A Quality Assurance Project Plan for Monitoring Gaseous and Particulate Matter Emissions from Broiler Housing

Transcription

1 Section No.: 1 09/22/06 Page i of iv A Quality Assurance Project Plan for Monitoring Gaseous and Particulate Matter Emissions from Broiler Housing Prepared by Lara B. Moody Iowa State University Hong Li Iowa State University Robert T. Burns Iowa State University Hongwei Xin Iowa State University Richard S. Gates University of Kentucky Steven J. Hoff Iowa State University Doug Overhults University of Kentucky Copyright 2008 by the American Society of Agricultural and Biological Engineers ISBN # ASABE # 913C0708e 1

2 Section No.: 1 09/22/06 Page ii of iv Foreword In January 2005, the United States Environmental Protection Agency (EPA) announced a plan, after negotiating with representatives of the animal agricultural industry, to collect scientifically credible data concerning air emissions from livestock and poultry facilities. This effort is titled the Air Compliance Agreement (ACA). Monitoring work performed as part of the ACA will have regulatory significance to future enforcements and decisions made by the EPA in regards to air emissions from animal agriculture. As such, projects within the ACA are required to operate with a Category 1 Quality Assurance Project Plan (QAPP). The QAPP is defined by the EPA as a tool for project managers and planners to define the type and quality of data needed for environmental decisions, and to describe the methods for collecting and assessing the data. The QAPP integrates technical and quality control aspects regarding planning, implementation, and assessment for a project. The goal is to ensure that the results of a project are of the type and quality needed and expected by the EPA. The four components of the plan are Project Management, Data Generation and Acquisition, Assessment and Oversight, and Data Validation and Usability. In the fall of 2005, Iowa State University and the University of Kentucky began implementation of the monitoring system at the sites proposed for use in the ACA study for southeastern broiler operations. This segment of the study will monitor air emissions from two mechanically ventilated commercial broiler houses in western Kentucky. The aerial emissions monitored include ammonia (NH 3 ), carbon dioxide (CO 2 ), hydrogen sulfide (H 2 S), non-methane hydrocarbons (NMHC), total suspended particulates (TSP), particulate matter of 10 µm diameter (PM 10 ) and particulate matter of 2.5 µm diameter (PM 2.5 ). The following sections describe the development and implementation of key quality assurance and control components for the project s Category 1 QAPP as required by the EPA. 2

3 Section No.: 1 09/22/06 Page iii of iv Acronyms and Abbreviations P change in pressure µg microgram A/O analog output AC relay alternating current relay ACA Air Compliance Agreement ADM average daily means AFO animal feeding operation API Advanced Pollution Instrumentation ARS Agricultural Research Service ASCII American Standard Code for Information Interchange ASTM American Society for Testing and Materials Standards Atm atmosphere Atm atmospheric pressure unit Bar a measurement unit of pressure BESS Bioenvironmental Structural Systems Btu British thermal unit C Celsius c critical Cal-gas calibration gas CD compact disc CDD complete-data days CH 4 methane CMOS complementary metal oxide semiconductor CO 2 carbon dioxide CPU central processing unit CS current switch CV Coefficient of Variation DAC/DAQ data acquisition DC direct current DHCP dynamic host configuration protocol DQO data quality objectives EH&S Environmental Health and Safety EPA Environmental Protection Agency ER emission rate F Fahrenheit FANS Fan Assessment Numeration System FEP (tubes) fluorinated ethylene propylene FID flame ionization detector FS full scale g gram GC gas calibration GSS gas sampling system HD hard drive Hg mercury H 2 S hydrogen sulfide hv App. K wavelength I/O input/output IFAFS Initiative for Future Agriculture and Food System WC water column IP internet protocol ISU Iowa State University kpa kilopascals L liter LED light emitting diode LPM liters per minute ma milliamps MAEMU Mobile Air Emissions Monitoring Unit mbar 10-3 atmosphere MC mass concentration ml milliliters MR mass rate MS Microsoft MSDS material safety data sheet mv millivolts NA not applicable NAEMS National Air Emissions Monitoring Study NAS National Academy of Science NH 3 ammonia SIT sample integration times SN# serial number SOP standard operating procedures SP static pressure STP standard temperature and pressure SW sidewall T absolute temperature 3

4 Section No.: 1 09/22/06 Page iv of iv TC thermocouple TE tunnel end TEMP. DIFF. temperature differential TEOM tapered element oscillating microbalance TF tunnel fan THAM tris hydroxymethyl aminomethance THC total hydrocarbons THC (propane) TM (computation) TS total solids TSP total suspended particulate UPS uninterruptable power supply USB universal serial bus USDA United States Department of Agriculture UV ultraviolet V Volt VAC voltage alternating current VDC voltage direct current VI virtual interface VOC volatile organic compounds WC water column 4

5 Section No.: 1 09/22/06 Page 1 of QA Project Plan Identification and Approval 5

6 Section No.: 2 09/22/06 Page 1 of Table of Contents Section Page Section Pages Version Date Foreword 2 ii 1.3 9/13/06 Acronyms and Abbreviations 3 iii 1.3 9/13/ QA Project Plan Identification and Approval 5 1/ /13/ Table of Contents 6 1/ /13/06 Table of Tables 9 4/5 Table of Figures 10 5/5 3.0 QAPP Distribution List 11 1/ /13/ Project/Task Organization 12 1/ /13/ Roles and Responsibilities 12 1/6 4.2 Participant Contact Information 14 3/6 4.3 Project Investigator and Team Member Qualifications 15 4/6 5.0 Problem Definition/Background 18 1/ /13/ Project/Task Description 20 1/ /13/ Project Objectives 20 1/8 6.2 Project Description 20 1/8 6.3 Project Personnel Requirements 21 2/8 6.4 Project Equipment Requirements 21 2/8 6.5 Project Schedule and Milestones (March 2005 to October 2007) 25 6/8 7.0 Quality Objectives and Criteria for Measurement Data 28 1/ /13/ Data Quality Objectives (DQOs) 28 1/ Measurement Quality Objectives (MQOs) 38 11/ Quality Control Checks 41 14/ References 41 14/ Special Training/Certification 42 1/ /13/ Field Activities 42 1/3 8.2 Laboratory Activities 43 2/3 9.0 Documents and Records 45 1/ /13/ QAPP Distribution 45 1/4 9.2 QAPP Updates 45 1/4 9.3 Identification and Recording of Project Records 45 1/4 9.4 Data Correction 48 4/ Biosecurity Plan 49 1/ /13/ Sampling Process Design 50 1/ /13/ Measurement of Gaseous and Particulate Matter Concentrations 50 1/ Measurement of Ventilation Rate 57 8/ Determination of Aerial Emission Rate (ER) 60 11/ Measurement of Air Temperature and Relative Humidity 62 13/ Litter Sampling 62 13/ Schedule of Peer Review Activities 62 13/ Procedures for Coping with Sample Design Changes 62 13/ Sampling Methods Requirements 63 1/ /22/ Gas Concentration Analysis Methods 63 1/ Gas Sampling Collection and Preparation 64 2/ Gas Sampling Equipment, Preservation and Handling Time Requirements 64 2/ Particulate Matter Concentration Methods 66 4/ Environment Conditions Sampling 68 6/11 6

7 Section No.: 2 09/22/06 Page 2 of 5 Section Section Page 12.6 Ventilation Rate Sampling 68 6/ DAQ System Recording Methods 68 6/ Sampling/Measurement System Corrective Action 69 7/ Litter Sampling 71 9/11 Pages Version Date 13.0 Sample Handling and Custody 74 1/ /13/ Gaseous and Particulate Matter Samples 74 1/ Litter Samples 74 1/ Analytical Methods 77 1/ /13/ Litter Samples 77 1/ Quality Control Measures 79 1/ /22/ Calibration 85 7/ Accuracy or Bias Checks 85 7/ Data Quality Control 92 14/ Control Charts 92 14/ Litter Sampling Quality Control Checks 92 14/ Instrument/Equipment Testing, Inspection, and Maintenance 93 1/ /13/ Testing 93 1/ Inspection 93 1/ Maintenance 96 4/ Instrument/Equipment Calibration and Frequency 97 1/ /22/ Instrumentation Requiring Calibration 97 1/ Calibration Method that Will Be Used for Each Instrument 98 2/ Calibration Standards 101 5/ Document Calibration Frequency 102 7/ Inspection/Acceptance of Supplies and Consumables 103 1/ /13/ Purpose 103 1/ Critical Supplies and Consumables 103 1/ Acceptance Criteria 103 1/ Tracking and Quality Verification of Supplies and Consumables 103 1/ Data Acquisition Requirements (Non-Direct Measurement) 106 1/ /13/ Data Management 107 1/ /13/ Background and Overview 107 1/ Data Recording 109 3/ Data Validation 109 3/ Data Transmittal 110 4/ Data Reduction 111 5/ Data Analysis 112 6/ Data Flagging 113 7/ Data Tracking 114 8/ Data Storage and Retrieval 115 9/ Data Acquisition/Processing Software Validation / Assessments and Response Actions 118 1/ /13/ Remote System Observance 119 2/ On-Site System Inspection 119 2/ Performance Evaluation Audits 119 2/ Internal Technical System Audits 119 2/ External Technical System Audits 120 3/ Data Completeness and Quality Reviews 121 4/ Audit of Data Quality 121 4/ Reports to Management 122 1/ /13/ Data Review, Verification, and Validation Requirements 124 1/ /22/ Gas and Particulate Matter Sampling System 125 2/4 7

8 Section No.: 2 09/22/06 Page 3 of 5 Section Section Page 23.2 Analytical Procedures 125 2/ Quality Control 126 3/ Calibration 126 3/ Data Reduction and Processing 127 4/4 Pages Version Date 24.0 Verification and Validation Methods 128 1/ /13/ Verification 128 1/ Validation 129 2/ Reconciliation with User Requirements 132 1/ /22/06 References 134 1/ /13/06 Appendix A: SOP of Information Required from Tyson Information for 136 the Producer 1/ /13/06 Appendix B: SOP of Gas Sampling System 137 1/ /13/06 Appendix C: SOP of Field Estimation of Ventilation Capacity Using 140 FANS 1/ /13/06 Appendix D: SOP of INNOVA 1412 Photoacoustic Multi-Gas Monitor 144 1/ /13/06 Appendix E: SOP of Temperature and Humidity Measurement 163 1/ /13/06 Appendix F: SOP of Differential Static Pressure Transmitters 171 1/ /13/06 Appendix G: SOP of Compact Fieldpoint Modules and LabView 175 1/ /13/06 Appendix H: SOP of Using Remote Panel of Southeast Broiler Emission 181 Monitoring Program (Client) 1/ /13/06 Appendix I: SOP of Data Management at ISU 186 1/ /13/06 Appendix J: SOP of Reporting and Calculation of Contaminant 199 Concentrations, Ventilation and Emissions 1/ /13/06 Appendix K: SOP of Model 101E UV Fluorescence H 2 S Analyzer 204 1/ /13/06 Appendix L: SOP of VIG Model 200 (Methane/Non-Methane/Total 212 Hydrocarbon) Analyzer 1/ /13/06 Appendix M: SOP of TEOM for TSP Measurement 217 1/ /13/06 Appendix N: SOP of Tapered Element Oscillating Microbalance 223 (TEOM) for PM 10 1/ /13/06 Appendix O: SOP of Tapered Element Oscillating Microbalance 229 (TEOM) for PM 2.5 1/ /13/06 Appendix P: SOP of Barometric Pressure Sensor 235 1/ /13/06 Appendix Q: SOP for Use of Rotem RSC-2 Scale System 237 1/ /13/06 Appendix R: SOP for Fan Current Switch Application 238 1/ /13/06 Appendix S: SOP of Litter Sample Analytical Methods 239 1/ /13/06 Appendix T: Maintenance Checklist 252 1/ /13/06 Appendix U: Monitoring Equipment Specifics 259 1/ /13/06 1. INNOVA 1412 Photoacoustic Field Gas-Monitor 259 1/31 2. Optical Filters for INNOVA /31 3. California Analytical Digital to Analog Module for INNOVA 266 8/31 4. Volgen America Switching Power Supply /31 5. Thomas Diaphragm Pump, Model 107CAB /31 6. Setra Differential Pressure Transducer /31 7. Vaisala Humidity and Temperature Sensor /31 8. Fluorotherm FEP Tubing /31 9. API UV Fluorescence Non-Methane Hydrocarbon Analyzer / Tapered Element Oscillating Microbalance (TEOM) / VIG Industries Hydrocarbon Analyzer / Rotem RSC-2 Poultry Scale System / Barometric Pressure Sensor /31 8

9 Section No.: 2 09/22/06 Page 4 of 5 Table of Tables Table Title Page Section Section Page 6.1 Project measurement equipment and personnel requirements /8 6.2 Project schedule /8 6.3 Project milestones /8 7.1 Sampling parameter and equipment quality control objectives / Temperature and humidity adjustment ratio of air emissions / Parameters for predicting emission rate (ER) uncertainty as affected by /14 concentration and ventilation uncertainties. 9.1 Project record identification and handling / Characteristics of the broiler houses monitored / Summary of instruments and sampling intervals used for the monitored /13 variables Sampling intervals for each air sampling location in each the broiler /13 house Fan number and ventilation stages for Tyson / Fan number and ventilation stages for Tyson / Gas sampling locations and sampling method/sops / Particulate matter sampling locations and sampling method/sops / Possible problems and planned corrective actions / Methods for litter analysis / QC checks of the project / Comparison of in-house NH 3 readings with those obtained from /14 location cycling by the MAEMU INNOVA Control charts / Inspections online / Inspections performed in the field before and after samples are taken / Preventive maintenance of field items / Supplies at Tyson 3-3 MAEMU and Tyson 1-5 MAEMU / List of SOPs for data processing / Validation check summaries / Data transfer operations / Report equations / Data archive policies / Data acquisition and processing software / Quality assurance assessments and implementation frequency / Reports to management / Single validation data flag for environmental condition values /4 9

10 Section No.: 2 09/22/06 Page 5 of 5 Table of Figures Figure Title Page Section Section Page 4.1 Project organization chart /6 6.1 Locations of measurement sites in Kentucky /8 6.2 Aerial pictures indicating the locations of each monitored broiler house /8 6.3 Tunnel fans and box air inlets representative of typical southeastern /8 broiler facilities. 6.4 Environmentally controlled Mobile Air Emissions Monitoring Units /8 (MAEMU). 6.5 Screen display of the broiler emissions monitoring program developed in /8 LabView View of hardware required to run pollutant sampling system /8 7.1 INNOVA analyzer dynamic response to step change in ammonia. The /14 settling time is approximately 120 s to better than 96% of true span (100% = 22.8 ppm). 7.2 Uncertainty estimates for ER as function of building emission rate and /14 ventilation uncertainty. 8.1 Information and responsibility sheet provided to project and broiler /3 facility managers Schematic layout of Tyson 1-5 and Tyson / Cross sectional view of the sidewall sampling points / Schematic representation of the positive pressure GSS used in the /13 MAEMU for measurement of broiler house air emissions Variation in the fan airflow rates among the 36-in and 48-in fans in a /13 Tyson broiler house Photographical views of the fan calibration and operation monitoring /13 devices Real-time monitoring of fan airflow rate in the LabView program / Photographs of the air sampling system / Schematic of litter sampling scheme / Example litter sample label / Litter sample chain of custody form / Picture of span gas injection from sampling points / Tyson 1-5, sampling system and INNOVA analyzer response time /14 check Tyson 3-3, sampling system and INNOVA analyzer response time /14 check INNOVA side-by-side comparison between in-house and MAEMU /14 NH 3 readings Ammonia readings from the MAEMU and in-house INNOVAs / Gas Sampling line leak check / Data tracking and chain of custody information / Flowchart of electronic data backup and storage /12 10

11 Section No.: 3 Page 1 of QAPP Distribution List Individuals listed here will receive original and updated copies of the QAPP. Robert Burns Iowa State University Hongwei Xin Iowa State University Hong Li Iowa State University Lara Moody Iowa State University Steve Hoff Iowa State University Nurun Nahar Iowa State University Richard Gates University of Kentucky Doug Overhults University of Kentucky John Earnest, Jr. University of Kentucky Steve Patrick Tyson Foods Kevin Igli Tyson Foods Steve Key Tyson Foods Sharon Nizich EPA Joe Elkins EPA The final approved QAPP will be available to all members of the project team. A bound copy of the document will be placed at both sites inside the Mobile Air Emissions Monitoring Unit (MAEMU). An electronic copy will be placed on the Internet for download by team members. The project team will be alerted of QAPP updates via an indicating when and where they can obtain a revised version. 11

12 Section No.: 4 Page 1 of Roles and Responsibilities 4.0 Project/Task Organization Principle Data Users The United States EPA will be the principle users of data resulting from this project. As such, the project is following a Category 1 QAPP. EPA Participants Sharon Nizich is the EPA Project Manager for this study. Her role is to ensure that EPA s goals for the project are met and that proper steps and procedures are followed to provide high quality project data. Joe Elkins is the EPA Quality Assurance (QA) Officer for this study. His role is to ensure that the project meets the QA requirements set forth in this document. Tyson Participants (funding organization) Steve Patrick is a contact between the project personnel and Tyson Foods. He will coordinate preparation of the sites, for example, the introduction/installation of power supply and highspeed Internet service for the MAEMU. Kevin Igli is a contact between the project personnel and Tyson Foods. He is the primary coordinator between EPA and Tyson Foods. He is also the major decision maker on project funding. Steve Key is the broiler service technician for the sites and assists the project team with production related issues, for example, providing the standard operation procedures of the broiler houses, and data concerning flock production conditions and performance. Iowa State University and the University of Kentucky (research organizations) Project Leaders Robert Burns, Hongwei Xin, Richard Gates and Steve Hoff are responsible for directing various actions occurring within the project, reviewing and approving the QAPP, and reviewing, analyzing and reporting the collected data. Robert Burns is the lead Principle Investigator (PI) for the project. He is responsible for technical decisions made for the project, directing the project team, providing technical expertise, and submitting progress and final reports. He is also responsible for interacting with any media inquiries. Hongwei Xin is responsible for providing technical expertise, assisting with the selection of monitoring equipment, and assisting with data review, analysis, and reporting. He is responsible for data review oversight. 12

13 Section No.: 4 Page 2 of 6 Richard Gates is responsible for coordinating scheduled daily and weekly operational and maintenance activities at the sites in Kentucky, maintaining a response team for flagged data excursions, overseeing regular fan calibration assessment using the Fans Assessment Numeration System (FANS) testing, and providing general logistical and technical expertise. Steve Hoff is responsible for providing overall technical expertise and technical guidance on particulate sampling and for assisting with data review, analysis, and reporting. Hong Li is a research associate working on the project and is responsible for instrument testing and monitoring, data collection and analysis, and data reporting. Li remotely monitors the data collection system inside the MAEMU and performs the data reviews. He works closely with individuals performing the on-site monitoring in Kentucky. He is responsible for documenting the completion of between flock QAPP requirements. Lara Moody is an extension program specialist. She is the Iowa State University (ISU) QA Manager. She prepares and maintains the QAPP, performs internal audits, and ensures that the QA procedures outlined in this document are performed accordingly. Raj Raman is an associate professor in the Department of Agricultural and Biosystems Engineering at Iowa State University. He will serve as the supervisor for Lara Moody for matters related to this project and will review the QA Project Reports that she submits. Doug Overhults is an associate extension professor stationed within 0.5 hour driving distance from the monitoring sites at the Western Kentucky Experiment Station in Princeton, Kentucky. He is responsible for directing regular on-site visits and for assisting with system installation and maintenance. He assists with QAPP documentation and site requirements during periods when animals are in the house and sampling is occurring. John Earnest, Jr. is an agricultural engineering technician stationed within 0.5 hour driving distance from the monitoring sites at the Western Kentucky Experiment Station in Princeton, Kentucky. He is responsible for ensuring proper operation, regular calibration and maintenance of the measurement instrumentation. Earnest conducts regular site visits (at least once a week) and also assists in system installation. During the time between flocks, Earnest is responsible for litter sample collection. He assists with QAPP documentation and site requirements during periods when animals are in the house and sampling is occurring. Nurun Nahar is a research associate in the Department of Agricultural and Biosystems Engineering at Iowa State University. She is the laboratory manager for the department s Agricultural Waste Management Laboratory. She is responsible for accepting the delivery of litter samples from Kentucky, for overseeing sample analysis, and for performing the laboratory quality control checks. The project organization chart is shown in Figure

14 Section No.: 4 Page 3 of Participant Contact Information Figure 4.1. Project organization chart. Name Affiliation Phone Sharon Nizich EPA nizich.sharon@epa.gov Joe Elkins EPA elkins.joe@epa.gov Robert Burns Iowa State University rburns@iastate.edu Hongwei Xin Iowa State University hxin@iastate.edu Steve Hoff Iowa State University hoffer@iastate.edu Hong Li Iowa State University lwblue@iastate.edu Lara Moody Iowa State University lmoody@iastate.edu Raj Raman Iowa State University rajraman@iastate.edu Nurun Nahar Iowa State University nnahar@iastate.edu Richard Gates University of Kentucky x 127 gates@bae.uky.edu Doug Overhults University of Kentucky x 237 doverhul@uky.edu John W. Earnest, Jr. University of Kentucky x 237 jearnest@uky.edu Steve Patrick Tyson Foods steve.patrick@tyson.com Kevin Igli Tyson Foods kevin.igli@tyson.com Steve Key Tyson Foods steve.keys@tyson.com Jamie Burr Tyson Foods jamie.burr@tyson.com 14

15 Section No.: 4 Page 4 of Project Investigator and Team Member Qualifications Resumes for the individuals conducting the research are included in Appendix V. Below is a summary of the team s qualifications and experience; experience is shown as barn months. A barn month is calculated as the number of months spent monitoring a particular barn (for example, two broiler houses monitored for three months equals six barn months). Robert Burns has fourteen years of experience working as an environmental engineer with air quality issues. In addition, he has worked closely with livestock and poultry production systems for the last eleven years. He has a unique combination of knowledge of both air quality issues and animal production systems. Dr. Burns holds a B.S. in Agricultural Engineering, an M.S. in Environmental Engineering and a Ph.D. in Civil Engineering (Environmental Engineering specialization) from the University of Tennessee. He is a licensed Professional Engineer (P.E.) and Certified Crop Advisor (CCA). Robert specialized in Air Pollution Control in both his Masters and Doctoral degrees. During his Masters degree he led the development of stationary and mobile source emissions inventories for volatile organic compounds and nitrous oxides for the State of Tennessee. Burns Ph.D. focused on the finite difference modeling of photochemical formation of tropospheric ozone in the southeastern United States. During his professional career Burns has published over 75 technical publications dealing with animal waste and air quality management, served as PI or Co-PI on 34 funded grants totaling $3,563,176 and served as a major or co-major professor to 16 engineering masters and doctoral students. In his current position, Burns research focuses on animal waste management and includes work on measurement and mitigation of air emissions from animal feeding operations, phosphorus recovery, anaerobic digestion and solids separation. Burns current research team is comprised of fifteen members and is currently working on projects involving the measurement or mitigation of air emissions from poultry broiler, layer and turkey production systems. Burns has a total of 114 barn months of agricultural air monitoring experience, all in broiler production. Hongwei Xin has nearly 25 years of training and experience in animal environmental engineering research. The commencement of his field experience in monitoring the environment and quantifying aerial emissions for animal feeding operations dated back 17 years when he was a post-doc research associate at the University of Arkansas ( ). At the University of Arkansas he conducted an extensive, automated 3.5-year monitoring of the housing environment, energy use, and production performance of four commercial-scale broiler houses owned by the University of Arkansas and two broiler houses owned by the cooperative producers. Since joining Iowa State University in December 1993, Xin and his associates (graduate students and post-docs) have independently and collaboratively conducted field monitoring on the following animal feeding operations: broilers (USDA-IFAFS project, in collaboration with colleagues at University of Kentucky and Penn State University), swine (farrowing and growing-finishing), pullets and laying hens, and growing turkeys. To date, Xin has totaled approximately 604 barn months of field monitoring for these species, of which 368 barn months were for the measurement of broiler housing air emissions. In addition, Xin has been collaborating with scientists in Brazil and China in monitoring and mitigating emissions of greenhouse gases (CH 4, CO 2, N 2 O) and noxious gases (NH 3, H 2 S) from animal feeding operations under conditions that 15

16 Section No.: 4 Page 5 of 6 are unique to the respective countries. Since 2004 Xin has been serving as the Chair of the United Egg Producers Environmental Scientific Panel that has the mission to serve as a clearinghouse for the egg industry on the state of air emissions research and as an advisory body to the industry toward seeking practical means to mitigate air emissions from egg operations. Richard Gates has nearly 15 years of experience monitoring and quantifying gaseous emissions from animal feeding operations. He has over 30 years of experience with broiler, layer, hog (grow-finish) and greenhouse operations, including designing systems for use in the United States, Japan, South Africa and Brazil. He has 216 barn months of experience monitoring broiler operations in Kentucky and Pennsylvania; 4 barn months monitoring layer operations in Iowa, and 12 barn months monitoring slurry from a hog grow-finish operation in Kentucky. He was PI on a recent USDA-IFAFS grant (with ISU and Penn State colleagues) to quantify ammonia emissions from U.S. poultry (layer and broiler) farms. Steve Hoff has been involved with air quality issues associated with animal agriculture for the past 15 years. The past 6 years were devoted to odor transport; odor modeling; gas, virus and PM emissions; and gas and odor mitigation, all primarily from swine production systems. He has worked continuously on several air quality monitoring projects over the past six years. These in total comprise the following: PSF Monitoring: 2 lagoon-barn combinations/month 24 months = 48 barn months IFAFS Monitoring: 2 barns/month 20 months = 40 barn months USDA-NRI A: 1 barn/month 10 months = 10 barn months USDA-NRI B: 2 barns/month 8 months = 16 barn months USDA-Special Grant: 2 barns/month 18 months = 36 barn months NPB: 2 barns/month 9 months = 18 barn months Hong Li has 4 years of experience monitoring and quantifying gaseous emissions from animal feeding operations. He has over 8 years of experience in agricultural environmental control. His research area is in environmental controls, air quality, and manure management systems. He has 30 barn months of experience monitoring layer operations in Iowa (USDA-IFAFS project). Lara Moody has 7 years of experience working as an agricultural engineer in the area of animal waste management. She has 5 years of experience directing waste management laboratory operations and acting as a project coordinator on multiple projects. She participates in research that focuses on animal waste management and includes work on waste treatment, nutrient management, phosphorus recovery, anaerobic digestion and solids separation at animal feeding operations. Nurun Nahar has 9 years of experience performing laboratory analyses on materials that include manures, soils and plants. She has an Masters degree in Soil Science from The University of Manitoba, as well as a Masters degree in Botany from The University of Dhaka. Doug Overhults has over 25 years experience providing statewide Extension education programs related to the design and operation of facilities for swine and broiler production. His primary area 16

17 Section No.: 4 Page 6 of 6 of expertise is planning, analysis, and engineering design of efficient animal production facilities, environmental controls, structures, and manure management systems. He has worked extensively with mechanical ventilation systems, cooling systems, and control systems in both swine and broiler facilities. Dr. Overhults has 84 barn months experience in monitoring energy use and the performance of an integrated environmental controller in a broiler facility in Kentucky. John Earnest has nearly 15 years of experience in utilization, application and design/fabrication of specialized agricultural equipment including energy monitoring equipment, power distribution, chemical application equipment, Global Positioning Systems, and specialized electrical and motor control systems. He had primary responsibility for on-site operation and maintenance of instrumentation and data collection systems for an extensive interior environment and energy use study at a broiler production site over a period of 72 barn months. He also has extensive experience with information technology including data collection and control software, AutoCAD, and ArcView and other Geographic Information System-related software. 17

18 Section No.: 5 Page 1 of Problem Definition/Background A comprehensive review by the National Academy of Science (NAS) in 2002 regarding air emissions data pertaining to the U.S. animal feeding operations (AFOs) concluded that such data is lacking under U.S. animal production conditions. The review called for collection of baseline emission data and development of process-based models to predict such air emissions. In response to NAS recommendations, the United States Department of Agriculture (USDA) has made quantification of air emissions from AFOs one of the top priorities in its Initiative for Future Agriculture and Food System (IFAFS) Program and subsequently the National Research Initiative (NRI) Program. As a result, since 2002 great strides have been made toward collection of baseline air emissions from U.S. AFO facilities. Noticeable among the funded studies was the six-state (IA, IN, IL, MN, NC, TX) project on air emissions from cattle, swine and poultry facilities, and the three-state (IA, KY and PA) project on ammonia (NH 3 ) emissions from layers (in Iowa and Pennsylvania; Liang et al., 2005) and broilers (in Kentucky and Pennsylvania; Wheeler et al., 2006). Because of the unfortunate passing of the key project personnel for the broiler part of the six-state project at North Carolina, data on air emissions from broiler houses experienced difficulties. Hence, there is a lack of air emissions (except for ammonia) data for broiler housing systems. During this time period, more research findings on ammonia emissions from European broiler houses have been reported (Nicholson et al., 2004). However, information regarding emission rates of particulate matter (PM), hydrogen sulfide (H 2 S) and hydrocarbons from broiler houses remains meager. This study will be an integral part of the National Air Emissions Monitoring Study (NAEMS) resulting from the ACA that has been reached between the USEPA and certain sectors of the animal industry. It will represent the southeastern broilers air emissions study. The aerial pollutants quantified in this monitoring study include ammonia (NH 3 ), carbon dioxide (CO 2 ), total suspended particulates (TSP), particulate matter 10 microns or less in aerodynamic diameter (PM 10 ), particulate matter 2.5 microns or less in aerodynamic diameter (PM 2.5 ), hydrogen sulfide (H 2 S), and non-methane hydrocarbons (NMHC). The emissions data from this monitoring study is expected to be used primarily by, but not limited to, a) the USEPA for development of emission estimation methodologies or emission factors for southeastern broiler operations; b) governmental agencies for improvement of national air emission inventories; c) the scientific community for development and/or verification of process-based emission models; and d) the broiler industry as they continue to strive for lower air emissions through practical mitigation strategies. There were two possible approaches considered for quantifying emissions from broiler houses. One approach was to monitor one broiler site for two years with a single monitoring system, as outlined in the ACA study. The other approach considered was to monitor two broiler sites with two sets of the monitoring system for one year. The former approach requires less capital investment for the monitoring equipment and setup (since only one set of the monitoring system would be involved). The latter provides a wider spectrum and thus, more representativeness of the data in terms of farm-to-farm variations in flock management, daily operation styles, and bird 18

19 Section No.: 5 Page 2 of 2 performance. Statistically, it provides a farm replication. This latter approach also allows collection of twice the emission data of the first approach considered. Hence, we elected to use the latter approach (two barns on two separate sites) in this study. 19

20 Section No.: 6 Page 1 of Project Objectives 6.0 Project/Task Description The objective of this study is to determine and report emissions of NH 3, CO 2, TSP, PM 10, PM 2.5, H 2 S and NMHC based on semi-continuous pollutant concentrations (measured on 120-second intervals) and fan flow data (measured on 1-second intervals) over a one year period from two broiler houses representative of commercial broiler production in the southeastern United States. It is anticipated that this data will be used to represent southeastern broilers in conjunction with the NAEMS. It is expected that data from the NAEMS will be used by EPA to develop air emission factors that will be used by animal production facilities to determine if they are required to be permitted under the Clean Air Act Amendments. 6.2 Project Description Two broiler houses associated with Tyson Foods broiler operations in western Kentucky are being monitored in this extensive field monitoring study. The location of the monitored facilities in Kentucky is shown in Figure 6.1, and the location of the specific house at each site is shown in aerial photos in Figure 6.2. The monitored broiler production houses use tunnel ventilation and box air inlets along the sidewalls (see Figure 6.3), which is representative of the typical production practices in terms of housing style (e.g., tunnel ventilated) and environmental control strategy (e.g., pancake brooder along with space heaters), bird management (e.g., half-house brooding), and typical litter management and handling schemes (e.g., de-caking houses between flocks). Each broiler house has its own Mobile Air Emissions Monitoring Unit (MAEMU) that houses air pollutant and fan flow monitoring systems, and it provides an environment-controlled instrument area as shown in Figure 6.4. Air samples from the broiler house sampling points (representing the exhaust air streams) to the instrument trailer/analyzers are protected against in-line moisture condensation with insulation and temperature-controlled resistive heating cable. Fan operational status and building static pressure are both continuously monitored (on 1-second intervals). This data is used in conjunction with individual fan operation curves to calculate the flow rate exhausted by each fan during operation. A real-time data acquisition system (DAQ) program developed using LabView 7 software (National Instruments, Corporation, Austin, TX) is used to acquire data, automate sampling location control, display real-time data, and deliver data and system operation status as shown in Figures 6.5 and 6.6. Each MAEMU houses a gas sampling system, gas analyzers, environmental instrumentation, a computer, data acquisition system, and other equipment needed for the study. Each building will be sampled continuously for 12 months. Gaseous and particulate matter sampling occurs when the house ventilation system is in operation. Gaseous samples are continuously collected and analyzed every 30 seconds, with every fourth concentration value used to calculate emissions. Using this approach gaseous emissions are sampled continuously on a 120-second interval. All three types of particulate matter (TSP, PM 10, PM 2.5 ) concentration are being sampled 20

21 Section No.: 6 Page 2 of 8 continuously with concentrations recorded on a 1-second interval. The 12-month duration ensures this project will meet the objectives of characterizing long-term emissions and to respond accurately to the need for annual emission factors from animal facilities by regulatory agencies and others. Long-term measurements allow the recording of variations in emissions as a result of seasonal effects, animal growth cycles, and diurnal variations. 6.3 Project Personnel Requirements The personnel required to sucessfully collect the emissions data at the level of quality that meets the Category 1 QAPP criteria include various professionals/individuals with specific skills. Namely, the project personnel have a strong working knowledge of southeastern broiler production systems, knowledge and experience to design, manufacture, and install the emissions sampling and data collection systems, training in the operation and maintenance of the emissions data collection systems, and knowledge and experience in data analysis and quality assurance. Our project team includes eleven senior project personnel including project investigators, postdoctoral research associates, masters level research associates, a QAQC coordinator and a number of undergraduate students who provide hourly assistance during installation of the air sampling and data collection systems in/for the broiler houses. Section 4.0 of this document provides a detailed explanation of the roles and responsibilities of all the regular project members. Table 6.1 provides a brief listing of the primary personnel requirements associated with each of the major pieces of monitoring equipment used in the project. More detailed descriptions of personnel resonsibilities are provided in Section Project Equipment Requirements The primary pieces of equipment utilized in the monitoring study are listed in Table 6.1. In order to collect air emissions data on a continuous basis, all selected monitoring equipment feature automatic operation. This allows for continuous collection of air samples and continuous analysis of sample concentrations. Monitoring of fan operational status and building static pressure is also automatic to facilitate continuous calculation of individual fan airflow. As indicated in Table 6.1, all emissions monitoring data is transferred as a digital signal with the exception of the on/off status of each fan, which is indicated as an analog signal. Detailed descriptions of each piece of equipment selected for this study can be found in Section 12.0: Sampling Methods Requirements. 21

22 Section No.: 6 Page 3 of 8 Table 6.1. Project measurement equipment and personnel requirements. Project Measurements* Method Data Type Equipment Requirement** Personnel Requirement NH 3 Automated Digital INNOVA 1412 Unit Calibration & Maintenance, Data Transfer, & Data Review CO 2 Automated Digital INNOVA 1412 Unit Calibration & Maintenance, Data Transfer, & Data Review TSP Automated Digital TEOM 1400 Unit Calibration & Maintenance, Mid-Flock Unit Move, Data Transfer, & Data Review PM 10 Automated Digital TEOM 1400 Unit Calibration & Maintenance, Mid-Flock Unit Move, Data Transfer, & Data Review PM 2 5 Automated Digital TEOM 1400 Unit Calibration & Maintenance, Mid-Flock Unit Move, Data Transfer, & Data Review H 2 S Automated Digital API 101E Unit Calibration & Maintenance, Data Transfer, & Data Review NMHC Automated Digital VIG 200 Unit Calibration & Maintenance, Data Transfer, & Data Review Barometric Pressure Automated Digital WE 100 Unit Calibration, Data Transfer, & Data Review Temperature Automated Digital Type T Thermocouple Unit Calibration, Data Transfer, & Data Review Static Pressure Automated Digital Setra 264 Unit Calibration, Data Transfer, & Data Review Ventilation Fan Automated Analog Current Switch Data Transfer & Data Review Operation Signal Relative Humidity Automated Digital HMW 61U Unit Calibration, Data Transfer, & Data Review Litter N Content Manual Numeric Rapid Still II and Digester Sample Collection & Laboratory Analysis * For detailed information about these measurements, see Section 12. **For specific information about the required equipment, see Appendix U. 22

23 A Quality Assurance Project Plan for Monitoring Gaseous and Particulate Matter Emissions from Broiler Housing Section No.: 6 Page 4 of 8 Tyson #1 House 5 Tyson #3 House 3 Figure 6.1. Locations of measurement sites in Kentucky. Tyson # 3 House 3 Tyson #1 House 5 Figure 6.2. Aerial pictures indicating the locations of each monitored broiler house. 23

24 Section No.: 6 Page 5 of 8 Figure 6.3. Tunnel fans and box air inlets representative of typical southeastern broiler facilities. Figure 6.4. Environmentally controlled Mobile Air Emissions Monitoring Units (MAEMU). 24

25 Section No.: 6 Page 6 of 8 Figure 6.5. Screen display of the broiler emissions monitoring program developed in LabView 7. Figure 6.6. View of hardware required to run pollutant sampling system. 6.5 Project Schedule and Milestones (March 2005 to October 2007) Table 6.2 provides the schedule for this project. Because this project is tied to a broiler NH 3 emissions study that began in the 2 nd quarter of 2005, the project schedule outlined in Table 6.2 had to be implemented in order to ensure that the planned monitoring could be completed with the available funding. The original NH 3 monitoring study that began in 2nd quarter of 2005 was expanded in the 4 th quarter of 2005 to include CO 2, TSP, PM 10, PM 2.5, H 2 S and NMHC as well 25

26 Section No.: 6 Page 7 of 8 as NH 3. Monitors for all pollutants were successfully installed at the sites in January A series of performance tests were conducted in January and February 2006 to confirm that the monitoring systems were working as designed and to determine representative locations for air sampling points and TEOM placement. Study data collection for all pollutants of interest formally began on February 20, 2006 with the placement of a new flock of birds in each house. Emissions data for all pollutants will be collected through February 2007, or until the flocks of broilers in the houses on that date, have completed the production cycle. In effect, emissions monitoring will be continued until the flocks in the houses on February 20, 2007 have been removed from the houses to ensure that emissions from more than one full year (five to seven flocks) of production is monitored at each of the two broiler houses. Purchase Monitoring Equipment Table 6.2. Project schedule th 1 st 2 nd 3 rd 4 th 1 st 2 nd Qtr. Qtr. Qtr. Qtr. Qtr. Qtr. Qtr. X 3 rd Qtr. Prepare QAPP X X EPA Review of QAPP X X QAPP Revisions X X Prepare Monitoring Trailers X X On-site Equipment Installation X X Monitoring System Testing X Collect Data X X X X X Analyze Data X X X X X X Mid-Term Progress Report X X Final Emissions Report X 26

27 Section No.: 6 Page 8 of 8 Major project milestones are provided in Table 6.3. In addition those milestones that have been completed to date are so noted along with their date of completion. Table 6.3. Project milestones. Project Milestone Status Completed Date Submit QAPP to EPA Completed 3/01/06 Install all emissions monitoring equipment Completed 1/06/06 Performance testing of emissions monitoring system Completed 2/10/06 Begin collection of study data Completed 2/20/06 Receive QAPP comments from EPA Completed 4/12/06 Revised QAPP submitted Completed 8/03/06 Revised QAPP approved by EPA Mid-Term Progress Report Due 3 rd Quarter 2006 Late-Term Progress Report Due 2 nd Quarter 2007 Final Emissions Report Due 3 rd Quarter