ASME QFO - I - 199x OCTOBER 1996 DRAFT CONTENTS Foreword iii Committee Roster (to be supplied later) x SECTION I SCOPE AND PURPOSE 1.1 Scope 1.2 Definitions SECTION 2 DUTIES AND QUALIFICATIONS 2.2 Duties 2.3 Operator Class Designations 2.4 Qualifications 2.5 Certification SECTION 3 TESTING 3.1 General 3.2 Part 1 3.3 Part 2 SECTION 4 CERTIFICATION PROCESS 4.1 Introduction 4.2 Application Process 4.3 Operator Certification 4.4 Certificate Transportability 4.5 Recertification 4.6 Changes to Facility 4.7 Change of Ownership 4.8 Revocation of Certification 4.9 Appeals STANDARD FOR THE QUALIFICATION OF HIGH CAPACITY FOSSIL FUEL FIRED PLANT OPERATORS Appendix 1. Examination Guidelines FOREWORD (This Foreword is not part of ASME QFO-1-1996) The American Society of Mechanical Engineers, at the request of the U.S. Environmental Protection Agency(EPA) and, in recognition of the needs and benefits associated with standard qualifications of operators of high capacity fossil fuel fired plants, established the Qualifications of High Capacity Fossil Fuel Fired Operator (QFO) Committee in 1994. The purpose of the QFO Committee is to develop and maintain such a standard for operators. This standard includes qualifications, duties, responsibilities and the certification requirements for operators as appropriate to the Clean Air Act as Amended in 1990 for fossil fuel fired plants with inputs equal to or greater than 10,000,000 BTU/HR (10 550 E + 06 J). This Standard does not cover the certification or validation of fossil plant operating procedures, operating practices, facility performance, nor compliance with any particular permit requirement. Certification is based on three components; recommended education, experience, and passing a written examination. There are six classes of available certification, which depend on the type of fossil fuel being tired and on the firing method(s). Class A certification applies to operators of fossil plants burning pulverized fuel (including cyclone). Class B applies to operators of fossil plants burning oil or gas or a combination of oil and gas in a single burner. Class C applies to operators of fossil plants that burn oil or gas or a combination of oil and gas in a multiple burner. Class D applies to operators of stoker fired fossil plants. Class F applies to operators of fluidized bed fossil plants. Class P applies to operators of auxiliary fired heat recovery steam generators (HRSG). Tile certification is not site specific and may be applied to the operation of a different facility provided the class of the certification is comparable with the equipment to be operated. This standard recognizes the tides or positions to which any particular fossil plant operator may apply will vary within a facility. Therefore, this standard does not attempt to identify the individual who is required to obtain certification in any class designation. The fossil plant owner is urged to contact the local jurisdiction in which the fossil plant is located in this regard. This standard does not in itself require certification but rather it serves as a means for complying with federal, state, and local regulations which required operators of fossil fuel fired boilers with inputs equal to or greater than 10,000,000 BTU/ HR (10 550 E + 06 J) to be certified. The requirements of this Standard should be taken into consideration when drafting and enforcing regulations; e.g., if modifications are made to any fossil fuel fired plant, a certain grace period should be allowed to let the existing certified operator be redesignated. Safety codes and standards are intended to enhance public health and safety. Revisions to this Standard result from committee considerations of factors such as technological advances, new data, and changing environmental and industry needs. Revisions do not imply that previous editions of this standard were inadequate. This Standard, which was approved by the QFO Committee and ASME, was approved by The American National Standards Institute and designated an American National Standard on STANDARD FOR THE QUALIFICATION AND CERTIFICATION OF OPERATORS OF HIGH- CAPACITY FOSSIL FUEL-FIRED PLANTS ASME QFO-1 - 199X INTRODUCTION SECTION 1.0 SCOPE AND PURPOSE 1.1 Scope This standard covers the qualifications, duties, responsibilities and certification requirements for an operator of a high capacity fossil fuel fired plant, (boiler), as appropriate to the Clean Air Act as Amended in 1990 for a fossil fuel fired boiler with input equal to or greater than 10,000,000 BTU / hr (10 550 E + 06 J). 1.1.2.(Certified operator) This standard provides a procedure for certification of testing and qualifications of the operator. The standard does not identify which or how many individuals will be certified. 1.1.3 Exclusions This standard does not cover plants (boilers) exclusively firing; (a) wood (b). wood residue (c). industrial waste (a). municipal waste (e). combustion turbine exhaust 1.1.4 Purpose This standard provides requirements to used in certifying an operator of a high capacity fossil fuel fired plant (boiler). These requirements recognize the knowledge, training, and experience in the physical operation of a plant (boiler) needed to comply with the plant's operating permits and related environmental criteria. This standard does not cover the certification or validation of plant operating procedures, operating practices, facility performance, nor compliance with permit requirements. 1.2 Definitions Air Quality Standards: The level of pollutants prescribed by law that Cannot be exceeded during a specified time in a defined area. Boiler: A closed vessel in which water is heated, steam is generated, steam is superheated, or any combination thereof by direct application of heat. The term boiler shall include fired units for heating or vaporizing liquids other than water where these Systems are complete within themselves. Continuous Emission Monitor (CEM): The total equipment, required under the emission monitoring sections in applicable subparts (40 CFR 60.2), used to sample and condition (if applicable), to analyze, and to provide a permanent record of emissions or process parameters. Coal: Solid hydrocarbons resulting from the decomposition of vegetable material under the influence of time, temperature, pressure and micro- organisms. Commercial Boiler: A boiler which produces steam or hot water primarily for heating in commercial applications with incidental use in process applications. Criteria: The standard EPA has established for Certain pollutants, which limits both the concentration and the number of violations per year. Emission Standard: The maximum amount of discharge legally allowed from a single source, mobile or stationary. Facility: See Fossil Fuel Fired Plant. Fossil Fuel: Natural gas, petroleum, coal, or solid, liquid or gaseous fuel derived from such materials. Fossil Combustion Operator (FCO:). The person certified under this Standard. See Paragraph 2.0 Fossil Fuel Fired Plant: Any facility containing one or more fossil fuel fired boilers with input rates per fired boiler of 10 million Btu/hr (10 550 E + 06 J) or greater. Fluidized Bed: A process in which a bed of granular particles is maintained in mobile suspension by an upward flow of air or gas. Fuel Oil: Any hydrocarbon oil defined by ASTM D396. General Industry: An enterprise(s) or organization(s) that produce or supply goods or Services. High Capacity: Aggregate heat input rate of 10 million Btu/hr (10 550 E + 06 J) or greater. Heat Recovery Steam Generator (HRSG): A heat exchanger that uses a series of heat transfer (e.g., superheater, evaporator, and economizer) positioned in the exhaust gas flow of a combustion turbine or an internal combustion engine to recover heat and supply a rated steam flow at a required temperature and pressure. Industrial Boiler: A boiler which produces steam or hot water primarily for one or more process applications in the industrial setting and may produce steam or hot water for industrial use with incidental use for heating. Industrial Process: The manufacturing or treatment of products, goods, or services. Natural Gas: A combustible mixture of methane or higher hydrocarbons emitted from the earth's crust through natural openings or bored holes and used chiefly as a fuel. Packaged Boiler: A boiler equipped and shipped complete with fuel burning equipment, mechanical draft equipment, automatic controls and accessories, usually shipped in one or more major sections. Plant: See Fossil Fuel Fired Plant. Pulverized Fuel: Solid fuel reduced to a size such that more than 50 percent will pass through a 200 mesh sieve (74 microns). Stoker (mechanical stoker): A device consisting of a mechanically operated fuel feeding mechanism and a grate, used for the purpose of feeding solid fuel into a furnace, distributing it over a grate, admitting air to the fuel for the purpose of combustion, and providing a means for removal or discharge of refuse. Utility Boiler: A boiler which produces steam primarily for the production of electricity in the utility industry. SECTION 2.0- DUTIES AND QUALIFICATIONS 2.1 This section establishes the duties and qualifications of a fossil combustion operator of a high capacity fossil fuel fired boiler. The titles of positions to which the fossil combustion operator will vary within each facility. The fossil combustion operator is the individual in direct charge and control of the fossil fuel fired plant or is responsible for the overall on-site supervision, technical direction, and performance of the plant. 2.2 Duties. The duties and responsibilities of a fossil combustion operator may include, but are not limited to, the following; a). overall operation of the boiler(s); b). establishing site specific operating procedures for the boiler(s); c). operating the boiler(s) in accordance with policies and procedures established for the location; d). assuring boiler plant personnel are qualified and trained in combustion technology, combustion equipment, emission control, and monitoring equipment, policies, and procedures; c). assuring boiler plant operation is consistent with applicable federal, state, and local environmental requirements; f). supervising, training, and monitoring performance of personnel that operate the boiler plant 2.3. Fossil Combustion Operator Class Designations: The fossil combustion class designations listed below are based on the type of fossil fuel fired and firing methods. Class A Pulverized fuel fired plants and cyclone furnaces Class B Single burner oil, gas, or combination fired plants Class C Multiple burner oil, gas, or combination fired plants Class D Stoker fired plants Class E Fluidized bed plants Class F Auxiliary fired heat recovery steam generators 2.4 Qualifications. The qualifications for fossil combustion operator under this standard are as follows; a). High school diploma or equivalent with two years experience in general industry or industrial process. A portion of this experience shall include boiler operations. or b). An associate degree in technical studies or sixty credits of course work from an accredited institution in the following subjects; 1). advanced mathematics 2). chemistry 3). fluid dynamics 4). thermodynamics 5). materials science 6). combustion theory 7). environmental, mechanical, civil, chemical, or electrical engineering with one year experience in general industry or industrial process. A portion of this experience shall include boiler operations. or c). A baccalaureate degree in physical science or engineering with one year experience in general industry or industrial process. A portion of this experience shall include boiler operations, and d). have demonstrated the understanding of fossil combustion principles and combustion safety principles by passing a written examination as outlined in Section 3 of this Standard. 2.5 Certification: Operator certification, renewal, or change in classification shall be in accordance with Section 4.0 of this Standard. SECTION 3.0 TESTING 3.1 General: There shall be separate examinations for each of the classifications listed in Paragraph 2.3. The examinations shall be structured as closed book, multiple choice, written examinations. Each examination shall consist of two parts. Part I - addresses general knowledge and shall include no less than 75 nor more than 125 questions. Part 1 shall be a two(2) hour examination. Part 2 - addresses the specific fossil combustion operator classification(s); one examination for each classification. Each specific classification examination shall include no less than 50 nor more than 75 questions. A One (1) hour time period will be allotted for each specific classification. To achieve certification, an applicant must correctly answer at least 70% of the questions in Part I and at least 70% of the questions in each Part 2 taken. 3.2 Part 1 The general knowledge examination shall include the categories as listed in the Examination Guidelines (Appendix 1). 3.3 Part 2. Each classification specific examination shall include applicable As questions on the various categories listed in the Examination Guidelines (Appendix 1). SECTION 4.0 CERTIFICATION PROCESS 4.1 Introduction This section covers the process necessary to certify the fossil combustion operator of a high capacity fossil fuel fired plant in accordance with this standard. 4.2 Application Process Each applicant for high capacity fossil fuel fired operator certification shall complete a written application on forms which allow for verification that the applicant's education and experience meet the requirements outlined in section 2.0 of this standard. 4.2.1 Single Classification Application Individuals desiring certification for a single classification shall submit a Single Classification Application. This application requires the individual to complete Part One(I) of the examination and one Part Two (2) of the examination. Single Classification Applications shall provide the following: (a) documentation of experience confirming operational knowledge of the equipment for the applied classification. Documentation shall include type and size of the applicable equipment. (b) a brief history of applicable training 4.2.2 Multiple Classification Application Individuals desiring certification for more than one classification shall submit a Multiple Classification Application. This application requires the individual to complete a Part One(1) examination and more than one Part Two (2) examination. Multiple Classification Applications shall provide the following: (a) Documentation of experience confirming operational knowledge of the equipment forall applicable classifications. Documentation shall include type and size of all applicable equipment. (b) A brief history of all applicable training. 4.2.3 Application for Additional Classification The "Application for Additional Classification" shall be completed by the applicant who is currently certified in one or more of the classifications outlined in paragraph 2.3 A currently certified individual is exempt from taking Part I of the examination. The Application for Additional Classification shall provide the following: (a) Documentation of experience confirming operational knowledge of the equipment for the applied classification(s). Documentation shall include types and sizes of the applicable equipment. (b) A brief history of applicable training. 4.2.4 Application Forms Application forms for certification can be obtained from QFO Certification Program ASME Accreditation & Certification 345 East 47th St. New York, NY 10017 Up on acceptance of the completed application, ASME will notify the applicant of the dates and locations of the next scheduled examinations. 4.3 Operator Certification 4.3.1 The certificate shall expire 5 years after its issue date unless renewed. A high capacity fossil fuel fired operator certificate will be issued when the following are met: (a) Certification qualifications for the classifications outlined in Paragraph 2.3 (b) Successful completion of an operator certification examination as outlined in section 3 of this standard. 4.3.2 Each certificate shall contain the following minimum information (a) identification as a high capacity fossil fuel fired operator certificate (b) class of certification in accordance with Paragraph 2.3 (c) certified individual's full name (d) effective date of the certification (e) expiration date of the certification (f) serial number to assure traceability and accuracy (g) signature of a designated ASME representative. 4.4 Certificate Transportability. The certificate is transportable and applies only to the scope of equipment and equipment classification listed on the certificate. 4.5 Recertification. The certificate holder shall submit an application for recertification prior to the expiration of an existing certification. A written examination for recertification is not required provided the certificate holder submits notarized documentation showing they have maintained experience in their classification for a minimum of 3 of the previous 5 years. The certificate holder shall take a written examination for recertification when they are unable to document operational experience in the classification. If the recertification experience requirement is not met, the existing certification will expire. To regain certification, the individual must complete the requirements of Paragraph 4.2 of this standard. 4.6 Changes to Facility. Equipment or modifications resulting in a new Class operator designation requires that the certified individual take the examination for the new Class certification. 4.7 Change of Ownership. A change in the ownership of a fossil fuel fired plant shall not invalidate the operator certificate. 4.8 Revocation of Certification. High capacity fossil fuel fired operator certification(s) may be revoked by ASME for reasons of falsifying or providing inaccurate information in the certification process. 4.9 Appeals. Appeals regarding operator certification(s) shall be conducted in accordance with the ASME appeal policies and procedures.