December 3, 2015

Roberto Bosco, MKS Instruments, Inc.

• Use Dursan® stainless steel regulator• Nitrogen and pressure purge

• Operate at flows above 3 LPM

• Material Selection• Calibration Lines: HDPE, PFA, and PTFE

• Sample Lines: PTFE, PFA, or Dursan® Stainless Steel

• AVOID untreated stainless steel

• Keep calibration bottles/regulators at room temperature

• Operate sampling system at 191 °C

• What is the current status of gas manufacturers?

• Experience with 2 PC and 1 EGU low HCl recovery when measured directly to instruments

• EGU delayed installation because gases ordered continued to fail certification• Installation occurred two months later than planned

• Some issues because of improper material selection• MKS has developed a Materials Selection Chart and Best

Measurement Practice through extensive laboratory testing• HCl as well as, NO2, NH3, CH2O, and HF

• PS18 Section 6.7: Moisture Measurement System….

”The following continuous moisture monitoring systems are acceptable: An FTIR system validated according to Method 301 or section 13.0 of Method 320 in appendix A to part 63 of this chapter; a continuous moisture sensor; an oxygen analyzer (or analyzers) capable of measuring O2 both on a wet basis and on a dry basis; a stack temperature sensor and a moisture look-up table, i.e., a psychrometric chart (for saturated gas streams following wet scrubbers or other demonstrably saturated gas streams, only); or other continuous moisture measurement methods approved by the Administrator.”

– Why is the FTIR method the only one that is to be validated?

– If “validation” is necessary can N2 be used to dilute the native H2O instead of spiking H2O?

• Currently, two allowable methods• Native and spike flow rates

• Tracer gas

• Addition of dilution factor using native gas component?• Use native CO2 as the “tracer”

• Dilution method using native CO2

concentration as the tracer gas

𝐷𝑖𝑙𝑢𝑡𝑖𝑜𝑛 𝐹𝑎𝑐𝑡𝑜𝑟 =(𝑁𝑎𝑡𝑖𝑣𝑒 𝐶𝑂2 𝐶𝑜𝑛𝑐 − 𝑁𝑎𝑡𝑖𝑣𝑒 𝐶𝑂2 𝐶𝑜𝑛𝑐 𝐷𝑢𝑟𝑖𝑛𝑔 𝑆𝑝𝑖𝑘𝑒)

𝑁𝑎𝑡𝑖𝑣𝑒 𝐶𝑂2 𝐶𝑜𝑛𝑐

% 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦 =𝑁𝑎𝑡𝑖𝑣𝑒 + 𝑆𝑝𝑖𝑘𝑒 𝐶𝑜𝑛𝑐 − (𝑁𝑎𝑡𝑖𝑣𝑒 × 1 − 𝐷𝐹 )

(𝐶𝑒𝑟𝑡𝑖𝑓𝑖𝑒𝑑 𝐺𝑎𝑠 𝐶𝑜𝑛𝑐 × 𝐷𝐹)× 100

• Section 8.1.3 of Procedure 6:“Unless specified otherwise by an applicable rule, your SA-elevated concentration may not exceed 100 percent of span when the SA and native HCl concentration are combined.”

• Span = 2 x Emission Limit rounded to the nearest 5 or 10

For PC Plants:

3 ppm x 2 = 6 ppm = 10 ppm Span Level

For EGUs:

1 ppm x 2 = 2 ppm = 5 ppm Span Level

Portland CementCalibration Gas "Actual" Concentration 73 69.35 (-5%) 76.65 (+5%) ppm

MCNative (Native Conc.) 3 3 3 ppm

MCSpiked (Spike + Native Conc.) 10.00 9.635 10.365 ppm

DF (Dilution Factor) 0.1 0.1 0.1 Recommended Maximum

Cspike (Spike Gas Concentration) 73 73 73 ppmThis remains constant b/c the bottle value is the "true" value

ESA (Effective Spike Addition) 7 7 7 ppmBased on the certified bottle concentration

DSE (Dynamic Spike Error) 0 -0.365 0.365 ppm

DSCD (PC) (Dynamic Spike Calibration Drift) 0 -3.65 3.65 %This is based on a 10 ppm Span

±3.65% Error just from the allowable (in)accuracy of the HCl bottle concentration

EGUsCalibration Gas "Actual" Concentration 41 38.95 (-5%) 43.05 (+5%) ppm

MCNative (Native Conc.) 1 1 1 ppm

MCSpiked (Spike + Native Conc.) 5.00 4.795 5.205 ppm

DF (Dilution Factor) 0.1 0.1 0.1 Recommended Maximum

Cspike (Spike Gas Concentration) 41 41 41 ppmThis remains constant b/c the bottle value is the true value

ESA (Effective Spike Addition) 4.0 4.0 4.0 ppmBased on the certified bottle concentration

DSE (Dynamic Spike Error) 0 -0.205 0.205 ppm

DSCD (MATS) (Dynamic Spike Calibration Drift) 0 -4.10 4.10 %This is based on a 5 ppm Span

±4.10% Error just from the allowable (in)accuracy of the HCl bottle concentration

• PS18 Table 1: Interference Test Gas Concentrations

Why is the NO2 test concentration so high?

Most plants have NO in amounts greater than NO2

Interferent GasesApproximate Test

Concentration

CO2 15% ±1%

CO 100 ppm ± 20 ppm

CH4 100 ppm ± 20 ppm

NO2 250 ppm ± 50 ppm

O2 3% ± 1%

SO2 200 ppm ± 20 ppm

NH3 10 ppm ± 5 ppm

CH2O 20 ppm ± 5 ppm

H2O 10% ± 1%

N2 Balance