MANUFACTURER’S CERTIFICATE OF CONFORMANCE Land Instruments 4500 MkIII CONTINUOUS OPACITY MONITORING SYSTEM SERIAL NUMBER: 198808 33 INSTALLED AT ISSUED 17-Aug-13 LAND INSTRUMENTS INTERNATIONAL LTD STUBLEY LANE DRONFIELD UK THIS OPACITY MONITORING SYSTEM HAS BEEN TESTED OR UPGRADED TO MEET COMPLIANCE REQUIREMENTS OF ASTM STANDARD D6216-07 AND UNITED STATES OF AMERICA FEDERAL REGISTER TITLE 40, PART 60, APPENDIX B PERFORMANCE SPECIFICATION 1 TABLE OF CONTENTS I. MANUFACTURER INFORMATION II. OPACITY MONITOR INFORMATION PART 1 – DESIGN AND PERFORMANCE SPECIFICATIONS – TESTED AT MANUFACTURER’S FACILITY PART 2 – DESIGN SPECIFICATIONS VERIFIED THROUGH TEST PRESCRIBED FOR AN OPACITY MONITOR SELECTED ON A MONTHLY BASIS, OR FROM EACH PRODUCTION LOT PART 3 – DESIGN SPECIFICATIONS VERIFIED BY TESTS PRESCRIBED FOR EACH SPECIFIC OPACITY MONITOR PART 4 - QUALITY ASSURANCE PROGRAM ATTACHMENT A – ANNUAL SPECTRAL RESPONSE DATA ATTACHMENT B – MODIFICATIONS FOR AOV TEST ATTACHMENT C – ISO 9001:2000 QUALITY CERTIFICATE ATTACHMENT D – CALIBRATION ERROR TEST ATTACHMENT E – RESPONSE TIME TEST ATTACHMENT F – SECONDARY FILTER CALIBRATION ATTACHMENT G – TEST REPORT MANUFACTURER’S CERTIFICATE OF CONFORMITY This document is provided by Land Instruments International, an original manufacturer of opacity monitoring systems that are intended to comply with standards of performance established by the US EPA 40CFR60, Appendix B, Performance Specification 1, Performance Specifications for Opacity Monitors. This EPA specification references ASTM Standard Practice D6216, which may be used by the manufacturer or supplier to demonstrate that the designated opacity monitor meets those performance requirements that can be tested and verified by the supplier prior to field installation. Data in this summary document (Part 1) have been generated in compliance with the procedures and specifications shown in the ASTM Standard Practice. These data confirm that the designated opacity monitor meets or exceeds the requirements of this Standard Practice. I. MANUFACTURER'S INFORMATION Company Name Location Land Instruments International Dronfield, United Kingdom II. OPACITY MONITOR INFORMATION Model Transceiver Type Transceiver Serial No. Retroreflector Part No AFU Serial No. (if included) CRU Serial No. (if included) Software Version No. 4500 MkIII Double pass LED 198808 33 801524 199129 33 MF0800051 V1.3.4 This opacity monitoring system has been tested or upgraded to meet compliance requirements of United States of America, Federal Register Title 40, Part 60, Appendix B, Performance Specification 1, dated August 10, 2000. Test Performed by Date Signature Martin Spooner 17-Aug-13 PART 1 – DESIGN AND PERFORMANCE SPECIFICATIONS – TESTED AT MANUFACTURER’S FACILITY Conformance with design specifications is demonstrated by testing two separate opacity monitors, each of which is representative of standard production. One opacity monitor is selected and tested annually and the other is selected from either a production lot of instruments not to exceed 20 in size, or from monthly production, and tested in accordance with procedures described in ASTM Standard Practice D6216. The tests associated with each of the above selected analysers is required to be repeated anytime there is a critical component change that is substantial, hardware or software change, or manufacturing process change that could affect performance with respect to said design specifications. The test data derived from each of the above described two analysers are summarized below, in Part 1 and Part 2, respectively. 1. Design Specifications Verified Through Testing Prescribed For An Opacity Monitor Selected On An Annual Basis. OPACITY MONITOR INFORMATION Model Transceiver Type Transceiver Serial No. Reflector Type AFU Serial Number CRU Serial No. Software Version No. 4500 MkIII Standard 194659 31 801524 n/a n/a V1.03.02 TESTS PERFORMED BY: Gill Helliwell Date: 15-Feb-13 Date: 15-Feb-13 TEST DATA REVIEWED AND CERTIFIED BY: Ian Bagshaw 1.1 Spectral Response Data listed below were obtained by calculation. A description of the calculations is included in Attachment A Parameter Peak response Mean response Max response beyond 700 nm Max response less than 400 nm Specification Between 500-600 nm Between 500-600 nm Less than 10% of peak Less than 10% of peak Actual Test Report 520nm 528.5nm 0.0% 0.0% Specification Mfr specified ºC Mfr specified ºC 10 - 20% opacity ≤ 2% opacity/ 22ºC (40ºF) Actual Test Result -20ºC 55ºC 16.01% 0.40% ≤ 2% opacity/ 22ºC (40ºF) 0.28% ≤ 2% opacity/ 22ºC (40ºF) 0.01% ≤ 2% opacity/ 22ºC (40ºF) 0.29% ≤ 2% opacity/ 22ºC (40ºF) 0.02% Specification ≥ 900 W/m2 10-20% opacity ≤ 2% opacity Actual Test Result 1138 16.40% -0.10% Mfr specified No ≤ 2% opacity 0.00% ≤ 2% opacity 0.02% 1.2 Thermal Stability Parameter Tested range, min temp Tested range, max temp Nominal measurement value Measurement drift, max deviation from nominal measurement value Zero drift from nominal without compensation Zero drift from nominal with compensation Span drift from nominal without compensation Span drift from nominal with compensation 1.3 Sensitivity to Ambient Light Parameter Max solar intensity Nominal measurement value Measurement drift, max deviation from nominal measurement value Drift was corrected for thermal effects, Yes or No Zero drift from nominal without compensation Span drift from nominal without compensation 1.4 Calibration Device Availability Parameter External zero device Ext zero device repeatability External filter access Specification Optional ≤ 1% opacity To be available Availability/Value N/A N/A AVAILABLE Specification 0 ± 0.5% opacity Test Result 0.0% 1.5 Zero/upscale Calibration Check Apparatus Parameter Indicated response to simulated zero calibration device Simulated Zero Check Response to upscale calibration device without electronic hardware or software modification Do automatic zero and span calibration devices check all active optics and electronics? Is automatic correction provided for zero drift? Is automatic correction provided for dust accumulation on exposed optics? Is automatic correction provided for span/cal drift? Simulated condition during which the energy reaching the detector is between 90% and 190% of the energy reaching the detector under actual clear path conditions* + 10% opacity to highest calibration attenuator value in Section 3.1 below. Required 99.5% 25.9% YES Mfr to specify YES If yes, specify frequency Mfr to specify 24 hours (typ) YES If yes, specify frequency Mfr to specify 24 hours (typ) NO If yes, specify frequency Note: * Negative opacity values of this magnitude can be calculated from the detector or preamplifier output by measuring the equivalent optical energy detected in the clear path condition and that produced by the zero calibration check device. 1.6 PLCF Security Precautions Condition Original certified value is fixed and not adjustable by user without assistance Value is output with zero and span values during each calibration cycle Flag (alarm) is activated when changed from original certified or permanently recorded value Specification One or more of listed conditions to be provided One or more of listed conditions to be provided One or more of listed conditions to be provided As Supplied (Y/N) YES YES NO 1.7 Faults and Alarm Conditions as Specified by Manufacturer Fault Conditions (Note 1&3) Conditions tested System fault Alarm Conditions (Note 2&3) Conditions tested Specified Indication Audible or visual, and electrical Visual and electrical Same Same Actual Indication Tested output Specified Indication Audible or visual, and electrical Same Same Same Same Same Actual Indication Tested output OK Note 1) Fault conditions are those conditions which, when they occur, are deemed by the manufacturer to result in performance which is not in compliance with this performance specification. Note 2) Alarm conditions are those conditions for which the manufacturer recommends review and/or corrective action by trained service personnel as appropriate to prevent further deterioration of instrument performance which could result in performance not in compliance with this specification. Note 3) Manufacturer may use other nomenclature to designate either general or specific alarms and/or faults, as long as they are appropriately defined in the operator’s manual. 1.8 Miscellaneous Parameter Resolution of visual measurement indication, if provided Resolution of analog output measurement indication Resolution of serial digital output if provided Bipolar range of visual measurement indication Capability of analog output measurement indication to indicate negative values to at least -4% opacity Are means available to monitor daily zero and span drift before correction? Is span drift corrected for zero drift in above method? Are means available to monitor dust accumulation on exposed optical surfaces? What surfaces are monitored for dust accumulation? Is an alarm provided for excessive dust accumulation? What level of dust accumulation triggers the above alarm? Is dust level measured separately from the accumulative zero drift? Are all dust (if provided), zero, and span values corrected to stack exit conditions? What is the normal update interval for opacity measurements? Do longer-term opacity averages include at least 6 approximately equal distributed individual measurement values per minute? Specification ≤ 0.5% opacity Test Result 0.1% ≤ 0.5% opacity 0.03% ≤ 0.5% opacity 0.01% +50% opacity or more to -4% opacity or less -25% to 100% Required -25% Optional YES Optional YES Optional YES Mfr to specify, if applicable Transceiver lens Mfr to specify, if automatic correction is provided Mfr to specify, if applicable YES 4% when PLCF = 1 Mfr to specify NO Required YES 10 sec max 1.8 sec Required YES PART 2. DESIGN SPECIFICATIONS VERIFIED THROUGH TEST PRESCRIBED FOR AN OPACITY MONITOR SELECTED ON A MONTHLY BASIS, OR FROM EACH PRODUCTION LOT The opacity monitor that was selected and tested to demonstrate the following design parameters was selected on the basis of a monthly selection. OPACITY MONITOR INFORMATION Model 4500 MkIII Transceiver Type Standard Transceiver Serial No. 197652 32 Reflector Type Standard Software Version No. V1.03.04 TESTS PERFORMED BY: Date: Martin Spooner 26-Jul-13 TEST DATA REVIEWED AND CERTIFIED BY: Date: Ian Bagshaw 26-Jul-13 2.1 Angle of View The complete opacity monitor was included in the test. The light source used in the test was directional. The detector and measurement electronics were not modified to measure response to designated light source. Parameter Angle of view, horizontal Angle of view, vertical Specification ≤ 4º for all radiation providing a response of ≥ 2.5% of peak response ≤ 4º for all radiation providing a response of ≥ 2.5% of peak response Actual Test Result 2 1.5 2.2 Angle of Projection The complete opacity monitor was included in the test. The photodetector used in the test was a Silicon photodiode. The tests were conducted with an AC coupled measurement circuit, and it was demonstrated that ambient light level did not saturate the detector. Further it was demonstrated that turning on/off ambient lights did not affect measurements. Parameter Angle of projection, horizontal Angle of projection, vertical Sm reading with lights on (bits) Sm reading with lights off (bits) Detector saturation level Specification ≤ 4º for all radiation providing a response of ≥ 2.5% of peak response ≤ 4º for all radiation providing a response of ≥ 2.5% of peak response No effect No effect Sm or Rm value < 65535 Actual Test Result 1.5 1.5 8311 8311 18234 2.3 Sensitivity to Supply Voltage Variations. Manufactures specified nominal voltage was 24V dc Manufacturers specified operating voltage range was 21.6 - 26.4V dc Parameters Minimum test voltage Maximum test voltage Nominal measurement value Measurement drift, max deviation from nominal measurement value from nominal to max DC voltage Measurement drift, max deviation from nominal measurement value from nominal to min DC voltage Zero drift from nominal to max DC voltage with and without compensation Zero drift from nominal to min DC voltage with and without compensation Span drift from nominal to max DC voltage with and without compensation Span drift from nominal to min DC voltage with and without compensation Specification Mfr's min. specified operating voltage Mfr's max. specified operating voltage 10-20% opacity Actual Test Value 21.6V 26.4V 16.7% ± 1% opacity 0.0% ± 1% opacity 0.0% ± 1% opacity 0.0% ± 1% opacity 0.0% ± 1% opacity 0.0% ± 1% opacity 0.0% PART 3. DESIGN SPECIFICATIONS VERIFIED BY TEST PRESCRIBED FOR EACH SPECIFIC OPACITY MONITOR The following tests were performed individually on the specific instrument described in the beginning of this test report. Further, the following signatures attest to the fact that the design and performance specifications tested on previous opacity monitors, as described in Sections 1 and 2, are representative of the design and performance of this specific monitor. TEST PERFORMED BY: Martin Spooner DATE: 17-Aug-13 DATE: 17-Aug-13 TEST DATA REVIEWED AND CERTIFIED BY: Ian Bagshaw 3.1 Calibration Error Filter Ident. Date of Calib. Low Mid High RX41 VA29 RX43 14-Aug-13 14-Aug-13 14-Aug-13 Specify Group Actual Filter Specified Actual Cal Group 1 or 2 Value Cal. Error Error 2 10.3% 1.5% 0.19% 2 27.2% 1.5% 0.18% 2 53.7% 1.5% 0.36% Pass / Fail Pass Note: Group 1 filters are 5-10, 10-20, 20-40 % opacity (low, mid, high) Group 2 filters are 10-20, 20-30, 30-60 % opacity (low, mid, high) 3.2 Misalignment Indication This opacity monitor uses manual alignment and visual alignment sighting devices. A. Rotational Misalignment Parameter Nominal measurement value Indication of centred alignment Clear indication of misalignment for rotational misalignment for transceiver/ transmitter in upward vertical direction which causes 2% opacity change Clear indication of misalignment for rotational misalignment for transceiver/ transmitter in downward vertical direction which causes 2% opacity change Clear indication of misalignment for rotational misalignment for transceiver/ transmitter in horizontal right direction which causes 2% opacity change Clear indication of misalignment for rotational misalignment for transceiver/ transmitter in horizontal left direction which causes 2% opacity change Specification 0 to 10% Acceptable? Test Result 0% Yes Acceptable? Yes ACCEPTABLE Acceptable? Yes ACCEPTABLE Acceptable? Yes ACCEPTABLE Acceptable? Yes ACCEPTABLE B. Lateral Misalignment, Same Test Conditions Clear indication of misalignment for lateral movement to the left which causes 2% opacity change Acceptable? Yes ACCEPTABLE Clear indication of misalignment for lateral movement to the right which causes 2% opacity change Acceptable? Yes ACCEPTABLE Clear indication of misalignment for lateral movement in upward direction which causes 2% opacity change Acceptable? Yes ACCEPTABLE Clear indication of misalignment for lateral movement in downward direction which causes 2% opacity change Acceptable? Yes ACCEPTABLE 3.3 Spectral Response Repeatability * Date of spectral response filter calibration Monotonically decreasing transmission between 500 and 600 nm Wavelength (nm) 500 510 520 530 540 550 560 570 580 590 600 625 Specification Transmittance > 80% 50% transmission point between 550 and 575 nm < 20% <5% above 625 nm Calculated nominal response to transmission filter @ PLCF = 1 Calculated allowable variation of the response @ PLCF = 1 OP high OP low 30-Nov-12 YES Actual Transmittance 81% 81% 80% 77% 72% 65% 56% 45% 33% 22% 13% 2% 25.1% 34.9% 20.9% Above opacity values converted to stack exit values according to the specific PLCF established for this installation: Calculated nominal response of analyzer to filter @ PLCF = OP nominal OP high OP low 1.238 30.0% 41.2% 25.3% Actual measured response of the instrument to listed filter Is measured response within previously calculated range? 30.1% Yes 3.4 Response Time Filter S/N: PLCF: Adjusted Filter Value: 95% point: 5% point: RX43 1.238 53.7% 51.0% 2.7% Parameter Response time to reach 95% Specification < 10 seconds Response time to reach 5% < 10 seconds Sample No. 1 2 3 4 5 Mean 1 2 3 4 5 Mean Test Result 5.0 5.0 6.0 6.0 6.0 5.6 5.0 5.0 6.0 6.0 6.0 5.6 3.5 Upscale Calibration Device Repeatability Parameter Mean value 95 % confidence coefficient Specification < 1.5% opacity Opacity of upscale calibration device: Sample No. 1 2 3 4 5 Test Result 30.33% 30.32% 30.33% 30.32% 30.32% 30.32% 0.01% 30.32% 3.6 Intrinsic Opacity Monitor Settings/Adjustments Listed below are all configurable parameters used to obtain the performance described in this report. These parameters typically include calibration check intervals, calibration check correction, procedure settings relating to flange-to-flange separation distance, range, averaging time, alarms, etc. CLEAR PATH CALIBRATION PARAMETERS Stack Flange to Flange distance Installation pathlength Monitoring pathlength Emission outlet pathlength: PLCF: 96 109.4 84 104 1.238 in in in in 2438 2779 2134 2642 mm mm mm mm REQUIRED INSTRUMENT SETTINGS: Span cal grid fitted: Retro reflector type: Lens focus spacers: Certified operating voltage: Calibration check interval: Alignment: 30.32% 801524 7mm 24V DC Vdc ± 10% 24 hours Spot must be within inner bullseye circle. REQUIRED ACCESSORIES Purge air blowers: Shutters: No Yes PART 4. QUALITY ASSURANCE PROGRAM 4.1 ISO, ANSI/ASQC, or other Quality System Certification Land Instruments International is certified to ISO 9001:2000. A copy of this certification is given in Attachment C. 4.2 QA Guideline Compliance Land Instruments International established and maintains a QA/QC program that is in compliance with the guidelines specified in ASTM Standard Practice D6216-03, The Technical Services and Quality Manager is responsible for the integrity of this quality program. ATTACHMENT A – ANNUAL SPECTRAL RESPONSE DATA Wavelength nm 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 600 610 620 630 640 650 660 670 680 690 700 710 720 730 740 750 Filter Transmission 65.0% 73.0% 78.0% 82.0% 85.0% 87.0% 89.0% 90.0% 92.0% 93.0% 94.0% 95.0% 96.0% 96.0% 97.0% 97.0% 97.0% 97.0% 96.0% 94.0% 91.0% 87.0% 82.0% 75.0% 67.0% 58.0% 48.0% 38.0% 29.0% 21.0% 14.0% 9.2% 5.7% 3.4% 1.9% 1.0% 0.5% 0.3% 0.1% 0.1% 0.0% Detector A.W-1 0.140 0.140 0.160 0.160 0.170 0.170 0.190 0.200 0.210 0.220 0.230 0.250 0.260 0.270 0.290 0.300 0.320 0.330 0.340 0.360 0.370 0.370 0.390 0.390 0.400 0.410 0.420 0.430 0.440 0.440 0.450 0.460 0.460 0.470 0.480 0.480 0.490 0.500 0.510 0.510 0.520 LED Arb U 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.01 0.02 0.07 0.20 0.54 0.98 0.78 0.50 0.30 0.15 0.09 0.05 0.02 0.01 0.01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 System Response 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.002 0.005 0.020 0.058 0.168 0.314 0.255 0.169 0.101 0.048 0.029 0.015 0.005 0.002 0.002 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 Normalised Response 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.008 0.017 0.063 0.186 0.534 1.000 0.812 0.539 0.322 0.154 0.092 0.047 0.017 0.008 0.006 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 Mean response Wavelength test values: Nominal opacity Max opacity Min opacity Calibration date Check filter serial no.: BG39 Response x Check Wavelength Filter 0.00 0 0.00 0 0.00 0 0.00 0.453 0.00 0.508 0.00 0.555 0.00 0.598 0.00 0.636 0.00 0.671 0.00 0.703 0.00 0.73 0.00 0.755 3.74 0.775 7.93 0.792 30.76 0.805 92.76 0.811 272.50 0.81 520.00 0.798 430.14 0.77 291.26 0.722 177.10 0.652 86.20 0.557 52.30 0.446 27.04 0.328 10.08 0.218 4.55 0.131 3.92 0.067 0.00 0.031 0.00 0.012 0.00 0.004 0.00 0.002 0.00 0 0.00 0 0.00 0 0.00 0 0.00 0 0.00 0 0.00 0 0.00 0 0.00 0 0.00 0 528.5 nm 25.1% 34.9% 20.9% Friday, November 30, 2012 ATTACHMENT B - MODIFICATIONS FOR AOV TEST NO MODIFICATIONS TO INSTRUMENT PERFORMED TO CONDUCT ANGLE OF VIEW TEST. ATTACHMENT C - ISO 9001:2000 QUALITY CERTIFICATES ATTACHMENT D – CALIBRATION ERROR TEST D.1 FACTORY CALIBRATION ERROR DATA Manufacturer: Test operator: Serial number: Test location: Date: Monitor emission pathlength: Emission outlet pathlength: PLCF correction: Flange to flange pathlength: LOW: MID: HIGH: Land Instruments Int. Martin Spooner 198808 33 Dronfield 17-Aug-13 84 in 104 in 1.238 96 in FILTER CORRECTED SERIAL NO.: OPACITY: RX41 10.29% VA29 27.18% RX43 53.69% LOW Run 1 Run 2 Run 3 Run 4 Run 5 Mean Error 95% confidence coefft Error MID 10.1% 10.1% 10.1% 10.1% 10.1% 10.1% 0.19% 0.00% 0.19% 27.0% 27.0% 27.0% 27.0% 27.0% 27.0% 0.18% 0.00% 0.18% HIGH 53.3% 53.4% 53.4% 53.4% 53.4% 53.4% 0.31% 0.06% 0.36% ATTACHMENT E – RESPONSE TIME TEST Test number Response Time Rise 95% of Peak (s) Response Time Fall 5% of Peak (s) 1 2 3 4 5 5.0 5.0 6.0 6.0 6.0 5.0 5.0 6.0 6.0 6.0 ATTACHMENT F - SECONDARY FILTER CALIBRATION Primary Filters Filter VC63 VC64 VC65 Reading 1 Reading 2 Reading 3 Reading 4 Reading 5 Cal value Cal date 8.4% 8.2% 8.2% 8.2% 8.2% 8.8% 30-Nov-12 30.7% 30.6% 30.7% 30.7% 30.7% 31.0% 30-Nov-12 51.8% 51.8% 51.8% 51.8% 51.8% 51.9% 30-Nov-12 Secondary Filters Filter UY92 RX41 RX42 VA29 RX43 RX44 RX84 Date Valid until Reading 1 Reading 2 Reading 3 Reading 4 Reading 5 Average Cal Value 3.4% 3.4% 3.4% 3.4% 3.4% 3.4% 3.4% 8.4% 8.4% 8.4% 8.4% 8.4% 8.4% 8.4% 16.5% 16.5% 16.5% 16.5% 16.5% 16.5% 16.6% 22.5% 22.5% 22.5% 22.5% 22.4% 22.5% 22.6% 46.1% 46.1% 46.1% 46.1% 46.1% 46.1% 46.3% 59.6% 59.6% 59.6% 59.6% 59.6% 59.6% 59.9% 83.6% 83.6% 83.6% 83.6% 83.6% 83.6% 84.0% 14-Aug-13 14-Feb-14 These filters were calibrated using Land Model 4500MkIII serial no. Calibration constants Filter VC63 VC64 VC65 Slope Slope OK? Error OK? Date OK? Average Error 8.2% 0.56% 30.7% 0.32% 51.8% 0.10% 1.00531145 YES YES YES 198809 33 ATTACHMENT G – TEST REPORT
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