
34.4.2.3 Rinse bottles with tap water.
34.4.2.4 Rinse bottles with deionized water.
34.4.2.5 Add 1:1 nitric acid to bottles, cap and shake briefly.
34.4.2.6 Allow bottles to stand for approximately 30 minutes, shaking them intennittently.
34.4.2.7
34.4.2.8
345.0
345.1
345.2
34.5.2.1
34.5.2.2
345.23
345.2.4
345.25
Pour acid from bottles and rinse thoroughly several times with deionized water.
Add 1 ml of concentrated nitric acid per 100 ml volume as preservative.
Preparation of Bottles for Other Water Quality Analysis
Bottles will beflastic (unless glass or other material specifically requested by
procedure) an the size would dependent and the number and type of
determination requested.
Procedure
Rinse bottles with tap water.
Soak bottles in detergent solution for approximately 30 minutes.
Scrub bottles clean with a brush.
Add acid solution to bottles, cap and shake briefly.
Allow bottles to stand for a minimum of 15 minutes, shaking them intermittently.
345.2.6 Pour acid solution from bottles and rinse them with tap water.
345.2.7 Rinse bottles several times with deionized water.
34.5.2.8 Allow bottles to dry, cap and store until use.
35.0
a
b
C
d
SAMPLE PRESERVATION PROCEDURES AND HOLDING TIMES FOR
AQUEOUS AND SOLID SAMPLES
"After the samples have been taken, they should be sent to the laboratory for
analysis as expeditiously as possible in order to insure that the most reliable and
accurate answers will be obtained as a result of the analysis. As a general rule,
storage at low temperature is the best: way to preserve most sampfes, although
the length of time the sample can be held-at low temperatures varies with the
analyte and matrix. The bottles should be packaged for shipping in insulated
containers, constructed to insure that the bottles will arrive at the .laboratory
intact."
"When the samples are received at the laboratory the time lapse between sample
acquisition and analysis may not exceed the time shown in the table attached.
Freezing samples to extend holding SHALL NOT be permitted."
"The following table summarizes containers, preservation, and holding require-
ments by analyte and sample matrix."
Preservatives and holding times are from Federal Register, Vol. 49, No. 209,
Friday, October 26, 1984, Page 43060 and Characterization of Hazardous Waste
Sites: A Methods Manual Volume Ij Methods. Second Edition, EPA-600/4· 84-
076. Container requirements are cons1Stent with these references.
P -Polyethylene
G • Amber Glass with Teflon-lined cap
S -Glass Vial with Teflon-lined septum cap
Sample preservation should be performed immediately upon sample collection.
For composite samples, each aliquot should be preserved at the time of
collection. When use of an automatic sampler makes it impossible to preserve
each aliq_uot, samples may be preserved by maintaining at 4 degrees C until
compositmg and sample splitting is completed.
When any sample is to be shipped by common carrier or sent through the U. S.
Mail, it must comply with the Department of Transportation Hazardous
Materials Regulations (49 CFR Part 172). The person offering such material for
trans_portation is responsible for ensuring such compliance. For the preservation
requuements in this table, the Office of Hazardous Materials, Materials
Transportation Bureau, Department of Transportation, has determined that the
Hazardous Materials Regulations do not apply to the following materials:
Hydrochloric acid (HCl) in water solutions at concentrations of 0.04% by weight
or less (pH about 1.96 or greater); Nitric acid (HN03) in water solutions at
concentrations of 0.15% by weight or less (pH about 1.62 or greater) ; Sulfuric
II
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acid (H2SO4) in water solutions at concentrations of 0.35% by weight or less (pH
about 1.15 or greater); and Sodium hydroxide (NAOH) in water so:lutions at
concentrations of 0.080% by weight or less (pH about 12.3 or less).
Samples should be analyzed as soon as possible after collection. The times listed
are the maximum times that samples may be held before analysis and still be
considered valid. Some samples may not be stable for the maximum time period
~iven in the table. A laboratory is obligated to hold the sample for a shorter time
if knowledge exists to show this is necessary to maintain sample integrity.
If samples cannot be filtered within 48 hours, add 1 ml of a 2. 71 % solution of
mercuric chloride to inhibit bacterial growth.
Should only be used in the presence of residual chlorine.
Maximum holding time is 24 hours when sulfide is present. Optionally, all
samples may be tested with lead acetate paper before pH adjustment in order to
determine if sulfide is present. If sulfide IS present, it can be removed by addition
of cadmium nitrate powder until a negative spot test is obtained. The sample is
filtered and then NAOH is added to pH 12.
For dissolved metals, filter immediately on site before adding preservative.
Guidance applies to samples to be analyzed by GC, LC, or GC/MS for specific
compounds.
The pH adjustment is not required if acrolein will be measured. Samples for
acrolein receiving no pH adjustment must be analyzed within three (3) days of
sampling.
When the extractable analytes of concern fall chemical category, the specified
preservative and maximum holding times must be observed for optimum
safeguard of sample integrity. %,-hen the analytes of concern fall within two or
more chemical categories, the sample may be preserved by cooling to 4 degrees
C, reducin~ residual chlorine with 0.008% sodium thiosulfate, storing in the dark,
and adjustmg pH to 6-9; samples preserved in this marmer may be held for 7 days
before extraction and 40 days after extraction. Exceptions to this optimal
preservation and holding time procedure are noted in footnotes g, m, and n.
m
n
0
p
q
If 1,2-diphenylhydrazine is likely to be present, adjust the pH of the sample to 4.0
0.2 to prevent rearrangement to benz1dine. .
Extracts may be stored up to 7 days before analysis if storage is conducted under
a inert (oxidant-free) atmosphere.
For the analysis of diJ?henylnitrosamine, add 0.008% Na2S203 and adjust pH to
7-10 with NAOH withm 24 hours or sampling.
The pH adjustment may be performed upon receipt at the laboratory and may be
omitted if the samples are extracted within 72 hours of collection. For the
analysis of aldrin, add 0.008% Na2S203.
Sample receiving no pH adjustment must be analyzed within 7 days of sampling.
This document is copied verbatim for the "U. S. Army Toxic and Hazardous
Materials Agency, Installation Restoration Program, Quality Assurance
Program", Section H, dated December 1985.
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36.0
36.1.0
36.2.0
363.0
36.4.0
36.5.0
VISITORS
Visitors, defined as any person who is not employed by YORK Research
Laboratory, must sign in and out on the Visitor Log.
Visitors will be provided with safety ~asses before entry into the laboratory areas
and will be required to wear the safety glasses at all times within safe1:y glasses
areas of the laboratory.
Visitors shall not enter the laboratory without being escorted by. a YORK
employee.
Visitors who stay for a reasonably long period (e.g. repair equipment) must be
supervised at all times while inside the laboratory by YORK personnel.
Consultants and employees from other YORK locations will be consi.dered as
visitors and should be treated as such.
37.0 QUALITY ASSURANCE REPORTS TO MANAGEMENT
Quality assurance reporting and documentation are important elements of final
project reports. Reports provided to agency and industrial clients contain I
sections which: (a) describe QNQC activities and criteria relevant to the
measurements reported; (b) provide results from the application of these acti-
vities; and ( c) address the impact of these· results on time measurements I
reported.
The QA procedures used in this test program generate sufficient documentation 1 to indicate data quality. QA results will be included in the final report. At a
minimum the following will be addressed in the final report:
a) Precision 1 1
) Recovery (accuracy)
de
c}m~ .1 Sampling and analysis equipment calibration
Cylinder gas audits and on-site equipment audits
f) Spike composition verification and recovery checks
g) GC/MS recovery checks I
h) Internal standard response tracking
All evidence of the execution of the QA guidelines is reviewed by management I
In addition, during regular meetings of YORK's task managers and project
managers, all aspects of the project are discussed, includin$ the CA of each task.
No written report results from this meeting because all mterested parties are I
verbally apprised of the situation during each meeting.
Two other reports are made to management which are not task related. YORK's 1 emission test and laboratory groups participate in national audits by EPA's
Quality Assurance Division, and the California Air Resources Board and
YORK'S QA coordinator makes several independent checks for management
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38.0
38.1.0
38.2.0
38.3.0
38.4.0
38.5.0
38.6.0
SAMPLE DISPOSAL
Samples will be transferred out of the refrigerated area seven days after issuance
of the report. The sample will be, retained in a specified area for at least 180
days. After 180 days and with the concurrence of the client, the samplle will be
disposed of in accordance with state and federal re~ations. The process used
for disposal of samples shall be recorded in the cham-of -custody fonns and any
other documents required by the state or federal agencies.
For solid samples known not to contain a hazardous or regulated (RCRA)
characteristic, RCRA, TSCA, PCB, or state listed contaminant, disposal through
a local municipal solid waste collection system is appropriate.
For water samples and generated aqueous waste, a carbon unit filtration system
shall be used.
Ignitable and combustible waste will be incinerated by Rollins Environmental
Service on a quarterly basis.
Regulated materials must be disposed of at a corporate approved facility. US
Pollution Control, Inc. is listed as the primary hauler and disposal facility.
Clients are encouraged to accept return of samples upon Certificate of Analysis
issue. The client will be invoiced for cost of transport and packagiog. The
original chain-of-custody will be sent with the samples and a copy rema.in in the
project file.
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39.0
39.1.0
39.2.0
REPORT ASSEMBLY AND DATA STORAGE
All raw data and processed data from the laboratory is submitted in report
format to the Organic and Inorganic Group Leaders. The managers shall
validate the reports, and the reports will then be signed and released by the
Laboratory Group Leader from the group which performed the work or his
designee.
The reports, along with the raw data, will be archived in files in chronological
order.
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40.0
40.1.0
40.1.1
40.1.2
40.13
40.1.4
40.2.0
40.2.1
40.2.2
40.23
40.2.4
403.0
IABORATORY DATA RECORDING AND VALIDATION
Data Recording
Entry of raw data into laboratmy documents, worksheets, or logbooks must be
made in indelible ink. Pencils shall not be used for data entry.
Corrections of raw data must be made in ink.
If an error is made, the analyst shall correct the data by drawing a single line
through it. The line shall be drawn in such a way as not to conceal the erroneous
entry. The analyst shall then date and initial the correction.
In situations where legible corrected entries are not feasible; the correction shall
be written in the closest available space where legible entries could be made.
The analyst shall initial and date both the deletion and the correction entry.
Data Validation
If the raw data is manually processed, all steps in the computation shall be
provided including equations used, response factors, calibration c:onstants,
dilution factors, etc.
All manual calculations must be checked by another analyst. Any changes made
by the checker shall be rechecked by the originator, and agreement must be
reached before the result is released.
If the raw data was input to a computer to manipulate the raw data, all input
entries must be verified by a checker.
If the raw data is acquired and processed by the instrument, then the analyst shall
verify that the following are correct.
project and sample numbers
calibration constants, response factors, dilution factors
units
detection limits
All validated data must be provided to the Group Leader for review and
signature.
41.0
41.1.0
41.2.0
413.0
41.4.0
41.5.0
41.6.0
41.7.0
41.8.0
41.9.0
41.10.0
41.11.0
41.12.0
SAMPLE ANALYSIS AND TRACKING
The sample analysis and tracking SOP monitors and documents the state of
analysis of the sample.
The analyst must document any analytical procedure performed on the sample.
When a sample is received, a copy of the sample log-in sheet will be provided to
the appropnate group leader (i. e. , General Chemistry, Metals, GC, GC/MS)
depending of the type of analysis requested.
The group leader will determine the method to be used for analysis, and the
appropriate personnel within the group will be assigned the task of analysis. If
extractions of the samples are involved, the individual groups will perform the
extractions.
The samples and extracts must be followed by chain-of -custody forms and/or
sample preparation work-sheets within a laboratory. Al documentation (i. e.
chain-of -custody forms, sample preparation worksheets, logbooks, etc.) must be
submitted to the Group Leader for review and subsequent reference in
project/case files.
All sample extracts not scheduled for analysis must be properly sealed and
refrigerated in a designated refrigerator by the Group Leader. The
temperature of this refrigerator must be maintained between 1 degree C and 7
degrees C at all times.
Sample extracts may be removed from the refrigerator only when the extracts are
scheduled for analysis. Each time the extract is removed or returned to the
refrigerator, the chain-of-custody form (if necessary) must be appropriately
completed.
Sequence of standards and samples analyzed will be dictated by the method used.
Each analysis (standard or sample) must be recorded in the instrument logbook.
If an autosampler is used, the tray number and position should be recorded in the
logbook.
Hard copies of: all data printed out must be labeled appropriately identifying
sample number, standard, concentration of standard, etc.
The data is now entered by the analyst onto check sheets and all the necessary
calculations performed. This data must be verified by another analyst (See Data
Recording SOP).
The remaining extracts will be placed in sealed vials and stored for a period of
three months, or for a longer period at the request of the clienL
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42.0
42.1.0
42.2.0
42.2.1
42.2.1.1
42.2.1.2
42.2.13
42.2.1.4
42.21.5
42.2.2
42.2.2.1
42.2.2.2
42.2.23
STANDARDS PREPARATION AND TRACKING SYSTEM
Preparation of standards for calibration must be made from pure materials ( of
known purity, 98% or better preferred) or from purchased concentrates certified
by NBS, EPA, or other acceptable agencies.
Standards for Analysis
Solvents used for preparation of standards must be checked for purity before
standard preparation.
If the solvents purchased are of pesticide grade and distilled in glass a check for
purity is not necessary, but is recommended.
If the solvents purchased are of pesticide grade each lot must be checked for
impurities by a GC/ECD or GC/FID method. Approximately 300 ml of the
solvent of one Jot is concentrated using a specially cleaned Kudema-Danish
Flask to 5 ml. Inject 50 uL of the concentrate. if peaks occur at the same
retention times as the analyses of interest at greater than 5% f.s.d, 1:hen the
solvent may be contaminated and may cause identification and quantitation
problems. These solvents may have to be distilled in glass before use.
Under no circumstance should solvents of lesser quality than pesticide grade by
used to prepare standards for analysis by GC, GQ'MS, or HPLC.
Freon used for preparation of standards and extraction of samples for oil and
grease content shall be distilled prior to use.
All standards, reagents, and solvents used for trace
spectro-quality. .
metal analysis must be
Preparation of Standards
Stock ·standards (approximately 100 ppm) may be prepared or purchased and
stored at -10 degrees C to -15 degrees C for a period of six months. Fresh stock.
standards must be prepared or purchased every six months.
Upon preparation of the standard, the following items must be recorded on the
bottle containing the standard:
-date prepared
-initials of the analyst preparing the standard
-a unique identification number for the standard
-an expiration date.
All other information regarding the standard including solvent used lot
number(s) of solvent use, the analyte source, purity and lot number,
concentration analyst's initials and date prepared must be entered in the Jog
book. A format similar to Form 1 and 2 could be used. All standard preparations
must be verified by a senior chemist or group leader prior to use.
Prepru:ation of intermediate standard solutions is strongly recommended for all
analysJS.
Working Standards
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42.2.2.3.1 Working standards include calibration standards, spiking solutions of analytes,
surrogates, etc., and must be stored at -10 degrees C to -15 degrees C when not I
in use.
42.2.2.3.2 Working standards for the analysis of volatile organic constituents must be
prepared at least once in two weeks.
42.2.2.3.3 Working standards for the analysis of semi-volatile organic constituents and
pesticides must be prepared at least once in two weeks.
42.2.2.3.4 Working standards for trace metal analysis, except for mercury, should be
prepared at least once a month. Working standards for mercury must be made up
daily.
42.2.2.3.5 Working standards for oil and grease and sulfate, must be prepared at least once
a month. Standards made for the ion-chromatograph must be prepared at least
once a week and all other standards must be prepared immediately prior to
analysis of samples.
42.2.2.4
42.2.3
42.2.3.1
42.2.3.2
42.2.3.3
42.2.3.4
42.2.4
42.2.4.1
42.2.5
42.2.5.1
A Laboratory Calibration Standard (LCS) must be prepared from a source other
than the stock standard. The concentration of the LCS must be verified using a
certified standard. LCS must be prepared by a senior chemist or group leader at
least once a month and be stored at -10 degrees C to -15 degrees C when not in
use.
Verification of Standards
All standards upon preparation must be analyzed by GC or GC/MS and the
response compared to the most recent standard response.
All new standard analyses must be maintained in a file in the individual groups
and copies of the responses must be submitted to the QC Coordinator.
LCS and working standard responses will be entered into the computer and
upper and lower control limits will be established by the QC Coordinator. Until
control charts are developed, the response for the new standards will not vary by
more than 20% of the response of the most recent standard.
LCS analysis data will be entered into the computer and 95% and 99%
confidence limits will be established. The 99% confidence interval for the LCS
must not exceed a 10% interval from the theoretical concentration of the LCS.
The QC Coordinator must be informed immediately if such a variance occurs.
Tracking of Standards
The identification of each standard prepared must be unique and all documents
related to sample analysis in which the standard was used must contain this
unique identification. The document should be such that all of the standard
information could be traced from the raw data for the sample.
Storage of Standards
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42 . .5.2 Standards must be stored in separate refrigerated areas to samples and extracts.
43.0
43.1.0
43.2.0
43.2.1
433.0
433.1
43.4.0
43.4.1
43.5.0
43.5.1
EQUIPMENT MAINTENANCE
Routine maintenance and frequency of such maintenance of major
instrumentation are covered in this Standard Operating Procedure.
Gas Chromatograph Maintenance
All routine maintenance to be performed as recommended by the manufacturer.
Gas Chromatograph -Mass Spectrometer Maintenance
All routine maintenance to be performed as recommended by the manufacturer.
Atomic Absorption and Inductively Couple Plasma Spectrophotometer
Maintenance
All routine maintenance to be performed as recommended by, the manufacturer.
Ion Chromatograph
All routine maintenance to be performed as recommended by the manufacturer.
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APPENDIX B
SITE SPECIFIC HEAL TH AND SAFETY PLAN
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HEAL TH AND SAFETY PLAN
1.1 INTRODUCTION
This site specific Health and Safety Plan (H & S Plan) program has been prepared by GDC
Engineering to ensure the health and safety of site personnel during the remediation of the GRU
materials at the Hoechst Celanese Corporation, Shelby, North Carolina facility. It addresses all
activities associated with field activities and will be implemented by the Health and Safety Officer
(HSO) or Designee during site work. Compliance with this H & S Plan is required of all persons
who enter the site. The field· activities associated with this program will be performed in
coordination with the regulating authorities, Hoechst Celanese, Westinghouse and the GDC's
HSO. All work will be in accordance with applicable federal, state and local regulations,
including the U.S. Department of Labor, Occupational Safety and Health Administration
(OSHA) Requirements of 29 CPR Part 1910.120 and the U.S. Environmental !Protection
Agency's (USEPA's) "Standard Operating Safety Procedures".
In no case may work be performed in a manner that conflicts with the intent of or the inherent
safety and environmental conservatism expressed in these procedures. Personnel visiting the site
will only be allowed in areas where personnel protection is not required or they will be required
to meet the standards set forth within this program. Visitors who violate safety procedures will
be directed to leave the site.
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1.2 PROGRAM OBJECTIVFS
It is the objective of this health and safety program to provide safe working conditions for
personnel at the site during activities associated with site remediation. Stringent safety
regulations will be employed during the work effort to ensure the protection of employees. The
safety organization and procedures have been established on the basis of analysis of potential
hazards and the personnel protection measures have been selected to respond to these risks. This
safety program defines the procedures to be used while at the site and personnel protective
equipment required.
1.3 HEALIB AND SAFETY ORGANIZATION AND PERSONNEL
The following Health and Safety (H&S) organization has been established for all personnel
associated with field activities. The development of the H&S organization is based upon specific
project requirements and the overall safety for all employees and all other on-site personnel,
visitors and local residents. The key participants will be:
Company Health and Safety Manager <CHSM} -Mr. Harzy &!wards
The CHSM has overall responsibility for development and implementation of this
H & S Plan. He also shall approve any changes to this plan, modification of any
procedures as required, or any new activities proposed.
The CHSM will be responsible for the development of any new company safety measures
and procedures necessary for field operations and will also be responsible for the
resolution of any outstanding safety issues which arise during the site work. All health
and safety related duties and responsibilities will be assigned only to qualified individuals
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1.4
Page 3
by GDC's CHSM. Authorization for personnel to perform work on-site (i.e., relative to
medical exams and training) must be approved by the CHSM.
Site Health and Safety Officer <HSO} -Mr. Stephen N. Bone
The HSO will be present on-site during the conduct of all Level A and B field operations.
The HSO will be responsible for all H&S activities and the delegation of duties to the
H&S staff in the field. Where the site is identified as Level C or Level D, the HSO may
direct the site H&S efforts through an H&S coordinator approved by the CHSM. The
HSO has stop-work authorization, which he will execute upon his determination that an
eminent safety hazard, emergency situation, or any other potentially dangerous situation
exists. The HSO will initiate and execute all contact with support facilities and personnel
when this action is appropriate.
Health and Safety Coordinators <HSC} -<to be determined}
One Health and Safety Coordinator will be on-site for each shift. His primary
responsibility is to provide the appropriate monitoring to ensure the safe conduct of field
operations. He will have access to communications with the HSO. The HSC will also
share responsibility with the Project Manager and the Field Engineer and the HSO for
ensuring that all safety practices are utilized by downrange teams and that during
emergency situations appropriate procedures are immediately and effectively initiated.
He will also be responsible for the control of specific field operations and all related
activities such as personnel decontamination, monitoring of worker heat or cold stress,
distribution of safety equipment, and conformance with all other procedures established
by the H & S Plan.
SITE msTORY AND PHYSICAL DESCRIPTION
1.4.1 Site Location
The Hoechst Celanese plant is located outside of Shelby, North Carolina, off of
N.C. Highway 198. The predominant areas of concern are located in the
southeastern portion of the facility.
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1.4.2 Site Description
The areas to be remediated are adjacent to the wastewater treatment plant within
the Hoechst Celanese confines. The areas consist of a section of stream requiring
sediment removal and an area containing buried GRU, plastic chips and bum pit
materials. The material in both areas will be processed for on-site incineration
and/or solidification.
1.4.3 Waste Description
The following information is presented to identify the types of materials which will
be encountered during the site activities at the Hoechst Celanese site. A sample
analysis was performed on the material by Westinghouse. The results from the
samples showed several organic and metal compounds. The primary compounds
of concern along with the maximum concentrations are as follows:
1.
2.
Compound
Ethylene Glycol
Antimony
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802
Concentration mg/kg
[phone]
28,727
6,000
FAX [phone]
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1.5 HAZARD ASSF.SSMENT
1.5.1 Site Operations
The risk associated with the ongoing operation will be evaluated and a,ddressed
before site work commences. Compliance with GDC Engineering Inc. 's Health
and Safety Manual will be required, in addition to this site specific H,!alth and
Safety Plan.
1.5.2 Chemical Hamre!
The risk associated with the various compounds at the site will depend on the
actual quantities encountered during site activities. Extreme precaution will be
taken during the entire project so that the quantities of the organic and inorganic
compounds are known and the proper levels of protection are used to ensure the
safety of all site personnel. The hazards associated with each of the primary
compounds are as follows:
o Ethylene Glycol -is a colorless, sweet tasting liquid which is considerably
hygroscopic. It will absorb twice its weight of water at 100% relative
humidity. Ethylene glycol is toxic by ingestion and inhalation. Repeated
exposures will cause irritation of the skin, mucous membranes, and eyes.
The primary toxicity is by ingestion and will cause CNS depression,
vomiting, drowsiness, coma, respiratory failure, and renal damage:. Lethal
dose in humans is approximately I 00 milliliters. Alcohol foan1, water,
CO,, or dry chemical should be used to extinguish fires. Ethylene Glycol
has a Threshold Limit Value of 50 ppm ceiling concentration in air.
®mm~rr
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Antimony is a silvery-white, lustrous metal which is not tarnished in dry
air and only slightly in moist air. It is used in the manufacturing of alloys,
hard lead, bullets, and bearing metals. Antimony and its compounds have
been reported to cause dermatitis, keratitis, conjunctivitis, and nasal septal
ulceration by physical contact or inhalation of dust and fumes. The
occupational exposure level is 0.5 mg/m' in air.
The exposure limits provided for each of the compounds are based on a 8-hour
time-weighed average concentration. Material Safety Data Sheets (MSDS) will
be provided to all site personnel before site activities commence.
1.6 PHYSICAL HAZARDS
All operations personnel participate in routine health and safety education and training programs.
These programs are designed to provide the employees with a thorough knowledge of hazardous
materials, health and safety hazard potentials and compliance with federal OSHA and EPA
requirements. Work in close proximity to heavy equipment presents a potential injury hazard to
personnel. This hazard will be avoided wherever possible, and personnel will remain alert and
cautious when working with and around this equipment.
Rotating machinery is equipped with guards to minimize likelihood of injury from belts and
motors. Machinery requiring maintenance, cleaning or other _activity will be shut down prior
to work commencing.
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX[phone]
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The mobile incineration system is designed so that all exterior surfaces are kept at or below 180
degrees Fahrenheit. The included draft fan maintains a negative pressure throughout the system,
and a backup fan is provided for emergency use.
1. 7 FIRE HAZARDS
Potential fire hazards areas at the site include the diesel fuel storage tank, the feed and discharge
ends of the primary chamber, the natural gas feed system on the secondary chamber, the exhaust
gas quench system and all mobile material handling equipment. All operations personnel will
receive training in the use of portable fire fighting equipment and be familiar with the locations
of the equipment outlined below.
Portable, dry chemical, ABC extinguishers will be located as follows:
Each piece of mobile equipment;
Support rone operations trailers;
The feed preparation area, accessible to exclusion rone personnel;
The area between the primary chamber feed and the secondary chamber burner
system;
The exhaust gas quench, scrubber/chemical feed area;
Diesel fuel storage tanks.
The mobile incineration system controls were designed to eliminate potential fire hazards through
the use of closed loop alarms and mechanically redundant systems.
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1.8 ELECTRICAL HAZARDS
All electrical power distribution systems for the Hoechst Celanese installation will be in
accordance with National Electrical Code (NEC) standards.
Personnel working at the site will receive comprehensive training on the incinerator power lead
routing, overload protection, local disconnects, and lockout procedures. Fire extinguishers rated
for use on electrical fires will be strategically located throughout the site and all personnel will
be trained in their proper use as well as their on-site location. The appropriate emergency
response agencies listed in this Section will be advised of system power requirements and the
electrical service entrance location for use in all electrical emergencies.
1.9 WORK ZONES/SITE CONTROL
For the purpose of health and safety, the Hoechst Celanese Site Project area will be divided into
three distinct work areas. The three separate classifications of wnes for the thermal treatment
project site are the exclusion wne, the contamination reduction wne, and the support wne.
During site set-up, these areas will be delineated through the use of barrier tape.
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1. 9 .1 Exclusion Z.One
The exclusion zo'.le is the work area where contamination does or could occur.
This zone will encompass the feed preparation area and existing contaminated area.
During the removal actions along the stream, the exclusion zone will encompass
the area where work is being performed with a 50 foot buffer zone extended past
the work area. This zone will move in conjunction with the removal action. All
persons entering the exclusion zones shall wear, at a minimum, Modified Level
D personal protection equipment.
1.9.2 Contamination Reduction Zone
The contamination reduction zone is located between the exclusion and support
zones and provides a transition zone between contaminated and clean areas of site.
This zone shall be located directly outside and adjacent to the exclusion zone. To
prevent cross contamination and for accountability purposes, all personnel shall
enter and leave the exclusion zone through the contamination reduction zone
where decontamination procedures will occur. Procedures for personnel
decontamination will be specified and posted in the Decontamination Trailer.
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1.9.3 Sut>l)Ort Z.One
The support zone shall be the uncontaminated area from which site activities shall
be directed. Thermal treatment system components, control facilities and other
support facilities will be located in this area. It is essential that contamination
from the exclusio:i zone be kept from this area. All personnel working in this area
are required to wear Level D personal protection as described in this program.
I. 10 EMPWYEE EDUCATION AND TRAINING
All GDC operations personnel assigned to field projects participate in routine health and safety
training programs and are thoroughly trained for the tasks they are assigned to perform. These
programs, directed by a full-time training coordinator, are designed to provide the employees
with a thorough knowledge of hazardous materials, health and safety hazard potentials and
compliance with applicable federal requirements. The training coordinator is responsible for
identifying training needs, developing training programs, and ensuring that training standards are
met and that training is presented by qualified instructors. As a minimum, this training includes
the following:
Selection, use, and maintenance of respiratory protection equipment
Selection, use, and maintenance of personnel protection equipment
Toxicology
Confined space entry procedures
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Health and safety considerations of hazardous materials
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Personal hygiene factors influencing chemical reaction rates
Labeling and placarding
Health surveillance program
Page 11
A training session, specific to the Hoechst Celanese Project, will also be conducted for all
operational personnel involved with the proposed project work prior to start-up. Topics to be
covered at this time include:
Acute and chronic effects of site-specific hazardous materials, required personal protective
equipment and respirators, exclusion zone entry and exit procedures, site specific
emergency response and contingency plans, and heat stress.
This training session will include the distribution and review of a Material Safety Data Sheet(s)
for site specific hazardous compounds. Prior to the project start-up, the training coordinator will
ensure that project personnel are briefed on the scope of work and the site safety plan. First Aid
and CPR certifications will be reviewed to ensure all site personnel are current. The site safety
plan and Material Safety Data Sheets will be available on-site for all personnel to review. All
personnel joining the ongoing project will be required to review the site safety plan and be
briefed on site procedures, protocol, and site specific hazards.
1.11 PERSONAL PROTECTIVE EQUIPMENT
At present, based on the nature of the known contaminants to be handled and the potential
hazards on the Hoechst CelaneSI! site, personal protective equipment Levels C and D have been
selected as the maximum possible level of protection required for work associated with the
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materials handling and !henna! treatment activities of the project. Level B protective equipment
will be available if required during any confined space entry or the removal of the stream
sediments. The actual level of protection will be revised based on air monitoring results during
initial phases of the work.
I. 11.1 Level D Protection
All operations employees involved with site work outside of the established
exclusion zone will be required to wear the following personal protective
equipment:
* Steel-toed work boots.
* Cotton gloves.
* Work clothes.
* Hearing protection (if necessary).
* Eye protection.
* Hard hat (when_ operating overhead equipment).
1.11.2 Modified Level D Protection
Depending on actual organic and fugitive emissions encountered during the
removal action, modified Level D protective equipment may be utilized by
personnel working in the Exclusion Zone.
*
822 NEOSHO AVENUE
Disposable Saran-coated (when contact with liquids is anticipated)
Tyvek suit with elastic wrists, and foot and hood attachments or
equivalent.
BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
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Page 13
Regular Tyvek coveralls (for dry operations) .
ln11er vinyl gloves covered by nitrite rubber gloves, taped around
the wrists of the coveralls.
Neoprene rubber boots with steel toe and shank, taped to prevent
materials from entering.
Hard hat.
Disposable Tyvek booties over steel-toed work boots may be
substituted.
1.11. 3 Level C Protection
All operations employees involved with the handling of contaminated materials
within the therm~J treatment unit feed zone will be required to wear the ~
equipment:
..
..
.. ..
..
.. ..
Full-face respirator equipped with organic vapor, toxic dust
cai tridges.
Disposable Saran-coated (when contact with liquids is anticipated)
Tyvek suit with elastic wrists, and foot and hood attachments or
equivalent.
Regular Tyvek coveralls (for dry operations) .
Inner vinyl gloves covered by nitrile rubber gloves, taped around
the wrists of the coveralls.
Neoprene rubber boots with steel toe and shank, taped to prevent
materials from entering.
Hard hat .
Disposable Tyvek booties over steel-toed work boots may be
substituted.
1.11.4 Respiratozy ProtectiQn
Use of air-purifying respirators may be necessary in the Exclusion Zone bJ prevent
unnecessary exposure to airborne contaminant concentrations equal to or greater
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than the permissible limits established in existing Occupational Safety and Health
Standards.
Respirators and cartridges for this project will be selected to provide maximum
protection against contaminated materials. All respirator cartridges will be
changed a minimum of once daily unless dusty conditions in the exclusion zone
necessitate more frequent changes.
All respirators and associated equipment will be decontaminated and hygienically
cleaned in the contamination reduction zone after each day's use, or more often
if necessary. No facial hair interference with the face to mask seal will be
allowed. Operations personnel in the exclusion zone will be fit tested week! y for
their chosen mask. It is the employee's responsibility to perform a positive and
negative pressure fit test whenever a respirator is used. Normal eyeglasses will
not be allowed under a full-face respirator. Employees requiring corrective lenses
will be required to use special lenses designed for use with respirators. Contact
lenses will not be allowed.
Respirators will x checked periodically by the Health and Safety Officer or
Health and Safety Coordinator before use by the wearer. Personnel will replace
worn or deteriorated parts with parts designed for the respirator. No
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attempt will be n1ade to replace components or to make adjustments or repairs
beyond the manufacturer's recommendations.
1.11.4 Temperature Extremes
Some temperature extremes may be encountered during the thermal treatment
project. Major problems in the use of full-face respirators at low temperatures
are poor visibility and freezing of exhalation valves. Operations personnel are
instructed in the use of anti-fog compounds which are used to coat the inside of
the Jens to prevent fogging at temperatures approaching O degrees Fahrenheit.
Heat stress monitoring, if applicable, will be performed as described in Section
1.17.10.
1.11.5 Communication
Effective speech c,0mmunication may be required between the exclusion zone and
support zone. Conventional respirators distort the human voice somewhat;
however, the reSJJirator valve will provide a pathway for speech transmission over
short distances. At least one worker in the exclusion zone will be prov:ided with
a hand held walkie-talkie for communication purposes. This procedure is sufficient
for necessary operational communications and emergency situations.
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1.12 AIR MONITORING
Air monitoring will be perfonned on a daily basis during the remedial activities at the Hoechst
Celanese Shelby, North Carolina facility. Prior to commencing waste handling activities,
baseline monitoring will be perfonned to establish background emission levels. Sensidyne BOX
44 Sampler pumps will be utilized to perfonn baseline emissions monitoring. Two (2) pumps
will be placed upwind of the site and two (2) downwind. One of the pumps will be equipped
with a 150 mg charcoal tube to detennine organic emissions and the other with a filter cassette
for detennination of fugitive emission levels. Each pump will be calibrated prior to placement
and upon removal from the site. Calibration will be perfonned using a Sensidyne EZ Cal
Flowmeter. Organics monitoring within the Exclusion, Contamination, Reduction and Support
Zones will be perfonned daily using a Foxboro Model 128-GC organic vapor analyzer with the
gas chromatograph option. Inorganics will be monitored using MSA Samplaire Pump.
Calibration will be perfonned on a daily basis in accordance with manufacturers specifications.
Sampler pumps and personnel monitoring badges will also be used on an as-needed basis to
detennine time weighted average exposures. Action levels defining the levels of protection will
be as follows:
Level of Protection
Level C
Level D
822 NEOSHO AVENUE
Airborne Concentration
Organics Fugitive Emissions
0.5 to l0.0 mg/m' 50 to 500 ppm
0 to 50 ppm
@W5m~u
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All samples will be tested by a independent laboratory certified by the American Congress of
Governmental Industrial Hygienists.
1.13 PERSONNEL DECONTAMINATION PROCEDURFS
Decontamination, the process of removing or neutralizing contaminants that have accumulated
on personnel and equipment, is critical to health and safety at the Hoechst Celanese project.
Decontamination will protect workers from hazardous materials that may contaminate and
eventually permeate the protective clothing, respiratory equipment, tools, vehicles, and other
equipment used in the exclusion zone, and it will protect all other support personnel by
minimizing the transfer of these materials into the support zone. In addition, proper p:rocedures
for dressing prior to entering the site exclusion zone will minimize the potential for hazardous
material to bypass the protective clothing and escape decontamination.
Prior to each use, the personal protective equipment will be checked to ensure that it cc,ntains no
cuts or punctures that could expose workers. Particular care will be taken to protect areas of
injury to the skin surface, such as cuts and scratches, that may enhance the potential for materials
that directly contact a worker's skin to penetrate into the body. Workers with large areas of
damaged skin will be kept from working in the exclusion zone until the skin heals.
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I. 13.1 Level C Decontamination
Decontamination of personnel exiting the Exclusion Zone will proceed in the
following manner:
Equipment used in the Exclusion Zone (tools, sampling devices and
containers, monitoring instruments, radios, clipboards, etc.) will be
deposited on a plastic drop cloth or plastic-lined container.
Rubber boots or boot covers will be scrubbed with a detergent/water
solution and rinsed.
Boot covers (if worn) will be removed and discarded.
Tape and outer nitrile gloves will be removed and discarded.
Hard hat (if worn) will be removed, scrubbed, rinsed, and stacked
for drying.
Saran-coated or regular Tyvek suit will be removed and discarded.
Rubber boots will be removed, scrubbed, rinsed and stacked for
drying.
Respirator will be removed and prepared for reuse or
decontaminated.
Inner gloves will be removed and discarded.
All disposable materials from the decontamination area and Contamination
Reduction Zone will be handled as contaminated waste and temporarily stored in
55 gallon drums located in the decontamination area. On a periodic basis this
material will be shredded and blended with the contaminated soil feed for eventual
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thermal treatment. Personnel handling contaminated protective clothing will be
required to wear neoprene gloves in addition to Level D protection.
1.13. 2 Personal Hygiene
Prior to exiting the Contamination Reduction Zone and before eating, smoking,
or drinking, personnel will be required to wash hands, arms, neck and face.
1.14 EQUIPMENT DECONTAMINATION
All equipment involved in field activities will be decontaminated prior to exiting the site. Such
equipment includes backhoes, tools, augers, pumps, and soil and water samplers, etc. This
equipment will be decontaminated by first removing any gross soil contamination foUowed by
steam cleaning and a final rinse with deionized water.
Field monitoring equipment, such as volatile organic analyzers and combustible gas meters, will
be wiped down with clean paper towels or a cloth wetted with isopropyl alcohol. Measures to
prevent contamination (placement in containers, wrapping in plastic bags) will be utilized when
possible for this equipment.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
?-age 20
1. 15 CONTINGENCY PLAN
The following contingency plan is presented to provide response in emergency situations. The
section will discuss the procedu::es to be employed in the event an emergency arises during the
project.
The Health and Safety Officer or Emergency Coordinator shall implement the contingency plan
whenever conditions at the site warrant such action. The HSO or HSC will be responsible for
assuring the evacuation, emergency treatment, and emergency transport of site personnel as
necessary, notification of emergency response units, and the appropriate management staff.
1.15.1 Emergency Teleyhone Numbers
The following err.ergency telephone numbers will be clearly posted near each site
telephone. All of the listed organizations will be contacted and familiarized with
the Hoechst Celanese site location, the number of site personnel, and the nature
of site operations prior to initiation of remediation activities.
1)
822 NEOSHO AVENUE
Local Hospital
Directions:
Cleveland Memorial Hospital
201 Grover Street
Shelby, North Carolina 28150
Turn right at plant entrance onto Highway 198 North.
After 2 miles, this road merges with Highway 226.
Follow 226 N. for 6 miles (also merges with
Highway 74) to Dekalb Street, entrance is
immediately on right.
BATON ROUGE, LOUISIANA 70802 [phone] FAX (504 I 383-2789
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13)
822 NEOSHO AVENUE
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Ambulance:
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HCC Security at O for HCC ambulance. In the
event the HCC ambulance is unavailable, call 482-
4422.
Local Fire Department
Local Police Department
Local Police
State Police
HCC, then 482-4422
HCC, then 482-8311
HCC, then 482-83 I I
HCC, then 482-8311
Hoechst Celanese Project Representative Mr. Ron Caldwell
[phone] Ext.4359
Mr. Bill Cairter
[phone] Ext.4150
Westinghouse Project Representatives Mr. Everett Glover, Jr.
[phone]
Project Director
GDC Engineering Inc.
Project Manager
GDC Engineering Inc.
Health & Safety Officer
GDC Engineering Inc.
EPA (RCRA-Superfund Hotline)
Chemtrec (24 hours)
Bureau of Explosives (24 hours)
(Association of American Railroads)
Ms. Madolyn Streng
[phone]
Mr. Neil Bc,rdelon
[phone]
Mr. Clinton Twilley
[phone]
Mr. Stephen, N. Bone
[phone]
1-800-424-9346
1-800-424-9300
[phone]
@fBLiJYU
BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
[GcDJ
Page22
14) Communicable Disease Center
(Biological Agents) [phone]
15) National Response Center, NRC
(Oil/Hazardous Substances) 1-800-424-8802
16) DOT, Office of Hazardous Operations [phone]
17) DOT, (Regulatory Matters) [phone]
18) U.S. Coast Guard
(Major Incidents) 1-800-424-8802
19) Pesticide Health Hotline [phone]
In addition to emergency telephone numbers, a map and directions to the nearest
medical facility will be posted in the Contamination Reduction Zone trailer and
all support trailers. A medical data sheet will completed by all site personnel for
use in the event of an emergency.
1.15.2 Emergency Equipment
In an emergency, equipment will be necessary to rescue and treat victims, to
protect response personnel, and to mitigate hazardous conditions on-site. All
equipment will be in working order, and available if and when an emergency
occurs on the Hoechst Celanese site. Safe and unobstructed access for all fire
fighting and emergency equipment will be provided. The following emergency
equipment will be available at the project site and will be located as described.
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@oom~11-
[phone] FAX [phone] I 822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802
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An emergency equipment station will be set up in the Support Zone. The HSO
or HSC will conduct regular inspections of this equipment to ensure that supplies
are maintained and equipment is in working order.
•
•
•
•
•
Emergency eye and body stations -Three stations will Ix: on-site .
One will be located at the Contamination Reduction Zone, adjacent
to the decontamination trailer. The remaining two will be located
in the support zone, adjacent to the primary chamber and th,e exhaust
gas scrubbing system.
First-aid kits -One kit will be located at the decontamination trailer
and another in a Support Zone office trailer.
Emergency oxygen -One unit will be located at the decontamination
trailer.
Stretcher -One stretcher will be located at the decontamination
trailer.
Fire extinguishers -Several will be available on-site and will be
inspected regularly to ensure full charge. At a minimum,
extinguishers will be located in the decontamination trailer, near and
around the thermal process equipment, in the process control trailer
and on all operating equipment.
Emergency air horns -Emergency air horns will be located in the
Ccntarnination Reduction Zone and in the process control trailer.
1.15.3 Medical Emergencies
The majority of medical emergencies associated with this type of project involve
physical injuries ,uch as cuts, sprains, and broken bones. The proper handling
of any medical emergency is dependent upon the nature, locatiion, and
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Page24
circumstances of the accident. Personnel are instructed to rely on good common
sense as well as established guidelines in implementing and directing a proper
response.
The following general guidelines will apply to most medical emergencies and will
be followed whenever possible.
*
*
*
..
*
*
Notify the site supervisor and/or HSO or HSC immediately.
Follow established emergency decontamination procedures if victim
is in the exclusion zone.
If the victim has difficulty breathing, loosen clothing and if
applicable remove respirator or proceed as directed by local medical
authority.
If a victim in the Exclusion Zone can be safely moved, remove the
person to the Contamination Reduction Zone.
If the victim cannot be safely moved, stay with the victim and send
for medical help.
Administer first aid as appropriate.
I. 15 .4 Personnel Exposure
The following emergency first aid procedures will apply for various exposures:
SKIN CONTACT: Use copious amount of soap and water. Wash/rinse affected
area thoroughly, then provide appropriate medial attention.
Eyewash emergency shower or drench system will be
provided on-site at the Support Zone. Eyes should be rinsed
for 15 minutes after chemical contamination.
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INHALATION;
INGESTION:
Page25
Move to fresh air and/or, if necessary, decontaminate and
transport to the hospital.
PUNCTURE WOUND:
Decontaminate and transport to emergency medical facility.
Decontaminate and transport to emergency medical facility.
HSO will provide medical data sheets to medical personnel
as requested.
OR LACERATION:
1.15.5 Emergency Decontamination
In addition to routine decontamination procedures, emergency decontamination
procedures have been established. In an emergency, the primary concern is to
prevent the loss of life or severe injury to Exclusion Zone personnel. If immediate
medical treatment is required to save a life, decontamination will be delayed until
the victim is stabilized. If decontamination can be performed without interfering
with essential life-saving techniques or first aid, decontamination will be performed
immediately. If an emergency due to a heat-related illness develops, protective
clothing will be removed from the victim as soon as possible to reduce the heat
stress. In case of an emergency, the following procedures will be implemented:
*
*
822 NEOSHO AVENUE
If decontamination can be done:
Wash, rinse and/or cut off protective clothing and equipment.
If decontamination cannot be done:
Wrap the victim in blankets or plastic to reduce contamination of
medical and other personnel.
BATON ROUGE, LOUISIANA 70802 [phone] FA>. [phone]
!'-age 26
Alert emergency and off-site medical personnel to potential
contamination: instruct them about specific decontamination
procedures if necessary.
Transport victim to medical facility and send along site personnel
familiar with the incident.
1.15.6 Fire Emergencies
When an uncontrolled fire outside of the thermal treatment system appears
imminent or has occurred, all activity related to waste feed to the system will
cease. The Health and Safety Coordinator, Health & Safety Officer or Project
Manager will assess the severity of the situation and decide whether the emergency
event is or is not readily controllable with available portable fire extinguishers or
site equipment and materials at hand. Fire fighting will not be done if the risk to
operations personnel appears high. The HCC fire department will be notified in
all situations in which fires have occurred.
If the situation appears uncontrollable, and poses a direct threat to human life, a
warning will be sounded to all personnel to secure their emergency equipment
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and immediately evacuate the process area. Local fire departments will be I
contacted, if necessary.
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The Health & Safety Officer or Health and Safety Coordinator will alert all
~~ w~ •1 ~u~ ,-~. u~renru,oo by fire mrnm~ 1l :
822 NEOSHO AVENUE BATON ROUGE. LOUISIANA 70802 [phone] FAX [phone] I
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All equipment used in the emergency will be immediately cleaned and prepared
for use in the event of any future emergency.
1.15. 7 Spill or Material Release Emergency
If a hazardous material spill, material release, or process upset res.ulting in
probable hazardous vapor release is noted, the information will be immediately
relayed to the H'!alth and Safety Coordinator, Health and Safety Officer and
Project Manager. The Health & Safety Coordinator, Health and Safety Officer
and Project Manager will assess the magnitude and potential seriousness of the spill
or release by reviewing the following information:
I.
2.
3.
4.
5.
6.
7.
Material Safety Data Sheet.
Source of the release or spillage of contaminated materu~.
An estimate of the quantity released and the rate of release.
The direction in which the spill or air release is moving.
Pe::sonnel who may be or may have been in contact with material,
or release, and possible injury or sickness as a result.
Potential for fire resulting from the situation.
Estimate of area under influence of release.
If the accident is determined to fall within on-site emergency response capabilities,
the HSC and/or HSO will implement the necessary remedial action. If th1: accident
is beyond the capabilities of the operating crew, the HSC and/or HSO will notify
the appropriate kcal agencies. In the event of an emergency spill or release, all
personnel not invplved with emergency response activity will be evacuated from
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Page28
the immediate area. The area will be roped or otherwise blocked off, and all waste
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feed systems to the thermal treatment system; and the system will have emergency
shutdown procedures imposed.
I. 15. 8 Severe Weather Emergencies
When severe weather is cited in the area, when a severe weather warning has
been issued, or when a lightning storm occurs, the information will be immediately
relayed to the Health & Safety Coordinator or Health and Safety Officer.
The HSC and/or HSO will immediately evaluate the situation and institute
emergency shutdown or equipment idle procedures, if necessary, and all personnel
shall proceed indoors after completing the appropriate procedures. In the case of
a lightning storm, waste feed shall be stopped, and all personnel shall standby for
emergency procedures. When the storm passes, inspection of all of the on-site
equipment will be performed to ensure it's readiness of operation. If any
emergency equipment, or equipment which effects the process interlocks or vessel
integrity has been damaged, the system will not be restarted until the equipment
has been repairecl or replaced. If the inspection indicates a fire or release has
occurred as a result of a severe weather condition, the established emergency
procedures will be initiated.
[ID ITJffi~Li
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 I 504) 383-8556 FAX[phone]
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1.15.9 Prevention of Fires or Releases
The thermal treat,ment system contains built-in standard operating safeguards to
control the system during an emergency situation to ensure that fires, or releases,
do not recur or spread to other areas of the project area.
Inert material to contain, divert and cleanup any spills will be used if the spills
cannot be contained by a dike or sump. Spills contained within a dike or sump
will be pumped or otherwise transferred back into appropriate storage drums.
All contaminated containment, cleanup materials and recovered contaminated soil
will be placed in drums for temporary storage, or immediately transported to the
feed preparation area for processing in the thermal treatment unit.
1.15.10 Post Emergenc;y F.quipment Maintenance
After an emergen~y event, all emergency equipment used will be cleaned so that
it is serviceable for future use or it will be replaced. Before operations are
resumed, an inspection of all safety equipment will be conducted to verify
satisfactory operational status.
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Page30
1.15.11 Evacuation Plan
The first person recognizing an emergency situation that threatens human health
or the environment shall notify the HSC and/or HSO, who will initiate a site
evacuation. The evacuation plan consist of:
1. The signal to evacuate will be by an air horn.
2. Leave the area quickly by the nearest safe exit. Operations personnel are
to escort visitors out of the immediate area. Personnel are to take note,
before leaving, of where the emergency situation exists so they do not
jeopardize their safety by walking into that area.
3. Assemble in the area designated by the HSC and/or HSO during the tailgate
safety meeting for head count and further instructions.
The HSC and/or HSO will further direct actions as necessary and initiate the
proper notification procedures for the agencies involved. No one is to return to
the site unless so instructed by the HSC and/or HSO or other recognized official
in charge issues an "all clear".
1.15.12 Emergency Evacuation Signals
Emergency air horns will be used to notify all site personnel in the event that a
general evacuation of the site is warranted. One long blast on the air horn will
be the signal for a general site evacuation. Personnel in the Exclusion Zone will
immediately proceed to the decontamination area, conduct a rapid decontamination,
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and proceed to predetermined evacuation stations: If the decontamination area is
not readily accessible, personnel shall decontaminate as thoroughly as practical at
the perimeter of the Exclusion Zone.
1.16 SPILL PREVENTION, CONTROL AND COUNTERMEASURES
During operations on the project site, the potential for contaminated material spills will exist.
This potential will be minimized with proper planning, site design, the development of ,operating
procedures with spill prevention designed in, and the training of employees in spill prevention
and control techniques.
1.16.1 Spill Prevention
The primary concern with spill prevention on the project is to keep conlaminated
waste from mixing with non-contaminated soils or materials. The means to
effective prevention of waste spillage are planning, inspection, and maintenance.
Planning involves the designing of a waste transfer system to minimize spills and
failures and locating the equipment to prevent accidents and deterioration due to
weather. Likewise, the potential for spills will be minimized by the design of
transfer systems :0 minimire leaks and the proper location of chemical storage
areas. Chemical storage areas will be clearly marked, and located out of the way
of vehicular or heavy equipment travel. The feed preparation and processed waste
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822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX[phone]
Page32
storage pads will be constructed to contain any potential spread of contaminated
waste as a result of heavy rains or liquid spills. Also, the diesel fuel tank for on-
site usage will be located just within the feed preparation/equipment
decontamination pad so that any spillage is contained.
The Health & Safety Officer or a designated employee will conduct regular
inspections of the entire thermal treatment process area including pumps, valves,
and pipe fittings for leaks or deterioration. In addition to scheduled maintenance,
any deteriorated process parts will be immediately replaced.
1.16.2 Spill Control
The mobile thermal treatment system will be installed on a specially designed
concrete pad. Th~ pad area for the primary furnace will be designed to be capable
of containing any spillage or processed waste. All material spills will be cleaned
and the affected area washed to prevent migration of potentially hazardous
materials. A concrete pad will be installed to isolate the feed material preparation
area.
The processed waste generated in the primary chamber will be quenched with
water, discharged and transported through the solidification system. The material
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
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The diesel fuel supply and acid gas neutralization agent for the scrubbing system
will be stored in separate areas on the site. These areas will be clear! y marked
and operations personnel will avoid tracking equipment near them except when
refueling or transferring chemicals.
1.16.3 Spill Response
Spilled solid materials and any resultant contaminated soils will simply be picked
up and placed in the waste feed preparation area for eventual processing. The
following is a summary of the procedures that will be used to respond to a liquid
spill on site.
2.
3.
4.
5.
6.
7.
822 NEOSHO AVENUE
Shut all valves or otherwise stop the flow of leaking material.
Instruct all unnecessary personnel to exit the spill area.
Assemble a cleanup crew and the necessary tools and response
equipment.
Identify the spilled material and determine proper personal pro tee ti ve
equipment.
If a flammable liquid is involved, remove all sources of ignition.
Use only non-sparking tools and explosion-proof equipment to
respond.
Isolate and capture any standing liquids using earthen berms,
ditches, drums, or available tanks.
Neutralize and/or absorb any non-recoverable liquid and place
absorbent material in drums.
BATON ROUGE, LOUISIANA 70802 [phone] FAX [504)383-2789
Page34
8. Excavate all contaminated soils and transfer to the feed preparation
area for subsequent processing.
Should an emergency situation ensue as a result of a spill, emergency response
procedures, as outlined in the previous section of this plan, will be implemented
by the Health and Safety Officer and Project Manager.
1.17 GENERAL SITE SAFETY
The Health and Safety Officer will be the designated emergency coordinator at the Hoechst
Celanese site. In his absence, the Health and Safety Coordinator will become the primary safety
officer and the Project Manager will be the emergency coordinator.
1.17 .1 Daily Safety Meetin~
A safety meeting will be held daily for each shift before work commences. The
scope of work for that shift, hazards of the work, hazards of the materials, use
of equipment, and hazardous areas of the site will be discussed. Periodically,
general subjects such as electrical safety, and heat/cold stress will be discussed.
1.17.2 Work Breaks
Eating, drinking, and smoking will be permitted only in designated areas. In
general, smoking will be permitted only in the office spaces, decontamination
trailer, and in outside areas as designated by the HSC or HSO.
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822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone] I
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1. 17. 3 Thermal Treatment Unit/Process Safety
Safety for the operation and maintenance of the equipment and thermal treatment
system is of paramount importance and will be the first consideration anytime
operations persor.nel are around the equipment. GDC has taken great care to
ensure that guards, interlocks, disconnects, etc. are provided to prevent accidental
human injury or damage to the equipment. Certain precautions and miscellaneous
maintenance safety requirements are outlined below.
a.
b.
C.
822 NEOSHO AVENUE
The mobile incineration system is adequately insulated such that the
external shell will not normally exceed 180°F. Certain parts, such
as shaft protrusions from the internal area of the furnace and their
mountings, may exceed this temperature. Care, therefore, will be
taken to avoid direct contact with bearings and shafts without proper
safety gloves during furnace operation.
View ports are provided in several areas of the system to observe
the internal process. These ports are equipped with gate:; to allow
for closure of the port to remove the site glass for cleaning. Care
should be taken to avoid close facial or other exposed contact to this
area during cleaning. A momentary increase in system pressure
could cause hot gases to escape with possible injury to personnel in
direct contact with the port. As a minimum, gloves wm be worn
when working with the view ports while the unit is operating as the
metal and/or glass may be hot. Operations personnel will wait at
least 30 minutes after the heating element power centers have been
shut down before opening any access ports.
Feed components may require rodding to clear material. In no
circumstance will this work be performed on a rotating piece of
equipment.
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Page36
· Rotating equipment will be covered by guards. The equipment will
not be operated without the guards properly installed. Should the
removal of the guards become necessary, the local disconnect for
the drive motor, the appropriate control console switch, and the
breaker in the motor control center should all be placed in the "Off"
position and locked out prior to any guard removal and maintenance.
When equipment is locked out, a tag will be placed on the switch
gear with the following information: DA TE, TIME, REASON FOR
LOCKOUT. As soon as the equipment is repaired the lock and tag
will be removed.
Due to hot temperatures, work gloves shall be worn when working
in the area of the secondary combustion burners. No smoking will
be allowed in this area when the unit is in operation. An area
check-out for gas leaks will be made if welding or cutting is to be
performed around the secondary combustion system.
Safety goggles and rubber gloves will be worn when sampling
liquids in the scrubber and chemical mixing area.
Entry permits or oxygen and temperature checks will be made
before personnel enter any process equipment.
All hoses used for chemical transfers or for any chemicals will be
marked or tagged on both ends and kept separated from all other
hoses.
Each electrical motor, power center, and control panel of the system
is protected by a series of disconnects, lockouts, breakers, and
controllers. When work is required around the furnace, the power
source for the area to be worked on will be locked out.
Water contact with any wire-way, conduits, or other power
transmission devices may ground high voltage, causing danger to
personnel and equipment. No washing or water spraying will be
allowed around any electrical device.
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P'age37
1.17.4 Drum Stora~e
An area in the site Contamination Reduction Zone will be designated and posted
for waste drum storage. Full drums will be periodically emptied and the contents
shredded or otherwise prepared for blending with the waste feed to be processed.
An additional drum storage area will be established in the Support Zone for the
accumulation of non-contaminated trash. This material will be periodically sent
off-site to local landfill.
1.17 .5 Health and Safety Plan Review
All personnel (workers and visitors) entering the site project area will be required
to review the Hea].th and Safety Plan and confirm that they understand the plan and
will comply with its content.
1.17.6 Site lnSl)eCtion
A site health and safety inspection will be conducted during project setup at the
Hoechst Celanese facility, and on a routine basis throughout the projtx:t, by the
GDC corporate health staff. The project Health & Safety Officer will also make
periodic inspections throughout the project, documenting and correcting .any unsafe
conditions found.\ As conditions at the site change, the HSC will institute more
or less stringent site safety procedures than those found in this pl.an. Any
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Page38
reduction of safety procedures will be implemented only after consultation with
appropriate Hoechst Celanese, Westinghouse and GDC corporate personnel.
1.17. 7 Personnel Health Monitorini:
Workers handling hazardous materials can experience high levels of stress. They
may develop heat stress while wearing protective equipment or working under
temperature extremes, or face life-threatening emergencies such as fires.
Therefore, a medical program has been established by GDC to assess and monitor
workers' health and fitness during the course of work: to provide emergency and
thorough treatment as needed; and to keep accurate records for future reference.
1.17. 8 Physical Examinations
All GDC operations personnel working on a suspected or confinned hazardous
materials site will have completed a baseline physical examination, as outlined
below, within 12 months prior to the site work. GDC field operations personnel
perfonn work on, various hazardous material sites and are therefore, subject to
potential exposure to numerous hazardous compounds. Personnel who have not
had such a physical will not be assigned to the Hoechst Celanese project. Drug
and Alcohol abuse testing will also be perfonned on all site personnel in addition
to the standard physical.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
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F-age39
1.17.9 Routine Physical Examination Guidelines for Hazardous Material Worl~
Medical/Occupational Questionnaire
Full Physical Examination
Vitals
Screening Audiometric Test
Pulmonary Function Test
Resting EKG
Laboratory Analysis:
Blood Chemistry Profile
Complete Blood Count with Differential
Urinalysis with Microscopic Examination
Zinc Protoporphyrin
Urinary Arsenic
Urinary Mercury
Urinary Cadmium
1.17 .10 Stress Monitoring
Protective clothing standards and decontamination procedures are established and
' will be enforced on the Hoechst Celanese project site to minimize the potential for
exposure to hazardous materials. Although the site specifics do not indicate the
existence of any potential exposure problems to workers properly clothed, specific
guidance for upgrading personnel health monitoring is provided below.
During cold weather, employees will be provided with insulated safety footwear
and oversized impervious suits to facilitate additional clothing required for thermal
protection.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 I 504) 383-8556 FAX[phone]
Page40
Individuals have variable limits as to the amount of heat they can tolerate. All
employees will Ix\ informed that they are responsible for their own physical well
being as only they know how they feel and what their limitations are. However,
it is recommended that at the end of each work period where the ambient
temperature exceeds 70"F, workers remove their protective clothing and do the
following:
I.
2.
3.
Take their oral temperature and proceed as outlined below:
a.
b.
C.
d.
99"F -no action.
99 to 99.7"F -cool them off with a water spray and do not allow
a return to work unless their temperature is 99"F at the end of the
rest period.
99. 7 to I00.4"F -cool them off with a water spray, double their rest
period, and do not allow a return to work unless their temperature
is 99"F. If heat exhaustion or heat stroke symptoms are present,
seek medical attention.
l(Y).4"F -cool them off immediately with a water spray, begin
standard first aid procedures, and seek medical attention.
Take and record blood pressure.
a. Upper limit 140/90
b. Lower limit -/fJJ
Take and record pulse rate.
a. Upper limit > 120 beats per minute
b. Lower limit < fJJ beats per minute
4. Take and record body weight. If a loss greater than 5 % of total body
weight is experienced, work rotation should be skipped until weight is
replenished.
822 NEOSHO AVENUE BATON ROUGE, LOUISIANA 70802 [phone] FAX [phone]
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APPENDIX C
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I A ct1v1ty
I Site Preparation
I Incinerator Mobazatlon
I lnclnelator Optknlzatlon
I Pre-Trial Eun Stack Teat
Sa111pil19 Crew Mc bll1allon
I lttal Bwn
I S.nplng Crew Demobllzallon
I ltlal Bwn Final Report
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•-"' <O 0 <O .... -..,
"' •-..; ...
<.!) z z ::::,
I "' ID
TRIAL BURN SCHEDULE
Time (Days)
0 day 10 day 20 day 30 day 40 day 50 day 60 day 70 day 80 day 1 40
I I I
• ---ii
HOECHST CELANESE CORP.
Incineration Project
Shelby, North Carolina
GDC .:!:.~~~;: .. ~~£:• INC. ENG.
DWN. CBD 4/16/90 PROJ. NO. 90·503
SHEET OF
(I04)SIS·l951
Ill Nl!OSMO AYENU! ----0----------------1
UT0II lt0UH. LA. 70102 CHK · EXHIBIT NQ