Planning a Successful Air. TCEQ Conference Austin, Texas May 4 5, 2010

Transcription

1 Planning a Successful Air Emissions Test TCEQ Conference Austin, Texas May 4 5, 2010

2 Discussion i Topics Pre test Events Pre test Events Safety Planning Creating a Test Plan (What really needs to be done) Providing for Testing Crew Needs Providing Site/Sampling Access Other Related Issues Testing Events Equipment Mobilization & Set up Sampling/Design of Experiment/Scientific Experiment Analysis of Samples, Real time or Onsite Tear Down and Demobilization Post Test Events In house Analysis of Samples Packing and Shipping Samples to Subcontract Labs (Haz Mat) Receiving Analytical Results Post Test Instrument Calibrations Create and Deliver Test Report

3 Pre Test: Safety Planning Common Stack Sampling Hazards Physical Hazards Fall Hazards Electrical Hazards Liftingg Burns Compressed Gases Noise Mechanical Hazards Pressure of Source Traffic Chemical Hazards Flue l Gas Area Process Chemicals Sampling Reagents Cleaning Agents Weather & Environmental Hazards Wind Rain/Snow Heat/Cold/ Sun/Darkness Lightning Psycho Social Hazards Fatigue Working Alone Shift Work

4 General Issues What safety training is required Pre Test: Safety Planning Safety Checklists Hot/cold work permits needed? Plant emergency phone #s # s Plant alarms/evacuation procedures Emergency meeting point Nearest first aid station & shower What PPE needed? Site Specific Issues Access to work site How will sampling location be accessed? Clear work area? Adequate lighting for early morning/late night testing Allowable electrical equipment? Site protected from outdoor elements Approximate ambient temperature Hazardous materials in work area Other site specific hazards Sampling location Height g of sampling location above ground Condition of ladders, platforms, railings Condition of winch or pulley Respirators required, type?

5 Pre Test: Creating a Test Plan Driving Force for the Testing Driving Force for the Schedule Desired Results Testing Parameters Sample Type (Compliance/Engineering) Target Analytes Sampling Methods (Required vs. Desired) SamplingLocations w/schematic drawings Stack/duct diameter Flow direction Magnitude and nature (+/ ) of static pressure Distances to upstream and downstream disturbances Configuration g of sample platforms Configuration f of sample ports: diameter, length, number Number of Runs Required for Test Sample Run Time Process Parameters and Samples Analytical Parameters In House or Subcontract Lab Analytical Methods (available options?) Turn Around Time

6 Pre Test: Site/Sampling Access Safety Training Vehicle Passes Security Notifications/Clearances Lists of Contacts and Phone Numbers Safety Information Travel & Lodging Information (if applicable)

7 Pre Test: Oh Other Related Rl dissues Notifications of Regulatory Authorities Test plan submittals: Who and When? Pre Test meetings Permit modifications or deviations to test methods Operational Issues Will unit be running during scheduled testing? Will it be running the right type and quantity of product? Batch or continuous process? Is all associated equipment functioning properly? (e.g., flowmeters calibrated and operational) Any construction in the testing area? (if applicable)

8 Pre Test: Test Team Needs Electricalhook ups connections and power Air supply needs for testing equipment Is there space available for Instrument/Laboratory Trailer/Van? Will the plant be providing lab space? Is it sufficient? How will the team leader and the process operators communicate? (plant radios)

9 Testing: Equipment Mobilization i & Set Up Equipment calibrations, standards selected, filters tared, necessary reagents and chemicals available Selection of proper sampling equipment such as analyzers and sample probe lengths Drive to Site Site entry and safety (permits) Set up mobile testing lab onsite adjacent to sampling location Set up equipment on stack (Where s that crane they promised!) Electrical hook up!!!

10 Testing: Sampling/Data Collection Onsite pretest analyzer calibrations Ensure correct naming of sampling locations and process equipment Perform the testing according to the PLAN For compliance testing each test should have at least three runs to demonstrate repeatability of approach, method, analyst. (Recommended for engineering evaluations also) Each run will be followed by calibrations and/or sample recovery At least eight (8) hours should be allotted for each test Analysis of Results (real time) Chainof i f Custodies and sample shipping i for offsite analyses

11 Post Test: Analysis of Results Sample Analysis: Onsite or Subcontract Laboratory Turnaround times for lab analyses? Calculation of Data (correct permit units) Reporting of Results (who gets the data?)

12 Post Test: Formal ltest Report Cover Page Introduction Permit # s Applicable regulations why the test was conducted Source information max and normal operating parameters Test team and others present during the testing Results summary Process Description including a diagram or schematic Problems encountered during the test Testing Methodology Calculations used all of them!! Results Appendices list of equipment used, field data sheets, Certificates of Analysis (COA s), Chain of Custody, Process data, analytical data. Certifications Quality Assurance Resumes

13 Ensuring a Smoothly Performed dtest Select a reputable testing firm Provide all required information to testing firm in a timely manner Provide adequate lead time to testing firm Know their eec electrical ca power requirements e e well in advance a Inform testing firm of any special plant entry requirements prior to day of testing Communicate continuously with testing firm before, during and after test Ensure testing crew s needs are met Provide plant data needed by testing firm to complete the calculations and formal report

14 How Do You Find A Quality Stack Testing Company Word of mouth from related sources or other regional plants within the company Check out listings on and Ask for references and follow up on them. Find out who will be on your test team for your project.

15 Conclusion It s possible to get a successful stack test accomplished but it requires effort and cooperation among all parties involved and attention to the seemingly smallest details. PPPPPP believe it, live it!

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