Vortex shedding flow meter . SUMMARY OF SUBMITTAL REQUIREMENTS FOR CAM . While manual methods may be sufficient for CAM in some instances (e.g.,
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Technical Guidance Document: Compliance Assurance MonitoringRevised DraftFor U. S. Environmental Protection Agency Office of Air Quality Planning and Standards Emission Measurement Center Research Triangle Park, NC 27711 Attn: Mr. Dan Bivins (MD-19) MRI Project No. 4701-05 August 1998
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iiiPREFACE This document was prepared by Midwest Research Institute (MRI) for the Office of Air Quality Planning and Standards (OAQPS), U. S. Environmental Protection Agency (EPA), under Contract No. 68-D2-0165, Work Assignment No. 4-06 and Contract No. W6-0048, Work Assignment No. 2-05. Mr. Dan Bivins is the work assignment manager.
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vTABLE OF CONTENTS Page INTRODUCTION 1.0OVERVIEW.1-1 1.1PURPOSE OF CAM1-1 1.2CAM PROCESS1-2 1.2.1Applicability Determination 1-2 1.2.2CAM Submittals 1-14 1.2.3Review and Approval of CAM Submittal .1-15 1.2.4CAM Implementation ..1-15 2.0MONITORING APPROACH SUBMITTALS.2-1 2.1MONITORING APPROACH SUBMITTAL OBJECTIVES.2-2 2.2ELEMENTS OF A MONITORING APPROACH SUBMITTAL.2-3 2.2.1Background .2-8 2.2.2Monitoring Approach ..2-8 2.2.3Justification for Selected Monitoring Approach and Indicator Range(s)2-14 2.3SELECTION OF MONITORING APPROACH AND SELECTION OF INDICATOR RANGE .2-18 2.3.1Selection of Monitoring Approach .2-18 2.3.2Selection of Indicator Range 2-27 2.4QUALITY IMPROVEMENT PLANS (QIP™s) 2-39 3.0CAM ILLUSTRATIONS3-1 3.1PURPOSE OF ILLUSTRATIONS.3-1 3.2FORMAT OF ILLUSTRATIONS.3-5 3.3ILLUSTRATIONS.3-7 3.3.1General Information 3-7 3.4PRESUMPTIVELY ACCEPTABLE CAM3-9 4.0TECHNICAL REFERENCE FOR MONITORING EQUIPMENT AND INSTRUMENTS4-1 4.1INTRODUCTION ..4-1 4.2TEMPERATURE MEASUREMENT SYSTEMS.4-4 4.2.1Introduction .4-4 4.2.2Thermocouples ,.4-5 4.2.3Resistance Temperature Detectors (RTD™s) 4-18 4.2.4Infrared (IR) Thermometry .4-24 4.2.5References for Temperature Measurement .4-28
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TABLE OF CONTENTS (continued) Page vi4.3PRESSURE MEASUREMENT SYSTEMS..4-30 4.3.1Manometers .4-31 4.3.2Mechanical Dial Pressure Gauges ..4-34 4.3.3Pressure Transducer 4-40 4.3.4References for Pressure Measurement .4-50 4.4FLOW RATE MEASUREMENT SYSTEMS.4-52 4.4.1Introduction .4-52 4.4.2Differential Pressure Flow Measurement Devices .4-52 4.4.3Magnetic Flow Meters .4-62 4.4.4Positive Displacement Flow Meters 4-66 4.4.5Turbine Flow Meters 4-72 4.4.6Vortex Formation Flow Meters 4-76 4.4.7Fluidic Oscillating Flow Meters 4-80 4.4.8Ultrasonic Flow Meters .4-83 4.4.9Thermal Flow Meters ..4-89 4.4.10Mass Flow Meters (Coriolis) ..4-94 4.4.11Rotameters .4-98 4.4.12References for Flow Measurement .4-102 4.5pH AND CONDUCTIVITY MEASUREMENT SYSTEMS ..4-103 4.5.1pH Monitoring .4-103 4.5.2pH Measurement Stations ..4-105 4.5.3pH Control Systems 4-108 4.5.4Operation and Maintenance of the pH Measuring System .4-110 4.5.5Calibration of the pH Meter 4-115 4.5.6Conductivity Measurement .4-118 4.5.7References for pH and Conductivity Measurement 4-120 4.6ELECTRICAL..4-120 4.7LEVEL INDICATOR4-120 4.8MOTION AND ROTATION 4-120
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TABLE OF CONTENTS (continued) Page viiiAPPENDIX B. CAM ILLUSTRATIONS B.1 FABRIC FILTERS..B-1 No. 1a. FABRIC FILTER FOR PM CONTROLB-3 No. 1b. FABRIC FILTER FOR PM CONTROL B-5 No. 1c. FABRIC FILTER FOR PM CONTROLB-6 No. 1d. FABRIC FILTER FOR PM CONTROL B-7 No. 1e. FABRIC FILTER FOR PM CONTROLB-9 B.2. ELECTROSTATIC PRECIPITATORS B-10 No. 2. ESP FOR PM CONTROLB-11 B.3 WET ELECTROSTATIC PRECIPITATORS..B-12 B.4 WET SCRUBBERS.B-13 No. 4a. WET SCRUBBER FOR PM CONTROL..B-14 No. 5. WET SCRUBBER FOR SO 2 CONTROLB-15 No. 6. SPRAY DRYER FOR SO 2 CONTROL.B-16 B.5 THERMAL OXIDIZERSB-18 No. 11a. THERMAL INCINERATOR FOR CO CONTROL..B-20 No. 11b. THERMAL INCINERATOR FOR CO CONTROL ..B-21 No. 16a. THERMAL INCINERATOR FOR VOC CONTROL.B-23 No. 16b. THERMAL INCINERATOR FOR VOC CONTROL B-25 No. 16c. THERMAL INCINERATOR FOR VOC CONTROL.B-27 B.6 CATALYTIC OXIDIZERS.B-29 No. 18. CATALYTIC OXIDIZER FOR VOC CONTROL ..B-31 B.7 FLARES.B-33 B.8 CONDENSERS .B-34 No. 21a. CONDENSER FOR VOC CONTROL B-35 No. 21b. CONDENSER FOR VOC CONTROLB-36 B.9 ELECTRIFIED FILTER BEDS.B-38 B.10 CARBON ADSORBERS ..B-39 No. 23a. CARBON ADSORBER FOR VOC CONTROL..B-40 B.11 CYCLONES B-41 No. 24a. CYCLONE FOR PM CONTROL.B-42 No. 24b. CYCLONE FOR PM CONTROL .B-44 No. 25. GRAVITY COLLECTOR FOR PM CONTROL ..B-46 B.12 OTHER SO 2 CONTROLS.B-48 B.13 NO X CONTROLS.B-49 No. 32a. SELECTIVE CATALYTIC REDUCTION FOR NO x CONTROLB-50 No. 32b. SELECTIVE CATALYTIC REDUCTION FOR NO x CONTROL..B-51 B.14 REFERENCES FOR CAM ILLUSTRATIONS ..B-52
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ixLIST OF FIGURES Page Figure 1-1.Flow diagram for CAM process..1-3 Figure 1-2.Definition of major source1-6 Figure 1-3.Examples of potential pre-control device emission estimates 1-10 Figure 1-4.Useful references for estimating potential pre-control device emissions.1-10 Figure 2-1a.Outline for monitoring approach submittal and justification .2-4 Figure 2-1b.Outline for monitoring approach submittal and justification for CEMS, COMS, and PEMS..2-5 Figure 2-2.Monitoring approach submittal example format .2-6 Figure 2-3.Monitoring approach selection process..2-19 Figure 2-4.Monitoring approach selection process worksheet..2-20 Figure 2-5.Indicator range selection process flow chart.2-34 Figure 2-6.Baghouse differential pressure by day 2-35 Figure 2-7.Recorded brine supply temperature for May .2-38 Figure 2-8.Recorded brine return temperature values for May..2-38 Figure 3-1.CAM illustration format .3-6 Figure 4.2-1.The Seebeck effect 4-6 Figure 4.2-2.Temperature measurement using a thermocouple 4-6 Figure 4.2-3.Thermocouple assembly .4-7 Figure 4.2-4.Setup for calibrating temperature measurement systems .4-12 Figure 4.2-5.Setup for calibrating a thermocouple transmitter using a thermocouple simulator..4-14 Figure 4.2-6.Setup for calibrating a thermocouple transmitter using an ice bath..4-14 Figure 4.2-7.Resistance temperature detector (RTD) system schematic ..4-20 Figure 4.2-8.Resistance temperature detector (RTD) assembly 4-20 Figure 4.2-9.Infrared temperature measurement system ..4-25 Figure 4.3-1.U-tube manometer 4-33 Figure 4.3-2.Differential manometer ..4-33 Figure 4.3-3.Bourdon-tube pressure gauge .4-36 Figure 4.3-4.Bellows-type pressure gauge .4-37 Figure 4.3-5.Diaphragm-type pressure gauge ..4-38 Figure 4.3-6.Setup for calibrating a pressure gauge using mercury column manometer4-41 Figure 4.3-7.Setup for calibrating a pressure gauge using a deadweight tester4-41 Figure 4.3-8.Wheatstone bridge 4-43 Figure 4.3-9.Strain gauge pressure transducer .4-43 Figure 4.3-10.Capacitance pressure transducer .4-44 Figure 4.3-11.Linear variable differential transformer (LVDT) .4-45 Figure 4.4-1. Venturi tube ..4-56 Figure 4.4-2.Flow nozzle ..4-56 Figure 4.4-3.Orifice plate ..4-57 Figure 4.4-4.Magnetic flow meter .4-64
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LIST OF FIGURES (continued) Page xFigure 4.4-5.Lobed-impeller flow meter ..4-68 Figure 4.4-6.Slide-vane rotary flow meter .4-69 Figure 4.4-7.Retracting vane rotary flow meter 4-69 Figure 4.4-8.Helical gear flow meter ..4-70 Figure 4.4-9.Turbine flow meter ..4-73 Figure 4.4-10.Vortex shedding flow meter ..4-77 Figure 4.4-11.Vortex precession flow meter 4-78 Figure 4.4-12.Fluidic oscillating flow meter 4-81 Figure 4.4-13.Time of flight ultrasonic flow meter .4-85 Figure 4.4-14.Doppler ultrasonic flow meter transducer arrangements .4-86 Figure 4.4-15.Thermo-anemometers in various shapes .4-91 Figure 4.4-16.Calorimetric flow meter (heated grid) 4-92 Figure 4.4-17.Coriolis mass flow meter .4-96 Figure 4.4-18.Rotameter .4-99 Figure 4.5-1.Applications for electrode assemblies 4-106 Figure 4.5-2.Extraction electrode assembly 4-107 Figure 4.5-3.Pressurized chamber electrode assembly .4-108 Figure 4.5-4.pH control system for batch process .4-109
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xiLIST OF TABLES Page TABLE 1-1.APPLICABILITY REQUIREMENTS FOR CAM..1-5 TABLE 1-2.SUMMARY OF CAM RULE EXEMPTIONS..1-11 TABLE 1-3.PART 60 AND 63 RULES PROPOSED AFTER NOVEMBER 15, 1990 ..1-12 TABLE 1-4.EXAMPLES OF CONTINUOUS COMPLIANCE DETERMINATION METHODS 1-14 TABLE 1-5.SUMMARY OF SUBMITTAL REQUIREMENTS FOR CAM1-16 TABLE 1-6.SUMMARY OF REQUIRED PERMIT CONDITIONS OR TERMS..1-16 TABLE 1-7.SUMMARY OF REPORTING AND RECORDKEEPING REQUIREMENTS FOR CAM..1-17 TABLE 2-1.MONITORING DESIGN CRITERIA2-9 TABLE 2-2.LEVEL OF CONFIDENCE..2-26 TABLE 2-3.BAGHOUSE PRESSURE DROP READINGS .2-35 TABLE 3-1.POTENTIAL CAM ILLUSTRATIONS.3-2 TABLE 3-2.SELECTED AIRS IDENTIFICATION CODES FOR CONTROL DEVICES.3-3 TABLE 3-3.PRESUMPTIVELY ACCEPTABLE MONITORING..3-11 TABLE 4.2-1.TEMPERATURE MONITORING SYSTEM CHARACTERISTICS4-4 TABLE 4.2-2.THERMOCOUPLE DESIGNATIONS, RANGES, AND TOLERANCES..4-9 TABLE 4.2-3.RESISTIVITY OF RTD ELEMENTS 4-19 TABLE 4.3-1.COMPARISON OF MECHANICAL PRESSURE SENSING ELEMENTS..4-31 TABLE 4.3-2.COMPARISON OF ELECTRICAL PRESSURE MEASUREMENT DEVICES4-32 TABLE 4.3-3.PRESSURE GAUGES COMMONLY AVAILABLE ..4-35 TABLE 4.3-4.PRESSURE GAUGE CLASSIFICATIONS .4-39 TABLE 4.4-1.COMPARISON OF FLOW MEASUREMENT DEVICES .4-53 TABLE 4.4-2.ADVANTAGES AND DISADVANTAGES OF ORIFICE PLATE FLOW METERS 4-58 TABLE 4.4-3.LOCATIONS OF ORIFICES AND NOZZLES RELATIVE TO PIPE FITTINGS.4-61 TABLE 4.4-4.ADVANTAGES AND DISADVANTAGES OF LOBED- IMPELLER FLOW METERS 4-68 TABLE 4.4-5.ADVANTAGES AND DISADVANTAGES OF HELICAL GEAR FLOW METERS .4-71 TABLE 4.4-6.ADVANTAGES AND DISADVANTAGES OF TURBINE FLOW METERS .4-74 TABLE 4.4-7.ADVANTAGES AND DISADVANTAGES OF VORTEX SHEDDING FLOW METERS ..4-79
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