APEX INSTRUMENTS, INC. Isokinetic Source Sampling Handbook

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APEX INSTRUMENTS, INC.

Isokinetic Source Sampling Handbook

Isokinetic

Handbook

2

ISOKINETIC SOURCE SAMPLING

Isokinetic Handbook

Apex Instruments, Inc.

204 Technology Park Lane

Fuquay-Varina, NC 27526 USA

Phone 919-557-7300 • Fax 919-557-7110

Web: www.apexinst.com

E-mail: [email protected]

Revision No: 8

Revision Date: October 2018

http://www.apexinst.com/

mailto:[email protected]

3

TABLE OF CONTENTS

Chapter 1: Introduction ................................................................................................................................... 5

System Description ......................................................................................................................................... 7

Source Sampler Console ............................................................................................................................. 8

Electrical Subsystem .............................................................................................................................. 8

Thermocouple Subsystem ...................................................................................................................... 8

Vacuum Subsystem ................................................................................................................................ 9

External Vacuum Pump Unit .................................................................................................................... 11

Probe Assembly ........................................................................................................................................ 12

Probe Liner ........................................................................................................................................... 13

Probe Heater ......................................................................................................................................... 14

Modular Sample Case ............................................................................................................................... 16

Umbilical Cable with Umbilical Adapter ................................................................................................. 17

Glassware Sample Train ............................................................................................................... 18

Chapter 2: Operating Procedures ................................................................................................................. 19

Set-up and Check of Source Sampling System............................................................................................. 19

Initial Set-up Procedure ............................................................................................................................ 19

Initial Sampling System Leak Check ........................................................................................................ 21

Test Design ................................................................................................................................................... 22

Site Preparation ............................................................................................................................................. 22

Mount the Filter Oven and Impinge Assembly............................................................................................. 25

Assemble Sampling Equipment and Reagents ............................................................................................. 28

Preliminary Measurements of Gas Velocity, Molecular Weight and Moisture............................................ 28

Method 1 – Determining Sample and Velocity Traverse Points .................................................................. 30

Determining Traverse Points .................................................................................................................... 31

Method 1A – Sample and Velocity Traverses for Small Stacks or Ducts .................................................... 37

Method 2 – Stack Gas Velocity and Volumetric Flow Rate ......................................................................... 39

Stack Gas Molecular Weight and Moisture .............................................................................................. 40

Using the Pitot Tube ................................................................................................................................. 41

Determine Flow Rate ................................................................................................................................ 41

Static Pressure ........................................................................................................................................... 44

Barometric Pressure .................................................................................................................................. 44

Calculate Volumetric Flow Rate ............................................................................................................... 44

4

Method 3 – Gas Analysis for Dry Molecular Weight ................................................................................... 46

Determine Dry Molecular Weight ............................................................................................................ 48

Method 4 – Moisture Content of Stack Gas.................................................................................................. 49

Reference Method 4 .................................................................................................................................. 51

Approximation Method ............................................................................................................................. 53

Calculating Stack Gas Moisture Content .................................................................................................. 55

Method 5 – Determination of Particulate Emissions .................................................................................... 56

K-Factor Calculations ............................................................................................................................... 58

Method 5 Test Procedure .......................................................................................................................... 59

Recommended Reading List for Isokinetic Sampling .................................................................................. 70

Chapter 3: Calibration and Maintenance .................................................................................................... 71

Calibration Procedures .................................................................................................................................. 71

Dry Gas Meter and Orifice Tube .............................................................................................................. 73

Metering System Leak Check Procedure (Vacuum Side) .................................................................... 73

Metering System Leak Check Procedure (Pressure Side) .................................................................... 74

Initial or Semiannual Calibration of Dry Gas Meter and Orifice Tube ................................................ 75

Post-Test Calibration of the Source Sampler Console ......................................................................... 78

Calibration of Thermocouples .................................................................................................................. 79

Calibration of Pitot Tube ........................................................................................................................... 80

Calibration of Sampling Nozzles .............................................................................................................. 82

Initial Calibration of Probe Heater ............................................................................................................ 83

Calibration of Pressure Sensors ................................................................................................................ 84

Maintenance .................................................................................................................................................. 85

Appendix A ...................................................................................................................................................... 86

Recommended Equipment for Isokinetic Sampling ..................................................................................... 87

Recommended Spare Parts ........................................................................................................................... 90

Equipment Checklist ..................................................................................................................................... 92

Appendix B ...................................................................................................................................................... 93

Calibration Data Sheets................................................................................................................................. 94

Appendix C .................................................................................................................................................... 102

Stack Testing Field Data Sheets ................................................................................................................. 103

Appendix D .................................................................................................................................................... 113

Calculation Worksheets .............................................................................................................................. 114

5

Chapter 1

Introduction The purpose of this manual is to provide a condensed understanding of the procedures established by the

United States Environmental Protection Agency (US EPA) in accordance with Reference Methods 1 through

5 – Determination of Particulate Emissions from Stationary Sources.

In addition to providing an easy-to-use guide for Methods 1 through 5, we have provided users with reference

information on system configuration, calibration procedures, maintenance and troubleshooting. Be on the

lookout for helpful tips and training aids throughout this manual.

We trust you will find this guide useful regardless of the sampling equipment you use and will use our

equipment for demonstrations and illustrations.

Isokinetic Sampling is the collection and measurement of a gas sample from a source at the same velocity as

the gas travels in the stack to provide a representative assessment of solid particulate matter that is in the

source.

To perform isokinetic testing, you must have a thorough understanding of the first five test methods presented

in Title 40 Part 60 Appendix A of the Code of Federal Regulations (40CFR60 App. A). While Method 5

outlines the general sampling train operation protocol, Methods 1 through 4 prescribe techniques that serve as

a foundation for Method 5 sampling activities. Together, these methods outline the basic protocols for

determining particulate concentrations and mass emission rates.

US EPA Method

Description

Method 1 Determination of Sampling Location and Traverse Points

Method 2 Determination of Stack Gas Velocity and Volumetric Flow-rates

Method 3 Determination of Dry Molecular Weight and Percent Excess Air

Method 4 Determination of Moisture Content

Method 5 Determination of Particulate Matter Emissions from Stationary Sources

6

You can easily adapt the basic Method 5 sampling train to test for many other gaseous and particulate emissions

from stationary sources. Adapting basic test methods allow you to expand testing to include parameters of

interest such as metals, polychlorinated biphenyls (PCBs), dioxins/furans, polycyclic aromatic hydrocarbons

(PAHs), particle size distributions and an ever-increasing group of other pollutants.

While the different methods are designated by other US EPA method numbers, they actually are variations of

Method 5 procedures. Variations might include using different impinger solutions, organic resin traps, different

filter media, various sampling temperatures, or a range of other alternative procedures.

The manual and the automated source sampling consoles can be used for the following isokinetic test

methods and pollutants:

Method No. Pollutants

5A PM from Asphalt Roofing 5B Non-sulfuric Acid PM 5D PM from Positive Pressure Fabric Filters 5E PM from Fiberglass Plants 5F Non-sulfate PM from Fluid Catalytic Cracking Units 5G PM from Wood Stoves - Dilution Tunnel 5H PM from Wood Stoves – Stack 8 Sulfuric Acid Mist, Sulfur Dioxide and PM

12 Inorganic Lead (Pb) 13A & 13B Total Fluorides

17 Particulate Matter 23 Polychlorinated Dibenzo-p-Dioxins and Dibenzofurans

26A Hydrogen Halides and Halogens 29 Multiple Metals

101 Mercury (Hg) from Chlor Alkali Plants 101A Mercury (Hg) from Sewage Sludge Incinerators 104 Beryllium (Be) 108 Inorganic Arsenic (As) 111 Polonium-210

201A PM10 Particulate Matter (Constant Sampling Rate) 202 Condensable Particulate Matter 206 Ammonia (Tentative) 207 Iso cyanates (Tentative) 306 Hexavalent Chromium from Electroplating and Anodizing Operations 315 PM and Methylene Chloride Extractable Matter (MCEM) from Primary Aluminum

Production 316 Formaldehyde from Mineral Wool and Wool Fiberglass Industries (Proposed)

Waste Combustion Source Methods in EPA-SW-846 Method No. Pollutants

0010 Semi volatile Organic Compounds 0011 Formaldehyde, Other Aldehydes and Ketones

0023A Polychlorinated Dibenzo-p-Dioxins and Dibenzofurans 0050 Hydrogen Chlorine and Chlorine 0060 Multiple Metals 0061 Hexavalent Chromium

7

System Description

The first step to successful sampling is to familiarize yourself with the standard equipment. To illustrate the

necessary components of source sampling, we’ve included a diagram of the five main components

demonstrated on the Apex Instruments Isokinetic Source Sampling System, shown in Figure 1-1:

1. Source Sampler Console, which includes a differential pressure transducer (or dual-column

manometers), sample flow control valves with orifice flow meter, dry gas meter, and electrical

controls.

2. Sample Pump External Rotary Vane (or internal diaphragm pump) , including hoses with quick-

connect fittings and lubricator.

3. Probe Assembly includes a stainless-steel probe sheath, probe liner, tube heater, Type-S pitot tube,

stack and heater thermocouples, and an Orsat line.

4. Modular Sample Case includes a filter oven for the filter assembly, an impinger case for the

impinger glassware and electrical connections.

5. Umbilical Cable includes electrical and pneumatic lines to connect the Modular Sample Case to the

Source Sampling Meter Console.

Figure 1-1: Apex Instruments Isokinetic Source Sampling Equipment

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Description of Component Parts

1. Source Sampler Console

The Source Sampler Console is the operator’s control station. It

monitors gas velocity and temperatures at the sampling location

and controls system sampling rate and system temperatures.

Housed within the console are the Electrical, Thermocouple, and

Vacuum sub-systems.

Electrical Subsystem:

The electrical subsystem provides switched power to several

circuits, including main power, pump power, manometer zero, timer,

probe heater and oven heater. Power rating should be chosen

according to your source of electricity. For example, the Apex

Instruments XC-500 Sampling Systems can be configured for

120VAC/60Hz or 240VAC/50Hz electrical power.

Note: When the main power switch is on, the cooling fan should

operate. Also, the pump has its own power cord, which is plugged

into the Source

Sampler Console.

The electrical system

contains circuit

breakers that detect

and interrupt

overload and short circuit conditions, an

important safety feature. If the circuit

breaker opens or “trips,” indicating

interruption of the circuit, investigate

and repair the electrical fault. Then

Tips from a Stack Tester

To reduce the probability

of nuisance tripping,

follow this start-up

sequence to reduce the

power surge: first, power

up the sample pump

because it runs on the

highest current. Wait a

few seconds after the

pump has started, then

power up the filter and

probe heaters.

Apex Instruments Product Highlight

When looking for a console, consider a user-friendly

design that simplifies field assembly and set-up. The Apex

Instruments XC-500 Series Console Meters place

connections for the sample line, pitot tube lines, vacuum

pump (non-reversible), and electrical (4-pin circular

connector and Thermocouple jacks) all on the front panel

for easy access. You also can remove the front and back

covers of the console to get to what you need. The XC-522

model is programmed for English-standard measurements,

while the XC-572 offers a metric version.

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reset the breaker by pressing the circuit breaker switch. The circuit breaker also can trigger a “nuisance trip,”

making it difficult to complete a test.

The MANOMETER ZERO switch operates two (2) 3-way solenoid valves. When the MANOMETER ZERO

switch is ON, the valves will produce an audible “click.” These valves open both legs of the ΔH side of the

dual-column manometer to atmosphere so that you can check and, if necessary, adjust the manometer fluid

zero pressure level.

The timer will begin to count when the TIMER switch is turned on and stops when the switch is turned off.

The display is reset to zero with a push switch on the face of the timer display. The timer is factory-set to read

hour/minutes/seconds but can read minutes and tenths of minutes if specified in the purchase order.

To activate the heaters in the filter compartment (Hot Box) and the probe heater, turn on the switches labeled

FILTER and PROBE. Adjust the dials to approximately 120°C (248°F) and check the temperature display to

verify that the heaters are working. Allow time for the temperatures to stabilize and then verify operation of

the circuits.

Thermocouple Subsystem:

The thermocouple subsystem displays, measures and provides

feedback for the temperature controls that are critical to

isokinetic sampling operation. The Apex Instruments

thermocouple system consists of Type-K thermocouples,

extension wires, male/female connectors, receptacles, a

thermocouple selector switch, and a digital temperature display

with internal compensating junction.

Existing consoles offer automatic and digitally programmable

temperature controllers for probe and filter oven heat. The

controllers receive temperature feedback signals to maintain

temperatures within range of the set point. The thermocouple

electrical diagram is presented in the electrical schematic, found

in the appropriate operator’s manual.

Vacuum Subsystem:

The vacuum pump assembly provides the vacuum action for

extracting the gas sample from the stack and through the various

components of the isokinetic source sampling system.

Typically, the vacuum subsystem consists of an external

vacuum pump assembly (or internal diaphragm pump), quick-

connects, internal fittings, two (2) control valves (coarse and fine), an orifice meter, and a dual-column inclined

manometer (or pressure transducer).

A popular method of controlling flow is the dual-valve design that helps the operator obtain very precise

control over the sample flow rate through use of the Coarse Control Valve and the Fine Increase Valve.

● The Coarse Control Valve is a ball valve with a 90° handle rotation from closed to full open. This

valve controls the flow from the SAMPLE inlet to the Vacuum Pump inlet.


By observing the orifice

reading (ΔH) on the front

side of the manometer, you

can quickly adjust the

sample flow rate using the

Fine Increase Valve so that

the sample is extracted

under isokinetic conditions.

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● The Fine Increase Valve is a needle-type valve with four (4) turns from closed to full open. The Fine

Increase Valve allows flow to re-circulate from the pump outlet back to the pump inlet. The Fine

Increase Valve is used for precise vacuum control during leak checks.

You can zero the ΔH manometer before or during a sampling run by flipping on the Manometer Zero switch

found on the front panel. This actuates the solenoid valves to vent the pressure lines to atmosphere. Then, you

can adjust the manometer’s fluid level using the knobs located at the bottom of the manometer.

Figure 1-2 below demonstrated the Apex Instruments Model XC-522 Source Sampler Console’s front panel

to provide an example of the layout of Source Sampling Console.

Did you know? You can zero the pitot tube manometer by disconnecting the pitot

lines at the quick-connects on the Source Sampler Console.

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Figure 1-2: Model XC-522 Source Sampler Console Front Panel

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Source Sampler Console Front Source Sampler Console Rear

2. External Vacuum Pump Unit

The External Pump Unit provides the vacuum that draws the sample from the stack. The most common type

of pump assembly attaches to the Source Sampler Console via an electrical receptacle and two (2) 1.524 m (5

ft.) hose extensions with 9.525 mm (3/8 in.) quick-connects (configured with a male connector on the pressure

side and a female connector on the suction side.

Figure 1-3: Picture of XE-0523 (Cased) and E-0523

(Open Frame) Lubricated Vane Vacuum Pump


Apex Instruments offers two pump styles: the E-

0523 lubricated rotary-vane pump and the

internal diaphragm housed inside the console.

Both pump assemblies are available in either

120VAC or 240VAC operation and customers

can choose from two enclosure options for the

external pump: a black polyethylene case with

molded handles and removable covers or an

aluminum open frame (seen to the right).

• The E-0523 features a 250-watt motor

with a measured flow of 88 lpm and a

maximum vacuum of 86.4 kPa.

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3. Probe Assembly

The main components of a Probe Assembly are:

● Probe Liner: 15.9 mm (5/8 in.) OD tubing made from either Borosilicate Glass, Quartz, Stainless Steel,

Inconel, or PTFE.

● Probe Heater: Removable rigid tube heater with coiled heating element, electric thermal insulation and

thermocouple, with a maximum recommended temperature of 260oC (500oF).

● Probe Sheath: 25.4 mm (1 in.) OD tube with quad-assembly attached that includes a replaceable,

modular S-type pitot tube, stack thermocouple and a 1/4 in. OD stainless steel tube to collect gas samples

for Orsat analysis.

● Small Parts Kit: Fittings to attach nozzle to Probe Assembly. Fittings include 5/8 in. bored union, nut

and ferrules.

Did you know? The most effective probe length in the stack is equivalent to 0.305 m

(1 ft) less than nominal length. Probe lengths vary from 0.914 m (3 ft) to 4.877 m (16

ft) nominal length.


Pumps that require lubrication, such as the E-

0523, generally are not pre-lubricated and need to

be filled approximately three-quarters (¾) full

with lightweight lubricating oil (Gast AD220,

SAE-10 or SAE-5) before first use.

14

Figure 1-4, right side, illustrates a standard Probe Assembly (top) and a Probe Assembly with the optional 50.8

mm (2 in.) Oversheath and Packing Gland (bottom).

The left part of the diagram shows the connection between the nozzle and probe using fittings from the small

parts kit.

Figure 1-4: Diagrams of Probes and Probe Assembly

Probe Liner:

Standard Probe Liners are constructed from 5/8 in. OD tubing and have #28 ball joints with an O-ring groove.

Available liner materials are borosilicate glass, quartz, stainless steel, Inconel, and PTFE. You will need a ball

joint adapter if you have a PTFE liner, straight liner, or liner with integrated nozzles. Figure 1-5 shows the

potential Probe Liner configurations.

Figure 1-5: Diagrams of Probe Liner Configurations

15

Important: Review maximum operating temperatures before selecting a Probe Liner material and

configuration. Table 1-3 shows the temperature limits for Probe Liner materials, while Table 1-4 reflects

temperature limits for various probe configurations.

Table 1-3: Maximum Stack Gas Temperatures for Probe Liner Materials

Material

Maximum

Temperature

PTFE Liners and Fittings 177°C (350°F)

Glass-Filled PTFE Fittings 260°C (500°F)

Borosilicate Glass Liners 480°C (900°F)

Stainless Steel Liners 650°C (1200°F)

Quartz Liners 900°C (1650°F)

Inconel or C276 Alloy Liners 870°C (1600°F)

Table 1-4: Probe Configuration Temperature Ratings

Probe Assembly Configuration

Maximum

Temperature

Stainless Steel Sheath and Glass Liner 480°C (900°F)

Stainless Steel Sheath and Liner 650°C (1200°F)

Inconel or C276 Alloy Sheath and Liner 870°C (1600°F)

Inconel or C276 Alloy Sheath and Quartz Liner 870°C (1600°F)

Probe Heater:

For accurate results, the sample temperature should remain in

the range of 120oC ± 5oC (248oF ± 9oF) as it travels through the

probe.

Important: Exposure to elevated temperatures can damage the

insulation and shorten the life of the heater. The maximum

recommended stack exposure temperature for Probe Heaters is

260oC (500oF). Partial probe heaters are recommended for

temperature above 500ºF.


With accurate sampling in mind, Apex

Instruments Probe Heaters feature a

rigid tube heater with coiled heating

element, electrical thermal insulation

with integrated thermocouple, and a

power cord sealed in silicone-

impregnated glass insulation.

Also, our mandrel-type heater design

allows you to replace the liner as

needed without removing the heating

element. Standard heaters are

configured for 120VAC operation;

240VAC configuration is available.

16

How to Connect the Probe Assembly to the Modular Sample Case:

The Probe Assembly connects to the Modular Sample Case with the following steps:

1. Mount the probe sheath to the Modular Sample Case using a probe clamp that is attached to the probe

holder.

2. Look for the thermocouple male connector extending from the probe assembly and connect it to the

female thermocouple connector of the Umbilical Cable.

3. Connect the electrical plug to the electrical receptacle on the Modular Sample Case Hot Box.

4. Insert the outlet ball of the Probe Liner through the entry hole of the Filter Oven (Hot Box)

compartment until the back of the sheath is even with the inside of the sample case.

5. Connect the pitot tube quick-connect lines, probe heater thermocouple, stack thermocouple and Orsat

gas sample line to the Source Sampler Console via the Umbilical Cable.

17

4. Modular Sample Case

The Modular Sample Case is used for support, protection and environmental control of the glassware in the

sampling train. The Modular Sample Case consists of an insulated heated filter compartment (Hot Box) and

insulated impinger case (Cold Box).

Figure 1-6 illustrates the major components and accessory connections on the Modular Sample Case.

Figure 1-6: Modular Sample Case Components and Accessories

The impinger case (cold box) holds the sampling train

impingers in an ice bath so that the stack gas sample is cooled

as it passes through the impingers to condense the water

vapor. This process allows you to measure stack gas moisture

volume, then use that reading to calculate stack gas density.

Figure 1–7: From left to right, SB-3, SB-4, SB-4SD, SB-

4SDM2, and SB-5 Impinger Boxes


Obtain multiple Impinger

Cases and sets of impingers

for rapid turnaround time

between test runs.

Some companies offer

impinger cases for a variety of

different number of impingers.

Filter Oven

Impinger

Case

Riser

Handle with Safety Clip

Door Latch (both sides)

Umbilical Adapter Clamp

Impinger Case Drain

Probe Power Receptacle

Amphenol Connector

Oven Thermocouple Connector

Hinged Probe

Clamp

Aux. Power

34.3cm

24.1cm

31.8cm

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5. Umbilical Cable with Umbilical Adapter

The Umbilical Cable connects the Modular Sample case and Probe Assembly to the Source Sampler Console.

The Umbilical Cable typically contains the gas sample and pitot lines, as well as thermocouple and power

lines.

Below is an example of the configuration of the umbilical connections (using the Apex Instruments product as

an example):

● The primary gas sample line (blue, 3/8 in. i.d./12.7 mm (5/8 in. o.d.)) has a male quick-connect on the

outlet, at the opposite end, a 12.7 mm (5/8 in.) female quick-connect on the inlet.

● The two (2) pitot lines, (black and white, 6.35 mm (1/4 in.)), have female quick-connects to the Probe

Assembly and 6.35 mm (1/4 in.) male quick-connects to the Source Sampler Console. There is an

additional gas sample line for Orsat analysis (yellow, 6.35 mm (1/4 in.)), which also can be used as a

spare pitot line.

● Multiple thermocouple extension cables for Type-K thermocouples, which terminate with durable full-

size connectors. The connectors have different diameter round pins to ensure proper polarity, and will not

fully connect if reversed. Each thermocouple extension wire in the Umbilical Cable is labeled and color-

coded for temperature measurement of Stack, Probe, Oven (Hot Box), Exit (Cold Box), and Auxiliary

(spare).

● The AC power cable (for Filter Oven and Probe Assembly heaters) terminates with a circular, military-

style connector on each end.

● The Umbilical Adapter connects the outlet of the last impinger to the Umbilical Cable and contains the

exit thermocouple. This adapter serves to relieve strain between the Umbilical Cable and the glassware

train.

● The body of the circular connector is grounded. A line-up guide is placed on each connector’s end, and

the retainer threads should be engaged for good contact. Figure 1-8 illustrates the circular connector with

pins labeled.

● The Umbilical Cable is covered with a woven nylon mesh sheath to restrain the cable and reduce friction

when moving the cable.

Figure 1-8: Circular Connector and Electrical Pin Designations

19

How to Construct a Glassware Sample Train:

The sample glassware train contains the filter holder for collection of particulate matter, glass impingers for

absorption of entrained moisture, and connecting glassware pieces.

Figure 1-9 below illustrates the glassware of the US EPA Method 5 sampling train.

The order in which a typical US EPA Method 5 glassware train is constructed is as follows:

1. Cyclone Bypass (GN-1), Optional: Cyclone (GN-2) and Cyclone Flask (GN-3)

2. 3 in. Glass Filter Assembly (GNFA-3). Assembly consists of the Filter Inlet (GN-3S), Teflon Filter Disk

or “Frit” (GA-3T), Filter Outlet (GN-3B), Filter Clamp (GA-3CA), and Glass Fiber Filter (GF-3 Series).

3. Double “L” Adapter (GN-8), or alternate GN-8-18K with thermocouple assembly

4. 1st Impinger Modified Greenburg-Smith (GN-9A)

5. U-Tube (GN-11)

6. 2nd Impinger Greenburg-Smith with Orifice (GN-9AO)

7. U-Tube (GN-11)

8. 3rd Impinger Modified Greenburg-Smith (GN-9A)

9. U-Tube (GN-11)

10. 4th Impinger Modified Greenburg-Smith (GN-9A )

Figure 1-9: Glassware Sampling Train Schematic

20

Chapter 2

Operating Procedures There are several steps to complete before testing for

particulate matter, which include:

1. Set up and inspection of source sampling system,

review of calibration records

2. Test design

3. Site preparation

4. Sampling equipment calibrations (see Chapter 3)

5. Assembling sampling equipment and accessories,

reagents, sample recovery equipment, and sample storage containers

6. Preliminary measurements of stack dimensions, gas velocity, dry molecular weight, and moisture.

1. Set-up and Check of Source Sampling System

When unpacking your sampling system for the first time, check each part for damage and ensure your shipment

is complete by checking items off the packing list.

If you purchased your product from Apex Instruments, please call us immediately at 800-882-3214 or email

us at [email protected] to seek help with any damaged or missing products.

A. Initial Set-up Procedure

These instructions are for a “dry run” set-up of the complete US EPA Method 5 sampling train.

Important: Do not load a glass fiber filter into the filter assembly or charge liquids and silica gel in the

impingers. The objective is just to set-up the equipment to verify that everything works. Start with these steps:

1. Remove all items from packaging and place in an open area.

2. Slide the Impinger Case (Cold Box) onto the Modular Sample Case’s heated filter oven (Hot Box),

using the steel slide guides. Check the fit and height of the Sample Case and Umbilical Adapter.

Adjust the steel slides to achieve the desired fit. Engage the spring latch that locks the Impinger Case

into place.

3. Inspect the Probe Liner and Probe Assembly. Wipe clean the quick-connects on the Probe Assembly.


A drop of penetrating oil

helps keep the quick-

connects in good working

condition. Inspect the pitot

tube openings for damage

or misalignment, and

replace or repair them if

necessary.

mailto:[email protected]

21

4. Slide the Probe Liner into the probe sheath. The liner’s plain end (no ball joint) should come out

approximately 1.27 cm (1/2 in.) at the pitot tube end of the Probe Assembly.

5. Insert the Probe Assembly into the probe clamp that is attached to the Filter Oven and tighten. Then,

carefully insert the outlet ball of the Probe Liner through the hole into the Hot Box. The back of the

sheath should be even with the inside of the Hot Box. Next, plug the Probe Heater electrical plug into

the probe receptacle on the Hot Box.

6. To install a nozzle on the Probe Assembly, consult Figure 2-1. Slide the ferrule system onto the plain

exposed end of the Probe Liner. Substitute high-temperature braided glass cord packing for the

ferrule when stack temperatures are greater than 260°C (500°F) or use liner with integrated nozzle.

Apex Instruments’ Probe Assembly Spare Parts Kit (the bag taped to probe sheath) contains fittings for

two (2) different ferrule installation options: 1) Stainless Steel Single Ferrule and 2) Backer Ring with O-

Ring. The recommended configurations for different liner options are detailed below:

• Stainless Steel Liner: Stainless Steel Single Ferrule or Backer Ring with O-Ring

• Glass Liner: Backer Ring with O-Ring, or PTFE Single Ferrule (Optional), or Glass-filled PTFE

Single Ferrule (Optional).

Figure 2-1: Installation of Stainless Steel and Glass Probe Nozzle Connectors

7. Thread the 15.875 mm (5/8 in.) union onto the nut welded to the probe sheath. This is a compression

fitting that is tapered to seal the ferrule system inserted on the Probe Liner.

Important: Tighten the fitting until the liner has a leak-tight seal, but DO NOT OVERTIGHTEN.

8. Connect the glassware sampling train completely in the Filter Oven (Hot Box) and Impinger Case

(Cold Box) (see Figure 1-9 and the related “How to Construct a Glassware Sample Train” at the end

of Chapter 1). Tighten all joints using the Ball Joint Clamps. The final connection is the Umbilical

Adapter, which slides into the clamp on the outside of the Impinger Case. Again, do not load the

Filter Assembly with a filter, and do not fill the impingers because this is a “dry run” set-up.

9. To connect the Umbilical Cable to the Modular Sample Case, first connect the Umbilical Cable

circular connector plug to the receptacle on the side of the Filter Oven (see Figure 1-6). Next, connect

the labeled Umbilical Cable thermocouple plugs into the receptacles on the Filter Oven, Probe

Stainless Steel Nozzle Glass Nozzle

22

Assembly, and Umbilical Adapter. Then, insert the Umbilical Cable sample line female quick-

connect into the Umbilical Adapter male quick-connect. Finally, insert the Umbilical Cable female

pitot line quick-connects into the Probe Assembly male quick-connects.

10. To connect the Umbilical Cable to the Source Sampler Console, first connect the Umbilical Cable

circular connector plug to the receptacle on the front panel of the Source Sampler Console. Then,

connect the labeled Umbilical Cable thermocouple plugs into the receptacles on the Source Sampler

Console front panel.

Next, insert the Umbilical Cable sample line male quick-connect into the Source Sampler Console

female quick-connect. Finally, insert the Umbilical Cable pitot line male quick-connects into the

Source Sampler Console female quick-connects (labeled + and −). The pitot lines are colored to

differentiate the positive and negative lines and ensure the connections are consistent between the

pitot tube and Source Sampler Console.

11. To connect the Vacuum Pump Assembly to the Source Sampler Console, first wipe the quick-

connects clean, then connect the pressure and vacuum hoses on the Vacuum Pump Assembly to the

pump connections located on the lower left of the Source Sampler Console front panel. Then, connect

the power cord of the Vacuum Pump Assembly to the receptacle labeled PUMP on the Source

Sampler Console.

12. Plug the Source Sampler Console into an appropriate electrical power source.

B. Initial Sampling System Leak Check

Remember to follow the set-up procedure detailed in the previous section before starting a system check

procedure. The system leak check described below is a “dry” run:

1. Close the Coarse Valve on the Source Sampler Console.

2. Seal the inlet to nozzle.

3. Turn on the Vacuum Pump with the PUMP POWER ON switch.

4. Slowly open the Coarse Valve and increase (which means turn clockwise until close) the Fine

Increase Valve.

5. The pump vacuum, as indicated on the Vacuum Gauge, should read a system vacuum within 10 kPa

(3 in. Hg) of the barometric pressure. Example: If the barometric pressure is 100 kPa (30 in. Hg),

then the Vacuum Gauge should read at least 92 kPa (27 in. Hg).

6. Wait a few seconds for the pressure to stabilize. When the Orifice Tube pressure differential (ΔH) has

returned to the zero mark, measure the leak rate for one minute, as indicated on the dry gas meter

display. The observed leak rate should be less than 0.56 liters per minute (lpm) (0.02 cubic feet per

minute (cfm)). If the leak rate is greater, check the tightness of all connections in the sampling train

and repeat.

23

2. Test Design

Before testing, define the test parameters by answering the following:

● Why is the test being conducted?

● Who will use the data?

● Which stacks or emission points are being tested?

● What process data is being collected and correlated with test results?

● Where are the sample ports located and what type of access is available?

● When is the test scheduled, and what are the deadlines for reporting?

● What is the specific method or procedure to follow?

● How many test runs or process conditions will be tested?

3. Site Preparation

Preparing the site so that sampling equipment can be positioned correctly is frequently the most difficult part

of the sampling process. When the sample ports do not have a platform or catwalk, then scaffolding must be

erected to reach the sampling site. At many sites, operators must use their ingenuity to get the sampling

equipment to the sampling location.

When selecting the site for sample ports, keep in mind that the distance from the probe to the bottom of the

sample case is about 33 cm (13.5 in.). This means that when traversing the stack, the sampling equipment

needs 33 cm of clearance below the port level to avoid bumping into guardrails or other structures.

To calculate the clearance needed along the sample port plane, start with the effective probe length (which is

stack diameter plus port nipple length) and add at least 91 cm (36 in.) to accommodate the length of the sample

case (Filter Oven, Impinger Case, and probe clamp).

Figure 2-2 on the next page illustrates the clearance zones required.

24

Figure 2-2: Clearance Zones at Stack for Isokinetic Sampling Train

25

Figure 2-3: Schematic of Non-Rigid Isokinetic Sampling Train


If you can’t find a solution for sampling train clearance problems,

Apex Instruments can provide one. We offer a Non-Rigid Method 5

sampling train with a separate and/or miniature heated Filter Box (SB-

2M), which allows you to put the Cold Box on the sampling platform,

where it is connected by the sample line and Umbilical Adapter (GA-

104).

Figure 2-3 on the next page illustrates the Non-Rigid Isokinetic

Sampling Train. The midget hot box decreases the clearance needed

between the monorail and guardrail of the stack.

26

Did you know? Although the Isokinetic Source Sampling System is

designed to fit into a 6.35 cm (2.5 in.) sample port, a larger port hole

measuring 7.6 cm (3 in.) or greater allows you to insert and remove the

probe more easily, without damaging the nozzle or picking up deposited

dust.

Figure 2-4: Schematic of Compact Isokinetic Sampling Train

Mount the Hot and Cold Boxes

There are two ways to mount the isokinetic sampling system (which includes the Filter Oven and Impinger

Case) on a stack:


A second solution for clearance problems is our Compact

Method 5 sampling train with a Heated Filter Assembly

(SFA-82H) and Power Box Adapter (UA-3J).

Figure 2-4 below illustrates the Compact Method 5 option.

The smaller heated filter assembly allows for greater

flexibility in small sampling areas.

27

1. Assemble a monorail system with lubricated roller hook above each sample port, or

2. Construct a wooden platform slide apparatus (where feasible).

Figure 2-5 illustrates an isokinetic sampling system mounted on a monorail system above a sample port with

a tee bracket system. Another way to do a monorail mounting is when there is an angle iron, with a hole or an

eyehook, welded to the stack.

Figure 2-5: Illustration of Monorail System for Sampling Train

Figure 2-6: Illustration of Apex Instruments

Monomount Monorail System


When no mounting support for a monorail

system exists, you can easily construct one

using the Apex Instruments Monomount

(P501) around the stack, as shown in Figure

2-6 on the next page.

28

Illustrated below is a complete stack set-up in two different configurations: Figure 2-7 shows the Hot

Box/Cold Box together (SB-1) and Figure 2-8 shows the Filter Oven and Impinger Case separated (SB-2M

and SB-3).

Figure 2-7: Stack Platform Set-up with Modular Sample Case on Monorail

29

Figure 2-8: Stack Set-up with Hot Box on Monorail Separated from Cold Box

Assemble Sampling Equipment and Reagents

Remember to use checklists when assembling the sampling equipment, reagents and auxiliary supplies for a

test. See Appendix A for checklists of recommended equipment, spare parts and reagents for isokinetic

sampling. Keep in mind that you may not need the entire list at the test site. Also, refer to Section 3 of US EPA

Method 5 for the list of reagents required to perform an isokinetic particulate test.

Obtain Preliminary Measurements of Gas Velocity, Molecular Weight and Moisture

Before attempting to calculate the parameters needed for isokinetic sampling – such as probe nozzle size,

ΔH/Δp ratio (K factor), gas sample volume, etc. – you first must determine several preliminary values

described in Table 2-1 on the next page.

Table 2-1: Preliminary Measurements for Isokinetic Sampling

No. Symbol Value Needed Obtain from

30

1. Δpavg Average stack gas velocity pressure head 1. Before the sample run (best), or 2. A previous test (often erroneous)

2. Ps Stack gas pressure 1. Before the sample run (best), or 2. A previous test (very small error)

3. Pm Dry gas meter pressure

Same as barometric pressure

4. Bws Stack gas moisture fraction 1. Before the sample run (best), or 2. A previous test (often erroneous)

5. Ts Average stack gas temperature 1. Before the sample run (best), or 2. A previous test (often erroneous)

6. Tm Average dry gas meter temperature Meter temperature rises above ambient

because of pump heat and is typically

estimated at 14°C (25°F) above ambient

7. Md Stack gas molecular weight 1. Before the sample run (best), or 2. A previous test (very small error)

8. ΔH@ Orifice meter calibration factor Determined previously from laboratory

calibration


Obtain most of the

preliminary values just

before the sample run

rather than using old data.

Relying on previous tests

for values such as average

stack gas velocity, stack

gas moisture, and average

stack gas temperature can

lead to erroneous results.

31

Method 1

Determining Sample and Velocity Traverse Points

Method 1 is the first step toward collection of a representative sample to measure a stack’s particulate

concentration and mass emission rate. Method 1 is applicable to gas streams flowing in ducts, stacks and

flues. Since the velocity and particle concentration in the stack are not uniform, you must traverse the cross-

section to obtain a representative sample.

Keep in mind: This method cannot be used when:

1. The flow is cyclonic or swirling and is skewed to one side.

2. A stack is smaller than 0.30 meter (12 in.) in diameter, or 0.071 m² (113 in.²) in cross-sectional area. For

stacks and ducts measuring less than 12 in. in diameter, see Method 1A immediately following this section.

Did you know? Methods 1 through 4 are like building blocks, providing the

preliminary values needed to complete Method 5 sampling. Thus, when you perform

a sampling run using Method 5, you will need to know Methods 1 through 4

procedures to collect the data needed for Method 5 sampling and calculations.

Through the rest of Chapter 2, we have provided concise and easy-to-use information

for performing US EPA Methods 1 through 5.

32

The number of required traverse points depends on the shape - or straightness - of the stack or duct. Straighter

lengths of stack or duct produce flow streamlines that are more uniform, so fewer traverse points are needed

to obtain a representative sample. Conversely, if your sampling site is close to bends in the stack or other flow

disturbances, you will need to use more traverse points to obtain a representative sample.

Method 1 describes procedures to:

● Select appropriate sampling locations on the stack (if sample ports do not already exist).

● Calculate the number of traverse points for velocity and particulate sampling.

● Calculate the location of the traverse points.

We can identify appropriate sampling sites by measuring their distance from any type of flow disturbance in

the stack. Disturbances can be bends, transitions, expansions, contractions, stack exit to atmosphere, flames,

or the presence of internal installations such as valves or baffles.

To calculate distance between the sampling site and flow disturbances, first we measure the internal stack

diameter. Then, we use that length to determine how many “diameters” are in between the sampling site and

the flow disturbance.

Figure 2-9 on the next page depicts how stack diameters are used to measure distance from a flow disturbance

such as a bend. The example on the left shows an acceptable sampling site, which is eight (8) diameters

downstream from a bend and two (2) diameters upstream from the stack exit. The example on the right is not

an acceptable sampling site because it is too close to a flow disturbance (the bend in the stack).

33

Figure 2-9: Visualizing Stack Diameters from Flow Disturbances

Calculate Traverse Points

Calculate the minimum number of traverse

points needed with the following steps:

1. Measure the stack diameter to within

0.3175 cm (1/8 in.).

a. Insert a long rod or pitot tube

into the duct until it touches the

opposite wall.

b. Mark the point on the rod where

it meets the outside of the port

nipple.

c. Remove the rod, measure and

record this length to the far wall

(Lfw.).

d. With a tape measure (or rod if

the stack is hot), measure the

distance from the outside of the


Measure the stack diameter from each

sampling port and use the average, since not

all circular stacks are round and not all

rectangular stacks are perfectly rectangular.

By measuring through each port, you can

often find in-stack obstructions and take

steps to avoid erroneous measurements.

If possible, shine a flashlight across the stack

to look for obstructions or irregularities.

If possible, using a gloved hand, reach into

the sampling port and check that the port

was installed flush with the stack wall (and

that it does not extend into the flow.)

34

port nipple to the near wall and record this length (Lnw).

e. Calculate the diameter of the duct from this port as D = Lfw - Lnw.

2. Repeat for the other port(s) and then average the diameter (D) values.

3. Then, measure the distance from the sample port cross-sectional (horizontal) plane to the nearest

downstream disturbance (designated Distance A).

4. Next, measure the distance from the sample port cross-sectional plane to the nearest upstream

disturbance (designated Distance B).

5. Calculate the number of duct diameters to the disturbances by dividing Distance A (to downstream

disturbance) by the average diameter (D). Do the same for Distance B (to upstream disturbance).

6. Using Figure 2-10 (for particulate traverses) or 2-10b (for velocity traverses), determine where Distance

A (top) intersects the solid traverse points line running through the middle of the graph. Then, determine

where Distance B meets the traverse points line, and select the higher of the two numbers as the

minimum number of traverse points needed for sampling.

Example: The dotted lines in Figure 2-10 represent a Distance A measurement of 1.7 duct diameters and a

Distance B measurement of 7.25 duct diameters. Looking at where the dotted lines intersect the solid

traverse points line, Distance A requires 16 traverse points, while Distance B requires 12 traverse points.

Always choose the higher of the two numbers. In this example, the sampling site requires 16 total traverse

points. The 16 points are arranged in two lines of eight points each which are 90° apart, forming a cross

shape.

Figure 2-10: Example of How to Determine Number of Traverse Points (Particulates)

35

Figure 2-10b: Example of How to Determine Number of Traverse Points (Non-Particulates)

Identify Minimum Number of Traverse Points

● For circular stacks with diameters greater than 60 cm (24 in.), the minimum number of traverse points

required is twelve (12), or six (6) in each of two directions 90° apart (see Figure 2-11). This applies

when disturbances are eight (8) or more duct diameters upstream and two (2) or more downstream.

● For circular stacks with diameters between 30 and 60 cm (12 and 24 in.), the minimum number of

traverse points required is eight (8), or four (4) in each of two directions 90° apart.

● For stacks less than 30 cm (12 in.) in diameter, refer to Method 1A for calculating traverse points.

● The minimum number of traverse points required for rectangular stacks is nine, or 3 x 3.

For rectangular stacks or ducts, first calculate an equivalent diameter using the following equation:

where De = equivalent diameter of rectangular stack

L = length of stack

W = width of stack

36

Determine the Location of Traverse Points

Circular Stacks

After determining the number of traverse points, you must calculate the location of each traverse point. The

method for locating the traverse points for circular stacks is as follows:

1. Divide the number of traverse points by four (4). The resulting number will give you the number of

concentric circles of equal area to use in your sample point matrix. In the example illustrated in Figure

2-11, twelve (12) traverse points divided by four (4) equals three (3).

2. Bisect the circles twice, cutting them into quarters, as shown below.

3. Place the sample points in the centroid (center of mass) of each equal area, as shown in Figure 2-11.

Figure 2-11: Traverse Points Located in Centroids for Circular Stack

Pinpoint and Mark Traverse Points

Follow this procedure to locate each traverse point across the

diameter of a circular stack and mark the corresponding point on

the probe assembly or pitot tube:

1. On a Method 1 field data sheet (which can be computer or

calculator generated), multiply the stack diameter by the

percentage taken from the appropriate column of Table 2-

2. For example, the 4th traverse point along a diameter

with 6 points is equivalent to 70.4% of the stack diameter

(D x .704).

Tips from a Stack

Tester

You may combine two

successive points to

form a single adjusted

point, which must be

sampled twice.

37

2. Add the port nipple length to the value calculated in step 1 for each traverse point.

3. Round each value to the nearest 1/8th (0.125) of an inch for each point (English units only).

4. For stacks greater than 60 cm (24 in.) in diameter, relocate any traverse points closer than 2.5 cm

(1.00 in.) to the stack wall to 2.5 cm and label them as “adjusted” points.

5. For stacks less than 60 cm (24 in.) in diameter, use an adjusted distance of 1.3 cm (0.5 in) to relocate

any points away from the stack wall.

6. Measure each traverse point location from the tip of the pitot tube and mark the distance with heat-

resistant fiber tape or “Wite-Out” correction fluid, as illustrated in Figure 2-13.

Table 2-2 Location of Traverse Points in Circular Stacks

(Percent of stack diameter from inside wall of traverse point)

Traverse point number on a diameter Number of traverse points on a diameter

4 6 8 10 12 4 93.3 70.4 32.3 22.6 17.7 5 85.4 67.7 34.2 25.0

6 95.6 80.6 65.8 35.6

7 89.5 77.4 64.4

8 96.8 85.4 75.0

9 91.8 82.3

10 97.4 88.2

11 93.3

12 97.9

38


After calculating the traverse point locations (before

adding sample port nipple length), you can check your

work quickly by noticing if the first and last traverse point

distances added together equal the stack diameter; then if

the second and next to last equal the same; then if the

third and third from last equal the same; and so on.

For instance, with a stack diameter of 60 cm and 12

traverse points, the 4th point is 10.62 cm (60 cm x 0.177)

from the port and the 9th point is 49.38 cm (60cm x

0.823) from the port. 10.62 cm + 49.38 cm = 60 cm.

39

Figure 2-13: Illustration of Marking Traverse Points on Probe Assembly

Rectangular Stacks

For rectangular stacks, the centroids for placing the traverse points are much easier to determine, as shown in

Figure 2-12.

Figure 2-12: Traverse Points Located in Centroids for Rectangular Stack

Table 2-3: Cross Section Layout for Rectangular Stacks

Number of Traverse Points Matrix Layout 9 3 x 3 12 4 x 3 16 4 x 4 20 5 x 4 25 5 x 5 30 6 x 5 36 6 x 6 42 7 x 6 49 7 x 7

40

Method 1A

Sample and Velocity Traverses,

Small Stacks or Ducts

Method 1A is the same as Method 1, except for the special provisions that apply to small circular stacks or

ducts where the diameter is between 4 and 12 inches (10.2 cm (4 in.) ≤ D ≤ 30.5 cm (12 in.)), or for small

rectangular ducts where the area is between 12.57 in.2 and 113 in.2 (81.1 cm2 (12.57 in.2) ≤ A ≤ 729 cm2 (113

in. 2)).

Important: You must use a standard type pitot tube for the velocity measurements. Do not attach the tube to

the sampling probe.

The procedure for determining sampling location, traverse points, and flow rate (preliminary or otherwise) in

a small duct is as follows:

1. Use Method 1 to locate traverse points for each sampling site and choose the highest of the four

numbers for the total traverse point number.

2. For measurements of particulate matter (PM) with a steady flow, or velocity with either a steady or

unsteady flow, select one sampling location and use the same criterion as described in Method 1.

3. For PM with a steady flow, conduct velocity traverses in the same port before and after PM sampling

to demonstrate steady state conditions, i.e., within ± 10% (vf/vi ≤ 1.10).

4. For PM with an unsteady flow, monitor velocity and sample PM at two separate locations

simultaneously. The velocity port should be downstream of the sampling port. See the location of the

two ports labeled in Figure 2-14 on the next page.

Did you know? In small diameter stacks or ducts, the conventional Method 5 stack

assembly (which consists of a Type-S pitot tube attached to a sampling probe

equipped with a nozzle and thermocouple) blocks a significant portion of the duct’s

cross-section, resulting in inaccurate measurements. Therefore, for particulate

matter sampling in small ducts, measure the gas velocity either:

➢ Downstream of the sampling nozzle (for unsteady flow conditions), or

➢ In the same sample port alternately before and after sampling (for steady

flow conditions).

41

Figure 2-14: Set-up of EPA Method 1A Small Duct Sampling Locations

42

Method 2

Stack Gas Velocity and Volumetric Flow Rate

Method 2 is used to measure the average velocity and volumetric flow rate of the stack gas stream. To

determine the average gas velocity in the stack, you must measure the gas density and the average velocity

head with a Type-S (Stausscheibe or reverse-type) pitot tube. Note: Have a thorough knowledge of at least

Method 1 before proceeding, as some of the steps reference Method 1 procedures.

Method 2 is used to:

➢ Determine the nozzle size and length of the sampling run before a particulate stack test series (also

known as a preliminary velocity determination).

➢ Ensure that the particulate sample is extracted from the stack at isokinetic conditions during each

stack test run.

The equation for average gas velocity in a stack or duct is:

Where vs = Average stack gas velocity, m/sec (ft/sec)

Kp = Constant, 34.97 for metric system (85.49 for English system)

Cp = Pitot tube coefficient, dimensionless

(√Δp)avg = Average of the square roots of each stack gas velocity head, mm H2O (in. H2O)

Ts = Absolute average stack gas temperature, °K (°R)

Ps = Absolute stack gas pressure (Pbar + Pg/13.6), mm Hg (in. Hg)

Did you know? Do not use Method 2 with measurement sites that are less than

eight stack diameters downstream or two stack diameters upstream from a flow

disturbance. Method 2 also cannot be used for direct measurement in cyclonic or

swirling gas streams (see section 11.4 of Method 1 to determine these conditions).

When faced with cyclonic or swirling gas streams, you must use alternative

procedures such as installing straightening vanes, calculating the total volumetric

flow rate stoichiometrically, or moving to another measurement site where the

flow is acceptable.

43

Pbar = Barometric pressure at measurement site, mm Hg (in. Hg)

Pg = Stack static pressure, mm H2O (in. H2O)

Ms = Molecular weight of stack on wet basis (Md (1 – Bws) + 18.0 Bws), g/g-mole

(lb/lb-mole)

Md = Molecular weight of stack on dry basis, g/g-mole (lb/lb-mole)

Bws = Water vapor in the gas stream (from Method 4 (reference method) or Method

5), proportion by volume.

Obtain Stack Gas Molecular Weight and Moisture

To calculate the average stack gas velocity (Vs), you must first obtain values for the molecular weight and

moisture (refer to Method 3 and Method 4 sections). The stack gas molecular weight dry basis (Md) is corrected

to the wet basis (Ms) using the moisture fraction (Bws) with the equation:

Figure 2-15 illustrates the relationship of Methods 1, 3 and 4 to Method 2.

Figure 2-15: Determination of Preliminary Velocity

Method 3 Stack Gas Molecular Weight Options:

• Sample with Orsat analysis

• Sample with Fyrite analysis

• Assign 29.0 if air

• Assign 30.0 if combustion

Method 1 Selection of Traverse Points

Method 2 Stack Gas Velocity

Method 4 Stack Gas Moisture Options:

• Reference Method

• Approx Method (Midgets)

• Drying Tubes

• Wet Bulb-Dry Bulb

• Psychrometric chart

• Previous experience

44

Using the Pitot Tube

Use a pitot tube connected to an inclined manometer to make velocity measurements in a duct. Alternatives to

the inclined manometer are a magnehelic pressure gauge or an electronic manometer, but you must calibrate

each of these devices periodically against an oil-filled inclined manometer (see Calibration in Chapter 3).

The S-type pitot tube has a fixed coefficient of 0.84 if it is manufactured and maintained to meet the geometric

specifications of Method 2. You may also use a standard or P-type (Prandl) pitot tube with a coefficient of

0.99 for these measurements.

Insert the S-type pitot tube into the stack with one leg (hole opening) pointing into the direction of gas flow,

as shown in Figure 2-16. The leg pointing into the flow stream measures impact pressure (Pi) of the gas stream,

while the opposite leg (pointing away from the flow) measures wake pressure (Pw).

The velocity pressure (Δp) is the difference between the impact and wake pressures:

Figure 2-16: Apparatus for Preliminary Velocity Measurement

45

Determine Flow Rate

The procedure for determining flow rate (preliminary or other) in a stack gas stream is as follows:

1. Fill out the top section of a Velocity Traverse field data sheet.

2. Mark the pitot tube with the traverse points according to Method 1 (see “Pinpoint and Mark Traverse

Points” in the Method 1 section).

3. Assemble the apparatus for flow velocity measurement using one of these configurations:

a. Pitot tube with thermocouple, pitot and thermocouple extension lines, inclined manometer, and

temperature display device, or

b. Probe Assembly, Umbilical Cable, and inclined manometer on Meter Console.

4. Pitot Line Leak-Check: Conduct a pre-test leak-check of the

pitot and lines by blowing lightly into the positive (impact) side

of the pitot tube opening until at least 7.6 cm (3 in.) H2O

registers on the manometer; then, close off the impact opening.

The pressure should remain stable for at least 15 seconds. Do

the same, except suck lightly, for the negative (wake) side.

5. Level and zero the manometer. If using a separate manometer,

cup a hand or place a glove over the pitot opening to prevent

wind from affecting the zero adjustment. If using the Source

Sampler Console, use the Zero Manometer switch. Periodically

check that the manometer is zeroed and leveled between ports.

6. Insert the pitot tube into the stack to a marked traverse point

and seal off the port opening with a rag or towel to prevent

ambient effects. Starting with the farthest points, measure the

velocity head and temperature and record the values on the

field data sheet. Allow the temperature reading to stabilize

before recording it.

7. Move to each subsequent traverse point, reseal the port and

record the velocity head and temperature. Switch to the next port and repeat traverse sampling.

8. Conduct a post-test

leak-check (which is

mandatory to prove

that no leakage

occurred) as

described in Step 4

above, and record it

on field data sheet.

Tips from a Stack

Tester

If the pitot tube is dirty or

chemically contaminated,

attach a short piece of

flexible tubing to the pitot

leg for leak checking, and

pinch it closed to hold the

pressure.

Did you know? The S-type pitot tube is most often used in stack

testing because it is:

➢ Compact and attaches easily to a Method 5 probe assembly,

➢ Relatively easy to manufacture,

➢ Relatively insensitive to plugging in stack gas streams, and

➢ Relatively insensitive to yaw and pitch errors.

46

9. Measure the static pressure in the stack. One reading is adequate.

10. Determine the barometric pressure at the level of the sample port.

11. Calculate the average stack temperature from the traverse readings and record it.

12. Calculate the average square root of velocity head by taking the square root of each velocity head reading

and averaging the square roots (sum the square roots and then divide by the number of traverse points).

Then, record it on the field data sheet.

Important: Ensure that you are using the proper

manometer or pressure gauge for the range of Δp

(velocity head of stack gas) values you encounter. If a

more sensitive gauge is needed, swap it in and

remeasure the Δp and temperature readings at each

traverse point, using the above procedures.

Measure Static Pressure

You can measure static pressure in any of three ways:

➢ Using a static tap,

➢ Using a straight piece of tubing and

disconnecting one leg of the manometer, or

➢ Using the S-type pitot tube and disconnecting

one leg of the manometer.

Measure Static Pressure with an

S-Type Pitot

If you are using an S-type pitot to measure static

pressure, follow these steps:

1. Insert the S-type pitot tube into the middle of the

stack.

2. Rotate the pitot about 90° until you obtain a zero or

null reading on the manometer.

3. Holding the pitot in place, disconnect the positive

side from the manometer and read the oil deflection

on the manometer gauge. Record the static pressure

as negative.

4. If the oil travels past the zero mark, reconnect the

positive side and disconnect the negative side, then

read the oil deflection in the manometer. Record the

static pressure as positive.


The easiest way to measure static

pressure is to insert a piece of metal

tubing connected to a U-tube water-

filled manometer into the

approximate middle of the stack, with

the other end open to atmosphere.

If the manometer deflects toward the

stack, record this as negative static

pressure (less than barometric

pressure). If the manometer deflects

away from the stack, record this as

positive static pressure.

If you are using an inclined

manometer, then place the connection

to the tubing on the negative (right-

hand) side of the manometer to read a

negative static pressure. Switch it to

the positive (left-hand) side to read a

positive static pressure. The

procedure is identical when using a

stack static tap.

47

After recording the static pressure (Pg), you must convert the value from mm H2O to mm Hg (in. H2O to in.

Hg) prior to inputting it into the velocity equation as Ps (absolute stack gas pressure). The density of mercury

is 13.6 times that of water, so the conversion equation is:

where Ps = Absolute stack gas pressure, mm Hg (in. Hg)



Obtain Barometric Pressure Reading

Obtain a barometric pressure reading (Pbar) at the measurement site by using a calibrated on-site barometer, or

by contacting a nearby weather station (within 30 km) to get the uncorrected station pressure (weather stations

report barometric pressure corrected to sea level, so ask for the “uncorrected” pressure). You also will need to

know the station’s elevation above sea level.

Correct the station’s barometric pressure reading by subtracting 0.832 mm Hg for every 100 m that the weather

station is above sea level (0.1 in. Hg for every 100 ft.). To get valid results, you also must know the sampling

site’s elevation.

Calculate the sampling site barometric pressure (Pbar) as follows:

where Pr = Barometric pressure at site ground level or at weather station, mm Hg (in. Hg)

A = Elevation at ground level or at weather station, m (ft. above sea level)

B = Elevation of the sampling site, m (ft. above sea level)

Calculate Volumetric Flow Rate

After calculating the average stack gas velocity (Vs, see the beginning of the Method 2 section), you can find

the volumetric flow rate. Begin by determining the area (As) for a circular stack with this equation:

48

Where π = 3.14159

Ds = Diameter of a circular stack

The formula to find the area of a rectangular stack is:

Where L = Length of a rectangular stack

W = Width of a rectangular stack

Now, you can calculate the stack gas volumetric flow rate (actual, standard, and dry standard) using the

following equations:

Where Qa = Volumetric flow rate, actual, m3/min (acf/min)

Vs = Average stack gas velocity, m/sec (ft/sec)

As = Area of the stack

Qs = Volumetric flow rate, standard, sm3/min (scf/min)

Ks = A constant of 21.553 for metric units (1058.8 for English units), used to convert

time to minutes and P/T (pressure divided by temperature) to standard

conditions


Ps = Absolute stack gas pressure (Pbar + Pg/13.6), mm Hg (in. Hg)



Qsd = Volumetric flow rate, dry standard, dsmm3/min (dscf/min)

Bws = Water vapor in the gas stream (from Method 4 (reference method) or Method

5), proportion by volume.

49

Method 3

Gas Analysis for Dry Molecular Weight

Method 3 is used to measure the percent concentrations of carbon dioxide (CO2), oxygen (O2), and carbon

monoxide (CO) if greater than 0.2%. Nitrogen (N2) is calculated by difference. With this data, you can calculate

the stack gas dry molecular weight, or density, and then apply that data to the equation for stack gas velocity.

There are three options for determining dry molecular weight:

1. Sample and analyze,

2. Calculate O2 and CO2 concentrations stoichiometrically for combustion sources, or

3. Use a dry molecular weight value of 30.0 if burning fossil fuels (coal, oil, or natural gas).

From the gas composition data, you can calculate the amount of excess air for combustion sources. In

jurisdictions where particulate emissions are regulated on a concentration basis, such as mg/m3, use the gas

composition data to correct the concentration results to a reference diluent concentration, for example 7% O2

or 12% CO2. Note: Before beginning, you first must have a thorough knowledge of Method 1 procedures,

which are referenced in Method 3.

Options for Collecting Stack Gas Sample

Use one of three options to collect the stack gas sample:

1. Grab-sampling stack gas from a single traverse point with a one-way squeeze bulb and loading it

directly into the analyzer. You also can use this technique to measure gas composition at individual

traverse points to determine if stratification exists.

2. Integrated sampling from a single traverse point into a flexible leak-free bag. This technique

recommends collecting at least 30 liters (1.00 cu. ft.); however, you may collect smaller volumes if

desired. Constant rate sampling is used.

3. Integrated sampling from multiple traverse points in a flexible leak-free bag. Use this technique

when conducting a Method 5 particulate traverse and using the Orsat gas collection line built onto the

probe assembly. Sample volume and rate recommendations are the same.

Analyze gas samples using either an Orsat or Fyrite analyzer. Figure 2-17 on the next page depicts the options

for sample collection and analysis.

50

Figure 2-17: Method 3 Sampling and Analysis Options

Compare Orsat and Fyrite Analyzers

Both the Orsat Analyzer and Fyrite Analyzer are gas absorption analyzers that measure the reduction in liquid

volume when a gas sample is absorbed and mixed into a liquid solution. They differ in the following ways:

● The Fyrite Analyzer uses separate gas absorption bulbs for O2 and CO2, while the Orsat Analyzer

(Model VSC-33) contains all three absorption bubblers for O2, CO2, and CO in a single analyzer train.

● The Orsat provides a more accurate analysis of gas composition, and is required by Method 3B when

pollutant concentration corrections are made for regulatory purposes.

● The Orsat analyzer does not typically measure the CO concentration for two reasons:

○ First, the detection limit of the analyzer is 0.2% by volume (2,000 ppmv), which is well above

most modern combustion source CO concentrations.

○ Secondly, the molecular weight of CO is the same as N2 (28 g/g-mole). Thus, the balance of

gas can be applied to N2 without any change in calculation of molecular weight.

Figure 2-18 on the next page illustrates an Orsat Analyzer connected to a bag sample collection enclosure. For

a more detailed discussion of gas analysis using an Orsat Analyzer, please refer to Apex Instruments’

Sampling Options

Gas Analysis

Options Single-point

Grab Sampling

Single-Point Integrated

Sampling

Multi-Point Integrated Sampling

Orsat Analyzer

Fyrite Analyzer

Bag Sample

51

Combustion Gas (ORSAT) Analyzer, Model VSC-33, User’s Manual and Operating Instructions, or the

operating instructions provided with the Fyrite Analyzer.

Figure 2-18: Illustration of Orsat Analyzer and Gas Sample Bag Container

Determine Dry Molecular Weight

Calculate the dry molecular weight (Md) of stack gas with the following equation:

Where 0.44 = Molecular weight of CO2, divided by 100

%CO2 = Percent CO2 by volume, dry basis

0.32 = Molecular weight of O2, divided by 100

%O2 = Percent O2 by volume, dry basis

0.28 = Molecular weight of N2 or CO, divided by 100

%N2 = Percent N2 by volume, dry basis

%CO = Percent CO by volume, dry basis

52

Method 4

Moisture Content of Stack Gas

Method 4 is used to determine the moisture content of stack gas, which is needed to calculate emission data.

A gas sample is extracted at a constant rate from the source, moisture is removed from the sample stream,

and moisture content is determined either volumetrically or gravimetrically. Before using this method, you

should have a thorough knowledge of at least Methods 1, 5 and 6.

There are two separate procedures for determining moisture content in stack gases:

➢ The Reference Method, which gives accurate measurements of moisture needed to calculate emission

data, and

➢ The Approximation method, which gives a close estimate of percent moisture to aid in setting

isokinetic sampling rates before a pollutant emission sampling run.

The approximation method is only a suggested approach. There are acceptable alternatives for approximating

moisture content, for example:

● Wet bulb/dry bulb techniques (applicable to gas streams less than 100°C),

● Stoichiometric calculations (applicable to combustion sources),

● Condensation techniques,

● Drying tubes, and

● Previous experience testing at a stack.

Equipment Set-Up for the Reference Method

Select either of the following sampling trains when setting up equipment for the Reference Method:

➢ The Isokinetic Source Sampling System (Hot Box and Cold Box), equipped with Probe Assembly

without nozzle, and a filter bypass piece of glassware (GN-13) instead of a filter assembly (you may

use a filter if particulate levels are high), or

➢ The Basic Method 4 Test Kit, which includes a Cold Box, Sample Frame with Probe Clamp (SB-8),

and Umbilical Adapter with power connector (GA-103), as shown in Figure 2-19 on the next page.

With this set-up, you can use either a standard heated Probe Assembly or a heated CEM probe (without

a pitot tube).

53

Did you know? The Reference Method is almost always performed simultaneously

with a pollutant emission measurement run. You also can use the Reference Method

when you need to correct to a dry basis your continuous monitoring for pollutants

such as SO2, NOx or O2.


Although glass impingers are typically used as the

condenser section in Method 4 and other isokinetic

methods, you can replace them with a stainless steel

equivalent coil condenser (S-4CN), which results in a

rugged and reliable system without the fragility of the

traditional glass assembly.

54

Figure 2-19: Set-up of Cold Box with Sample Frame and Probe Clamp

Method 4 Reference Method

Use the following procedure for accurate measurements of moisture content:

Part 1: Preparation

1. Select the appropriate minimum number of traverse points and locate them according to Method 1:

a. Eight (8) traverse points for circular ducts less than 60 cm (24 in.) in diameter.

b. Nine (9) for rectangular ducts less than 60 cm (24 in.) in equivalent diameter.

c. Twelve (12) for all other cases.

2. Transfer about 100 ml of water into the first two impingers. Leave the third impinger empty. Weigh

each impinger to the nearest 0.5 g.

3. Transfer 200-300 g of silica gel into the fourth impinger. Weigh it to the nearest 0.5 g.

4. Select a total sampling time that allows you to collect a minimum total gas volume of 0.60 scm (21

scf) at a rate no greater than 0.021 m3/min (0.75 cfm). Perform moisture sampling simultaneously

with the pollutant emission rate test run (and for the same length of time).

5. If the gas stream is saturated or contains moisture droplets, attach a temperature sensor (± 1.3°C) to

the probe or check the saturation moisture at the measured stack temperature. See Step 4 below.

Part 2: Sampling

1. Assemble and set up the sampling train.

2. Turn on the probe heater and, if applicable, the filter heating system to temperatures of about 120°C

(248°F). Allow time for the temperatures to stabilize. Place crushed ice in the ice bath container

(Cold Box) around the impingers.

3. Optional: Leak-check the sampling train by disconnecting the probe from the first impinger or, if

applicable, from the filter holder. Plug the inlet to the first impinger (or filter holder) and pull a 380

mm (15 in.) Hg vacuum. It is not acceptable to have a leakage rate greater than 4% of the average

55

sampling rate, or 0.00057 m3/min (0.020 cfm),

whichever is less. If the leakage rate exceeds the

allowable rate, either reject the test results or correct the

sample volume as in section 12.3 of Method 5.

Following the leak check, reconnect the probe to the

sampling train.

4. Position the probe tip at the first traverse point. Sample

at a constant (± 10%) flow rate. Record data on a field

data sheet.

5. Traverse the cross-section, sampling at each traverse

point for an equal period of time.

6. Add more ice and, if necessary, salt to maintain a

temperature of less than 20°C (68°F) at the silica gel

impinger exit.

7. After the last traverse point of the cross-section, turn off

the sample pump, switch to the next sample port, and repeat steps 5 and 6 above.

8. After completing sampling, disconnect the probe from the first impinger (or from the filter holder).

9. Mandatory: Leak-check the sampling train, as required at the end of the run (see step 3 above).

Part 3: Sample Recovery

1. Disassemble the impinger glassware and weigh each impinger to the nearest 0.5 g. Record weight

data on a field data sheet.

2. Verify constant sampling rate.

3. Calculate the stack moisture percentage (refer to the stack gas moisture equations at the end of the

Method 4 section).

In the Case of Saturated or Moisture Droplet-Laden Gases:

1. Measure the stack gas temperature at each traverse point. Calculate the average stack gas temperature

by adding all of the readings and dividing by the number of traverse points.

2. Determine the saturation moisture content by either:

a. Using saturation vapor pressure tables or equations, or

b. Using a psychrometric chart and making appropriate corrections if stack pressure is different

from what is found on the chart.

3. Use the lower of these values or the value from Part 3 above.


Make sure to wipe off

moisture from the outside

of each impinger before

weighing it. Do not weigh

impingers with U-tubes

connected.

56

Method 4: Approximation Method

The Method 4 approximation method specifies use of midget impingers and a Source Sampler Console sized

for midget impinger trains, such as the one used for Method 6 sampling of SO2.

Use the following procedures to make approximate measurements of moisture content:

Midget Impinger Train

Part 1: Preparation

1. Transfer about 5ml of water into each impinger (2) and weigh each impinger to the nearest 0.5 g.

2. Assemble the sampling train.

3. Connect a pre-weighed drying tube to the back of the impinger train.

Part 2: Sampling



(248°F). Allow time for the temperatures to stabilize. Place crushed ice in the ice bath container (Cold

Box) around the impingers.

3. Optional: Leak-check the sampling train by disconnecting the probe from the first impinger or, if

applicable, from the filter holder. Plug the inlet to the first impinger (or filter holder) and pull a 380

mm (15 in.) Hg vacuum. It is not acceptable to have a leakage rate greater than 4% of the average

sampling rate, or 0.00057 m3/min (0.020 cfm), whichever is less. If the leakage rate exceeds the

allowable rate, either reject the test results or correct the sample volume as in section 12.3 of Method

5. Following the leak check, reconnect the probe to the sampling train.

4. Position the probe tip well into the stack. Sample at a constant (± 10%) flow rate of twenty-one (21)

lpm until the dry gas meter registers about 30 liters, or until visible liquid droplets carry over from the

first impinger to the second. Record initial and final data on a field data sheet.

5. Add more ice and, if necessary, salt to maintain a temperature of less than 20°C (68°F) at the silica gel

impinger exit.

6. Mandatory: Leak-check the sampling train as described in Step 3 above. After the leak-check,

reconnect the probe to the sampling train.


Did you know? Many stack testers perform preliminary moisture measurements for

input into their isokinetic calculations nomograph by using a full-size sampling train

and collecting approximately 0.283 sm3 (10scf) of gas sample. These runs take about

15 to 20 minutes.

57

1. Disassemble the impinger glassware and weigh each impinger or drying tube to the nearest 0.5 g.

Record weight data on a field data sheet.


3. Calculate the stack gas moisture percentage (see the equations at the end of this section).

Large Impinger Train

Part 1: Preparation

1. Transfer about 100ml of water into the first two impingers. Leave the third impinger empty and

weigh each impinger to the nearest 0.5 g.

2. Transfer 200-300 g of silica gel to the fourth impinger and weigh to the nearest 0.5 g.

Part 2: Sampling



(248°F). Allow time for the temperatures to stabilize. Place crushed ice in the ice bath container

(Cold Box) around the impingers.

3. Optional: Leak-check the sampling train from the first impinger inlet or, if applicable, the filter

holder (see leak-check procedures described in the Midget Impinger Train section on the previous

page).

4. Position the probe tip well into the stack. Sample at a constant (± 10%) flow rate of less than twenty-

one (21) lpm (0.75 cfm) until the dry gas meter registers 0.283 m3 (10 cf). Record initial and final

data on a field data sheet.

5. Add more ice and, if necessary, salt to maintain a temperature of less than 20°C (68°F) at the silica

gel impinger exit.

6. Mandatory: Leak-check the sampling train (as detailed in Part 2, Step 3 on the previous page).


1. Disassemble the impinger glassware and weigh each impinger or drying tube to the nearest 0.5 g.

Record weighing data on a field data sheet.


3. Calculate the stack gas moisture percentage (see equations next page).

58

Equations for Calculating Stack Gas Moisture Content

To calculate the stack gas moisture content (Bws), first use the following equations to compute the sample gas

volume (Vm(std)) and gas moisture volume (Vwc(std)):

Calculate sample gas volume:

where K3 = 0.3858 °K/mm Hg (metric units), or 17.64 °R/in. Hg (English Units)

Y = Dry gas meter calibration factor

Vm = Dry gas volume measured by dry gas meter, dcm (dcf)


ΔH = Average orifice tube pressure during sampling, mm H2O (in. H2O)

Tm = Absolute temperature at dry gas meter, °K (°R)

Calculate gas moisture volume:

where K2 = 0.001335 m3/g (metric units), or 0.04715 ft3/g (English units)

Wf = Final weight of water collected, g

Wi = Initial weight of water collected, g

Calculate stack gas moisture content:

where Bws = Proportion of water vapor, by volume, in the gas stream

Vm(std) = Sample gas volume

59

Vwc(std) = Gas moisture volume

Method 5

Determination of Particulate Emissions

Method 5 involves withdrawing particulate matter (PM) isokinetically from the source and collecting it on a

temperature-controlled glass fiber filter. The PM mass is determined gravimetrically after the removal of

uncombined water. To perform Method 5, you must have a thorough understanding of Methods 1, 2 and 3.

To maintain an isokinetic sampling rate, you will need to calculate the appropriate probe nozzle size and the

optimal ratio of orifice tube pressure (ΔH) to stack gas velocity (Δp). This ratio is called K-factor.

Determine nozzle size and K-factor in one of the following ways:

➢ Calculate by hand or on a worksheet (see worksheets in Appendix D).

➢ Use a specially designed stack testing slide rule nomograph (M5A-1M or M5A-1), as shown in

Figure 2-21.

➢ Use a pre-programmed handheld calculator (M5A-C).

➢ Input figures into specialized spreadsheets for data collection and reduction (ISOCALC 2.0) using a

personal or laptop computer, as shown in Figure 2-21.

Figure 2-21: Stack Sampling Slide Rule and Laptop Computer with IsoCalc 2.2

Preliminary Data Needed For Isokinetic Sampling

The following preliminary information is needed before you can determine the nozzle size and calculate the

K-factor:

➢ Δpavg: Average stack gas velocity head. Measure this before the sample run, or take it from a

previous test.

➢ Bws: Stack gas moisture fraction, or percent (%H2O). Determine this from a preliminary run, previous

test, or calculate it (see Method 4).

60

➢ Md: Stack gas dry molecular weight. Use a value from a preliminary run, previous test, or estimate it

(see Method 3).

➢ Ps: Stack gas pressure. Measure this before the sample run, or use barometric pressure if the static

pressure of the stack is very low (such as when sample ports are near the stack exit).

➢ ΔH@: Source Sampler Console orifice calibration factor. This is determined from the laboratory

calibration and should be readily available on-site (see Calibrations).

➢ Tm: Meter temperature. Temperature at the meter rises about 14°C (25°F) above ambient temperature

due to heat from the vacuum pump. Measure the ambient temperature at the Source Sampler Console

site.

➢ Pm: Meter pressure. Same as barometric pressure.

Probe Nozzle Size Calculation

The equation most commonly used for calculating the probe nozzle size is:

where Dn = Nozzle diameter, mm (in.)

K5 = 0.6071 (metric units) or 0.03575 (English units)

Qm = Test meter volume flow rate reading, m3/min (ft3/min)

Pm = Test meter average static pressure, mm Hg (in. Hg)

Tm = Average DGM temperature, °K (°R)

Cp = Pitot tube calibration coefficient, dimensionless

Bws = Water vapor in gas stream (Method 4 or alternative), proportion by volume

Ts = Average stack gas temperature, °K (°R)

Ms = Molecular weight of stack gas, wet basis, g/g-mole (lb/lb-mole)

Ps = Absolute stack or duct pressure, mm Hg (in. Hg)

Δpavg = Average stack gas velocity head

61

K-Factor Calculations

After selecting the appropriate nozzle from the Nozzle Set (shown in

Figure 2-22), calculate the K-factor ratio used to maintain an

isokinetic sampling rate at each traverse point for the sampling test

run. K-factor refers to the ratio of ΔH/Δp such that ΔH = KΔp. Use

the following equation:

where ΔH = Average orifice tube pressure during

sampling, mm H2O (in. H2O)

Δp = Average stack gas velocity head

K6 = 0.0000804 (metric units) or 849.842 (English units)

Dn = Nozzle diameter, mm (in.)

ΔH@ = Source Sampler Console orifice calibration factor

Cp = Pitot tube calibration coefficient, dimensionless

Bws = Water vapor in gas stream (Method 4 or alternative), proportion by volume

Md = Molecular weight of stack gas, dry basis, g/g-mole (lb/lb-mole)

Tm = Average DGM temperature, °K (°R)

Ps = Absolute stack or duct pressure, mm Hg (in.

Hg)

Ms = Molecular weight of stack or duct gas, wet

basis, g/g-mole (lb/lb-mole)

Ts = Average stack gas temperature,

°K (°R)

Pm = Test meter average static

pressure, mm Hg (in. Hg)

Important: Check the total sampling time (number of traverse

points multiplied by minutes per point) as well as the final


You may need to

experiment with selecting

K-factors and/or nozzle

sizes that will yield an

acceptable sampling

volume and time.

Figure 2-22: Probe Nozzle Set

62

estimated gas sample volume (Vm(std)) against any applicable environmental regulations to see if you have

met acceptable minimum sampling times and volumes.

Method 5 Test Procedure

Part 1: Pre-Test Preparation (Before Traveling to Site)

1. Check filters visually against light for irregularities, flaws or pinhole leaks. Label the filters on the back

side near the edge using numbering machine ink.

2. Desiccate the filters at 20° ± 5.6°C and ambient pressure for more than 24 hr. Then weigh them at

intervals of greater than 6 hours to a constant weight (less than 0.5 mg change from previous weighing).

Record results to the nearest 0.1 mg. During each weighing, do not expose the filter to the laboratory

atmosphere for more than 2 minutes, or to a relative humidity of more than 50%.

3. Optional: If you are measuring condensable or back-half particulate matter, run analytical blanks of

the deionized/distilled water to eliminate a high blank on actual test samples.

4. Clean the Probe Liners and Probe Nozzles internally by brushing first with tap water, then

distilled/deionized water, followed by reagent-grade acetone. Rinse the Probe liner with acetone and

allow to air-dry. Inspect visually for cleanliness and repeat the procedure if necessary. Cover the Probe

Liner openings to avoid contamination. Keep nozzles in a case to avoid contamination or damage to

the knife-edge.

Note: Special cleaning procedures may be required for other test methods (for example, metals or

dioxin).

5. Clean the Glassware (Filter Assemblies, Impingers and Connecting Glassware) internally by wiping

grease from the joints, washing with glass cleaning detergent, rinsing with distilled/deionized water,

and then rinsing again with reagent-grade acetone, before allowing to air-dry. To avoid contamination,

cover all exposed openings with parafilm, plastic caps, serum caps, ground-glass stoppers or aluminum

foil (do not use foil with metals).

Note: Special cleaning procedures may be required for other test methods (for example, metals or

dioxin).

Part 2: Preliminary Determinations

1. Select the sampling site, measure the stack or duct dimensions and determine the number of traverse

points (see Method 1).

2. Determine the stack gas pressure, range of velocity pressure heads and temperature (see Method 2).

3. Select the proper differential pressure gauge (see Method 2).

4. Determine or estimate the dry molecular weight (see Method 3).

5. Determine the moisture content (see Method 4).

6. Select a suitable Probe Assembly length such that all traverse points can be sampled.

63

7. Select a nozzle size and determine the K-factor for an isokinetic sampling rate. Important: Do not

change the nozzle size during the sampling run.

8. Select the total sampling time and standard gas sample volume specified in the test procedures for the

specific industry. Select equal sampling times of more than 2 minutes per traverse point.

Part 3: Preparation of Sampling Train

1. Mark the Probe Assembly with heat-resistant tape or “Wite-Out” to denote the proper distance into the

stack or duct for each sampling point (See Method 1).

2. Insert the Probe Nozzle into the probe sheath union and hand-tighten the union fitting. Avoid over-

tightening to prevent cracking of the glass probe liner. Keep the nozzle tip and ball joint on the glass

probe liner covered until you complete the train assembly and are about to begin sampling. Secure the

Probe Assembly to the Sample Case by tightening the probe clamp.

3. Prepare each set of impingers for a sampling run:

a. Impingers 1 & 2: 100 ml water in each

b. Impinger 3: Empty

c. Impinger 4: 200 to 300 g of silica gel

TIP: You can prepare more than one sampling run at once by using multiple sets of glassware!

4. Weigh each impinger to the nearest ± 0.5 g using a top-loading electronic balance (BAL-1200) and

record initial weights on a field data sheet.

Figure 2-23: Top-Loading Electronic Balance

5. Assemble the impingers in the Cold Box with U-tubes, Double “L” Adapter, and the Sample

Case/Umbilical Adapter, using Ball Joint Clamps or Clips. See Figure 2-24.

64

Figure 2-24: Top View of Assembled Impingers

Figure 2-25: Exploded View of Filter Assembly

6. Using tweezers or clean disposable surgical gloves, place the tared filter on the grooved (inlet) side of

the Teflon Frit (TFE) filter support in the Filter Holder. Check the filter for tears after placement, and

center it on the filter support. Assemble the Filter Holder (as shown in Figure 2-25), and tighten the

clamps around the Filter Holder to prevent leakage around the O-ring. Record filter number on the field

data sheet.

7. Using Ball Joint Clamps, connect the Filter Holder and Cyclone Bypass (GN-1) in the Hot Box to the

Probe Liner ball joint and to the “L” Adapter. Close the Hot Box doors and fasten shut.

Figure 2-26: Assembled Sampling Train Before Umbilical Hookup

65

8. Connect the Umbilical Cable electrical and pitot tube lines to the assembled sampling train and to the

Source Sampler Console. If applicable, also connect the Orsat line.

9. Place the assembled sampling train near the first sample port, either on the monorail or with other

support.

10. Turn on and set Probe and Hot Box heaters. Allow the Hot Box and Probe to heat for at least 15 minutes

before starting the test, and then make periodic checks and adjustments to ensure the desired

temperatures. Check all thermocouple connections by dialing through each selection and noting

ambient or heated temperatures. Place crushed ice and a little water around the impingers.

11. Optional: Leak-check the sampling train (see Leak-Check Procedure for Isokinetic Sampling Trains in

Reference Method 4 on page 50, and Pitot Tube and Line Leak-Check Procedures in Method 2 on page

41).

Part 4: Sampling Run Procedure

1. Open and clean the portholes of dust and debris.

2. Level and zero manometers that gauge Δp (avg. stack gas velocity head) and ΔH (avg. orifice tube

pressure).

3. Record data on a field data sheet. Record the initial dry gas meter (DGM) reading.

4. Remove the nozzle cap, verify that the Hot Box/filter and probe heating systems are up to temperature,

and check alignments and clearances for the pitot tube, temperature gauge and probe.

5. Close the Coarse Valve and fully open the Fine Increase Valve. Position the nozzle at the first traverse

point. Record the clock time, read Δp on the manometer, and determine ΔH from the nomograph.

6. Immediately start the pump and adjust the flow to set the orifice tube pressure (ΔH), first by adjusting

the Coarse Valve and then the Fine Increase Valve.

Note: If necessary to overcome high negative stack pressure, turn on the pump while positioning the

nozzle at the first traverse point.

7. When the probe is in position, block off the openings around the probe and porthole using duct tape,

rags, gloves or towels (make sure the materials are flameproof for hot stacks).

66

Figure 2-27: Blocking off the Porthole During Sampling

8. Record readings for the ΔH manometer and pump vacuum, as well as temperatures for stack gas, DGM,

filter box, probe, and impinger exit.

9. Record the ID numbers for the DGM, thermocouples, pitot tube, and Sample Box.

10. If simultaneously running a Method 3 gas bag collection, turn on the Orsat pump. Turn Orsat pump off

during port changes.

11. Traverse the stack cross-section for the same time period at each point without turning off the pump,

except when changing ports.

Important: Do not bump the probe nozzle into the stack walls.

a. Make periodic adjustments to maintain the Hot Box temperature (around the filter holder) at

the proper level.

b. Monitor the Δp (gas velocity head) during sampling of each point. If the Δp changes by more

than 20%, record another set of readings.

c. Periodically check the level and zero of the manometers and readjust if necessary.

d. Record DGM readings at the beginning and end of each sampling time increment, before and

after each leak-check, and when sampling is halted.

e. Take other readings (ΔH, temps, vacuum) at least once at each sample point during each time

increment to ensure the ΔH/Δp isokinetic ratio is maintained.

f. Add more ice and, if necessary, salt to maintain a temperature of less than 20°C (68°F) at the

silica gel impinger exit.

12. At the end of the sample run, turn off the Coarse Valve, remove the probe and nozzle from the stack,

turn off the pump and heaters, and record the final DGM reading.

13. Mandatory: Leak-Check the sampling train (See Method 4, page 50) at the maximum vacuum achieved

during the sample run. Record leak-check results on field data sheet.

14. Mandatory: Leak-Check the pitot lines (See Method 2, page 41). Record results on field data sheet.

15. Allow the probe to cool. Wipe off all external particulate material near the tip of the probe nozzle and

cap the nozzle to prevent contamination or sample loss.

Hint: Open the Hot Box doors to allow the filter holder to cool.

16. Before moving the sampling train to the clean-up site, disconnect the probe from the Cyclone Bypass

inlet and cover both ends. Avoid losing any condensate that might be present. Disconnect the Filter

Holder from the “L” Adapter and cap off the Filter Holder.

17. Disconnect the Umbilical Cable from the Sample Box and cover the last impinger outlet and first

impinger inlet. Disconnect the Cold Box from the Hot Box. Now, the Probe/Nozzle Assembly, Filter

Holder, and impinger case are ready for sample recovery.

18. Transfer the probe and filter-impinger assembly to an area that is clean and protected from the wind.

Part 5: Variations and Alternatives

67

1. Acceptable alternatives to glass probe liners are metal liners; for example, 316 stainless steel, Inconel,

or other corrosion-resistant metals made of seamless tubing. These liners can be useful for cross-

sections over 3 m (10 ft.) in diameter.

2. For large stacks, consider sampling from opposite sides of the stack to reduce the length of the probe.

3. Use either borosilicate or quartz glass probe liners for stack temperatures from 480° to 900°C (900–

1,650°F). The softening temperature for borosilicate glass is 820°C (1,508°F); for quartz, it is 1,500°C

(2,732°F).

4. Rather than labeling filters, label the shipping containers (glass or plastic petri dishes) and keep the

filters in these containers at all times except during sampling and weighing.

5. Use more silica gel in impinger 4, if necessary, but ensure that there is no entrainment or loss during

sampling.

Hint: Loosely place cotton balls or glass wool in the neck of the silica gel impinger outlet stem to avoid

spillage.

6. If you are using a different type of condenser (other than impingers), measure the amount of moisture

condensed either volumetrically or gravimetrically.

7. For moisture content, measure the impinger contents volumetrically before and after a sampling run.

Use a pre-weighed amount of silica gel in a shipping container. Then, after the run, empty the silica gel

back into the container for weighing at another time.


Whenever practical, make

every effort to use

borosilicate glass or

quartz probe liners. Metal

liners will bias particulate

matter results higher than

actual.

68

Figure 2-28: Recover Silica Gel for Weighing Figure

2-29: Determine Moisture Volumetrically

8. If you expect the total particulate catch to

exceed 100 mg or more, or when water droplets

are present in the stack gas, use a Glass Cyclone

between the probe and Filter Holder.

9. If you have difficulty maintaining isokinetic

sampling due to high pressure drops across the

filter (with a high vacuum on the gauge), replace

the filter.

10. Use a single train for the entire sampling run,

except when:

a. Simultaneous sampling is required in

two or more separate ducts, or

b. Simultaneous sampling is required at

two or more different locations within

the same duct, or

c. Equipment failure necessitates a change in trains.

In all other situations, obtain approval from the regulatory agency before using two or more trains.

11. When using two or more trains, analyze separately the front-half and (if applicable) impinger catches

from each train, unless you used identical nozzle sizes on all trains. In this case, you may combine the

front-half catches (and the impinger catches) and perform one analysis of the front-half catch and one

analysis of the impinger catch. Consult with the regulatory agency for details concerning the calculation

of results when using two or more trains.

12. If using a flexible line between the first impinger or condenser and the Filter Holder, disconnect the

line at the Filter Holder and let any condensed water or liquid drain into the impingers or condenser.

13. Do not cap off the probe tip too tightly while the

sampling train is cooling down as this would

create a vacuum in the Filter Holder, which may

draw water from the impingers into the Filter

Holder.


Note: Sample Recovery is an extremely important step

that requires a high level of precision. If sample loss

occurs, your results will be biased low, and if sample

contamination occurs, your results could be biased

high.


You can opt to use another filter

assembly, rather than changing the

filter itself. Remember to conduct a

leak-check before installing a new

filter. Add the filter assembly

catches to the total particulate matter

weight.


Instead of trying to catch the probe

rinse with a glass funnel and sample

container (which can easily result in

sample loss), clamp an Erlenmeyer

flask outfitted with a female ball joint

on the probe liner ball joint when

conducting the probe rinse

procedure. If the probe is short, one

person can perform the brushing and

rinsing.

69

1. Place 200 ml of acetone from the wash bottle you are using for clean-up in a glass sample container

labeled “Acetone Blank.”

2. Inspect the train prior to and during disassembly and note any abnormal conditions on the data sheet.

3. Container No. 1: Filter

a. Using a pair of tweezers (TW-1) and/or clean disposable surgical gloves, carefully remove the

filter from the Filter Holder and place it in its identified petri dish container. If necessary, fold

the filter so that the particulate matter cake is inside the fold.

b. Using a nylon bristle brush (DB-3) and/or a sharp-edged blade (LS-1), carefully transfer to the

petri dish any particulate matter (PM) and/or remaining pieces of filter or filter fibers that

adhered to the filter support or gasket.

4. Container No. 2: Acetone Rinses

Note: Recover all of the rinses listed here in a single glass container.

a. Recover any PM from the internal surfaces of the Probe Nozzle, swaged union fitting, front half

of the Filter Holder, cyclone (if applicable), and probe liner (use a glass funnel to aid in

transferring the liquid wash to the container, see figure 2-30).

b. Before cleaning the front half of the Filter Holder, wipe all joints clean of silicone grease.

c. Rinse with acetone, brush with a small nylon bristle brush, and rinse with acetone again until

there are no visible particles (see figures 2-31 and 2-32). Make a final acetone rinse.

d. For the probe liner, repeat the rinse-brush-rinse sequence at least three times for glass liners and

six times for metal liners.

e. Make a final rinse of the probe brush with acetone.

f. For the Probe Nozzle, use the nylon nozzle brush and follow the same sequence of rinse-brush-

rinse as with the probe liner.

g. After completing the rinse, tighten the lid on the sample container. Mark the height of the fluid

level and label the container.

70

Figure 2-30: Sample Recovery from Probe Liner

Figure 2-31: Rinsing Probe Nozzle

Figure 2-32: Brushing Probe Nozzle

Figure 2-33: Front Half of Acetone Rinse Samples

5. Container No. 3: Silica Gel

a. Determine whether silica gel has been completely spent, and note its condition and color on

the data sheet.

b. Discard and reload the impinger. Alternatively, you can reuse the impinger in the next run,

using the final weight from this run as the initial weight for the new sampling run.

6. Impinger Water

a. Note on the data sheet any color or film in the liquid catch.

71

b. Discard the liquid, unless you are required to do an analysis of the impinger catch. Store as is

appropriate.

Note: Whenever possible, ship sample containers in an upright position.

Calculations at the End of the Sampling Run

At the conclusion of each sampling run, it is prudent to calculate the stack gas moisture (for the next

sampling run), as well as the average isokinetic rate.

To calculate the stack gas moisture content (Bws), use the following equations to compute the sample gas

volume (Vm(std)) and gas moisture volume (Vwc(std)):

Sample Gas Volume:

where K3 = 0.3858 °dK/mm Hg (metric units), or 17.64 °R/in. Hg (English units)

Y = Dry gas mater calibration factor

Vm = Dry gas volume measured by dry gas meter, dcm (dcf)


ΔH = Average orifice tube pressure during sampling, mm H2O (in. H2O)

Tm = Absolute temperature at dry gas meter, °K (°R)

Gas Moisture Volume:

where K2 = 0.001335 m3/g (metric units), or 0.04715 ft3/g (English units)

Wf = Final weight of water collected, g

Wi = Initial weight of water collected, g

Stack Gas Moisture Content:

72

where Bws = Proportion of water vapor, by volume, in the gas stream

Vwc(std) = Gas moisture volume (see equation above)

Vm(std) = Sample gas volume (see equation at top of page)

Average Stack Gas Velocity:

Next, calculate the average stack gas velocity. The equation for average gas velocity in a stack or duct is:

where Vs = Average stack gas velocity, m/sec (ft/sec)

Kp = Constant, 34.97 for metric system (85.49 for English system)

Cp = Pitot tube coefficient, dimensionless

(√Δp)avg = Average of the square roots of each stack gas velocity head


Ps = Absolute stack gas pressure, mmHg (in. Hg), calculated with the equation:

Ps = Pbar + Pg/13.6



Ms = Molecular weight of stack on wet basis, g/g-mole (lb/lb-mole), calculated with

the equation: Ms = Md (1-Bws) + 18.0 (Bws)

Md = Molecular weight of stack on dry basis, g/g-mole (lb/lb-mole)

Bws = Proportion of water vapor, by volume, in the gas stream

Isokinetic sampling rate:

The average percent isokinetic sampling rate is calculated as:

73

where K4 = 4.320 (metric units) or

0.09450 (English units)

Ts = Absolute average stack

gas temperature, °K (°R)

Vm(std) = Sample gas volume

Ps = Absolute stack gas

pressure, mmHg (in. Hg), calculated

with the equation:

Ps = Pbar + Pg/13.6

Pbar = Barometric pressure at

measurement site, mm Hg (in. Hg)

Pg = Stack static pressure,

mm H2O (in. H2O)

Vs = Average stack gas

velocity, m/sec (ft/sec)

An = Cross-sectional area of

the nozzle, m2 (ft2)

θ = Sampling time, minutes

Bws = Proportion of water vapor, by volume, in the gas stream

Recommended Reading List for Isokinetic Sampling

● Code of Federal Regulations. Title 40. Part 60, Appendix A. Office of the Federal Register. National

Archives and Records.

● Compliance Test Coordination and Evaluation. Workshop Manual. U.S. Environmental Protection

Agency. APTI 01-94a. 1994.

● Jahnke, J. A., et al. Source Sampling for Particulate Pollutants. Student Manual, APTI Course 450.

Edition 3.0. Raleigh, NC: North Carolina State University, 1995.


During port changes, many stack testers scan or

quickly average values for p, H, stack gas

temperature, and DGM temperature to calculate %I

before the sampling run is finished (this all assumes

that Bws will not change substantially). Some

sophisticated calculator programs and most laptop

computer programs monitor %I for each point and

cumulatively.

74

● Manual for Coordination of VOC Emissions Testing Using EPA Methods 18, 21, 25, and 25A. U.S.

Environmental Protection Agency. EPA 340/1-91-008. September 1991.

● Quality Assurance Handbook for Air Pollution Measurement Systems. Vol. 3. Stationary Source

Specific Methods, Section 3.4. U.S. Environmental Protection Agency. EPA-600/4-77-027b. 1988.

● Rom, J. J. Maintenance, Calibration, and Operation of Isokinetic Source Sampling Equipment.

Publication No. APTD-0576. Office of Air Programs. U.S. Environmental Protection Agency.

Research Triangle Park, NC. 1972

Chapter 3

Calibration and Maintenance

Establishing and adhering to a routine maintenance program is beneficial in two ways. First, properly

maintaining the isokinetic sampling system helps to ensure trouble-free operation. Secondly, carefully

documenting your maintenance and calibration system will help you obtain the most accurate results during

stack testing activities.

This chapter describes calibration, maintenance and troubleshooting procedures for the various subsystems of

the isokinetic sampling system.

Calibration Procedures

It is critical to create and maintain a regularly scheduled calibration and record-keeping protocol for your

stack testing program. If you fail to ensure proper calibrations, you will not be able to verify that the test was

conducted isokinetically and your stack emission test results will be meaningless.

The results of a particulate sampling test cannot be checked for accuracy because no independent technique

or test atmosphere exists to provide a standard or known particle concentration. Collaborative testing

conducted by the US EPA has determined that the interlaboratory standard deviation is ± 12.1%. Only

through careful calibration, maintenance and record keeping can you ensure that the data collected during the

stack test is representative of the site’s particle concentrations and mass emission rate.

The particulate sampling system components that require calibration are:

1. Dry Gas Meter and Orifice Tube,

2. Thermocouples (Stack, Probe, Filter Box, Impinger Exit, and Dry Gas Meter) and Digital

Temperature Indicator,

3. Pitot Tube,

75

4. Sampling Nozzles, and

5. Probe and Filter Box Heater System.

Table 3-1 presents a summary of the components that require calibration and the equipment used to do so, as

well as acceptable calibration factor limits, recommended calibration frequency, and steps to take if your

system fails to meet calibration acceptance limits.

Component

Calibrated Against

Calibration Factor

Y Acceptance Limits Frequency

Action If

Unacceptable

Dry Gas Meter Initial 5-point

1. Wet Test Meter 2. Secondary Reference DGM

Yi = Y ± 0.05Y Semiannually Recalibrate, repair

or replace

Post-test 3-point 1. Wet Test Meter 2. Reference DGM 3. Critical Orifices

Y = Y ± 0.05Yavg After each field

test Recalibrate at 5-

points

Orifice Tube Measured during DGM

calibration ΔH@ = 46.7 ± 6.4 mm

H2O (1.84 ± 0.25 in.

H2O)

With DGM Repair or replace

Thermocouples and

Digital Indicator Certified Hg-in-glass

thermometer in ice

slush and boiling water

Stack: ±1.5% °K DGM: ±3°C Probe: ±3°C Filter: ±3°C Exit: ±1°C

After each field

test Recalibrate, repair

or replace

Pitot Tube 1. Standard pitot tube

in wind tunnel and

calculate Cp (pitot tube

coefficient)

If part of Probe

Assembly, calibrate

with assembly.

σ (avg. deviation) ≤

0.001 for side A & B

Quarterly, or after

each field test Recalibrate, repair

or replace

2. Measure with angle

indicator to

demonstrate meeting

geometric

specifications and

assign Cp = 0.84

α1 ± 10° α2 ± 10° β1 ± 5° β2 ± 5° Z = ≤ 0.125” W = ≤ 0.031” PA - PB ≤ 0.063” 0.188” ≤ DT ≤ 0.375”

Quarterly, or after

each field test Recalibrate, repair

or replace

Sampling Nozzles Micrometer with at

least 0.025-mm (0.001-

in.) scale

Average of 3 inner

diameter

measurements; ΔD ±

0.1-mm (0.004-in.)

Before each field

use Recalibrate,

reshape, or

resharpen when

dented or

corroded

76

Probe and Filter Box

Heater System Gas thermocouple Capable of

maintaining 120°C ±

14°C at 20-lpm flow

rate

Initially Repair or replace,

and verify

calibration

Table 3-1: Sampling System Equipment Calibration and Frequency

1. Calibration of Dry Gas Meter and Orifice Tube

Calibrate the dry gas meter and Orifice Tube simultaneously (reference US EPA Method 5, Section 5.3 for

the calibration procedure). In short, you should:

• Conduct an initial (or full) calibration at five (5) selected flow rate (ΔH) settings.

• Repeat the procedure once every 6 months, or if the results of a post-test 3-point calibration show

that the dry gas meter calibration factor (Y) has changed by more than 5% from the pre-test

calibration value.

When performing quarterly or post-test calibrations, use the abbreviated calibration procedure described in

Section 5.3.2 of Method 5, which includes three (3) calibration runs at a single intermediate flow rate (ΔH)

setting.

The dry gas meter (DGM) calibration factor (Y) is the ratio of the wet test meter’s measured volume to the

dry gas meter’s measured volume. The DGM calibration factor is part of calibrating the Source Sampler

Console.

The Orifice Tube calibration factor (ΔH@) represents the pressure drop across the orifice for a sampling flow

rate of 21.2 lpm (0.75 cfm), which is the standard sampling rate for solving the isokinetic equation and

setting up the nomograph (sets of equations) for testing.

Find the true Orifice Tube calibration factor with the following equation, where Km is the orifice calibration

factor:

ΔH@ = 0.9244/Km2

Described below are both the initial and intermediate calibration procedures. Prior to conducting a

calibration run, perform a leak-check on the portion of the sampling train from the pump to the Orifice Tube

in the Source Sampler Console, as described below.

Metering System Leak-Check Procedure (Vacuum Side):

The following steps describe the leak-check procedure for the Vacuum Side of the Source Sampler Console.

See Figure 3-1 for a plumbing diagram of the MC-500 Series Source Sampler Console.

1. Connect the Vacuum Pump to the Source Sampler Console.

77

2. Close the Coarse Valve on the Source Sampler Console.

3. Insert a plugged male quick-connect into the SAMPLE quick-connect inlet.

4. Turn on the pump.

5. Open the Coarse Valve and fully close the Fine Increase Valve.

6. The Vacuum Gauge should read 92-kPa (27 in. Hg) for a barometric pressure of 100 kPa (30 in.

Hg).

7. After the ΔH manometer has returned to the zero mark, note whether the leak rate exceeds 0.28

lpm (0.01 cfm) using the dry gas meter gauge and a wristwatch or timer. If the leak rate is too

high, turn off the Pump and check tubing and piping connections on the Pump, Vacuum Gauge,

and Metering Valves. Also check the tubing for leaks.

8. Close the Coarse Valve and observe the Vacuum Gauge. If there is no vacuum loss, the vacuum

side of the Source Sampler Console is leak free.

9. Perform the Pressure Side Leak-Check next by following the directions in the next section.

Note: The Rockwell Dry Gas Meter in the MC-522 (English version of the MC-572) will indicate a leak by

running backward on the Pressure Side when completing the Vacuum Side Leak-Check. However, the

Kimmon Dry Gas Meter in the MC-572 will not run backward, thus requiring a Pressure Side Leak-Check.

Figure 3-1: Source Sampler Console Plumbing Diagram for Leak-Check

78

Metering System Leak-Check Procedure (Pressure Side):

There are several techniques for performing a “back-half,” or pump discharge, Source Sampler Console leak-

check. The following procedure is based on US EPA recommendations in Section 5.6 of Method 5:

1. Connect the Vacuum Pump to the Source Sampler Console.

2. Plug the outlet of the Orifice Meter with a rubber stopper.

3. Insert both pitot (Δp) manometer plastic connectors into the right side of the dual-column

manometer.

4. Insert both orifice (ΔH) manometer plastic connectors into the left side of the dual-column

manometer.

5. To pressurize the system, remove one of the ΔH plastic connectors and then blow lightly into the

tubing until the ΔH reads 177.8 to 254 mm (7 to 10 in.) H2O.

6. Pinch off the tubing securely, and insert the ΔH plastic connector back into the manometer. Allow

the manometer oil time to stabilize.

7. Observe for one minute. If you note any loss of pressure during this minute, you have a leak

which must be corrected. Check all connections and tubing for leaks.

Initial or Semiannual Calibration of Dry Gas Meter and Orifice Tube:

Calibrate the Source Sampler Console (Dry Gas Meter and Orifice Tube) by connecting the Source Sampler

Console to a wet test meter or secondary reference dry test meter, according to the set-ups shown in Figures

3-2 and 3-3.

Conduct a series of five (5) calibration runs at differing flow rates (ΔH settings) that bracket the range of

expected sampling rates during particulate sampling tests.

If using a wet test meter as the calibration standard, it should have a meter correction factor of 1.000.

Alternatively, you may use a properly calibrated secondary reference dry gas meter to calibrate the Source

Sampler Console’s dry gas meter.

The calibration steps are as follows:

1. Before starting the calibration, record the following data on a meter calibration data sheet (or a

computer spreadsheet) as shown in Appendix C:

a. Barometric pressure at the start of calibration,

b. The Source Sampler Console and wet test meter identification numbers

c. Date and time of calibration, and

d. Confirmation of acceptable leak-checks on the Source Sampler Console.

2. Connect the outlet of the wet test meter to the inlet (SAMPLE) of the Console Meter.

3. Turn on the Vacuum Pump and adjust the Coarse and Fine Control Valves on the Source Sampler

Console until you obtain an orifice pressure (ΔH) of 12.7 mm (0.5 in.) H2O at a vacuum of 8 to 15

79

kPa (2 to 4 in. Hg) on the Vacuum Gauge. Allow both

meters to run in this manner for at least 15 minutes to let

the meter stabilize and the wet test meter to wet the

interior surfaces.

4. Turn off the Vacuum Pump.

5. Record initial settings of ΔH, dry gas meter volume

reading, wet test meter volume reading, dry gas meter

temperature, and wet test meter temperature.

6. Start the Vacuum Pump and quickly adjust the ΔH to the

desired setting. Start the Elapsed Timer on the Source

Sampler Console at the same time you start the pump.

7. Let the Vacuum Pump run until a dry gas volume of

approximately 140 liters (5 cubic feet) is indicated on the

dry gas meter. Allow the calibration run to continue until

the next minute elapses, and then stop the Vacuum Pump

and Elapsed Timer.

8. Record the final dry gas meter volume reading, wet test meter volume reading, dry gas meter

temperature, and wet test meter temperature. Calculate the dry gas meter and wet test meter volumes

by subtracting initial readings from final readings. Calculate the average dry gas meters and wet test

meter temperatures.

9. Repeat the calibration run at each successive setting of ΔH, recording the same data as before.

Suggested ΔH values are 13, 26, 39, 52, 65 and 78 mm H2O (0.5, 1.0, 1.5, 2.5, 3.5 and 4.5 in. H2O).

10. At the conclusion of the five calibration runs, calculate the average Y value to obtain the dry gas

meter calibration factor, as well as the average orifice pressure (ΔH@). The tolerance for individual Y

values is ± 0.02 from the average Y. The tolerance for individual ΔH@ values is ± 6.4 mm (0.25 in)

H2O from the average ΔH@.

11. If the Y and ΔH@ are acceptable, record the values on a label on the front face of the Console Meter.


If you don’t obtain a value

of ± 6.4-mm (0.25-in)

H2O from the average

ΔH@, adjust the orifice

opening or replace the

Orifice Tube.

80

Figure 3-2: Set-up for Calibrating the Source Sampler Console Against Wet Test Meter

Figure 3-3: Illustration of Console Meter Calibration with Secondary Reference Dry Gas Meter

81

Figure 3-4: Critical Orifice Used for Calibration

Post-Test Calibration of the Source Sampler Console:

Conduct a post-test, or 3-point, calibration of the Source

Sampler Console after each test series or trip to and from the field

to ensure that the dry gas meter correction factor (Y) has not

changed by more than 5%.

Conduct the post-test calibration check at the average ΔH and

highest system vacuum observed during the test series. The steps

are as follows:

1. Before starting the calibration, fill out a meter

calibration data sheet (it can be a computer

spreadsheet) as shown in Appendix C. Record the

following:

a. Barometric pressure at the start of

calibration,

b. Identification numbers for the Source

Sampler Console and wet test meter (or

secondary DGM or critical orifice),

c. Date and time of calibration, and


With a critical orifice set

as shown in Figure 3-4,

you can do a post-test

calibration in the field

before departing the test

site. Follow the same

directions described on

the next page, except

substitute the critical

orifice for the wet test

meter and ensure that the

vacuum is 25 to 50 mm

Hg (1 to 2 in. Hg) above

the critical vacuum.

82

d. Confirmation of acceptable leak checks on the Source Sampler Console.

2. Connect the outlet of the wet test meter to the inlet (SAMPLE) of the Source Sampler Console, as

depicted in Figure 3-2. Insert a valve between the wet test meter and the inlet of the Source Sampler

Console to adjust the vacuum to the desired level. If using a Critical Orifice, simply insert the male

quick-connect end of the critical orifice into the inlet (SAMPLE) of the Source Sampler Console.

3. Turn on the Vacuum Pump and adjust the Coarse and Fine Control Valves on the Source Sampler

Console until you obtain an orifice differential pressure (ΔH) reading equivalent to the average ΔH

observed during the test series. Set the calibration system vacuum to the highest vacuum observed

during the test series. Allow both meters to run like this for at least 15 minutes to let the meter stabilize

and the wet test meter to wet the interior surfaces.

4. If using a Critical Orifice, select an orifice with ΔH properties similar to the average ΔH observed

during the test series. Note that the vacuum will be independent of the vacuum observed during the test

series, due to the physics of the critical orifice requiring the vacuum to be greater than the theoretical

critical vacuum. Theoretical critical vacuum can be estimated at one-half (1/2) of barometric pressure.

It is recommended to sample at 1-2 inches Hg (25-50 mm Hg) above the critical vacuum with the

Coarse Valve fully opened and the Fine Valve adjusted.

5. Turn off the Vacuum Pump.

6. Record initial settings of ΔH, dry gas meter volume reading, wet test meter volume reading, dry gas

meter temperature, and wet test meter temperature.

7. Start the Vacuum Pump and quickly adjust the ΔH to the desired setting. Start the Elapsed Timer on

the Source Sampler Console at the same time that the pump is started.

8. Let the Vacuum Pump run until the dry gas meter indicates a volume of approximately 140 liters (5

cubic feet). Allow the calibration run to continue until the next minute elapses, and then stop the

Vacuum Pump and Elapsed Timer.

9. Record the final dry gas meter volume reading, wet test meter volume reading, dry gas meter

temperature, and wet test meter temperature. Calculate the dry gas meter and wet test meter volumes

by subtracting initial readings from final readings. Calculate the average dry gas meter and wet test

meter temperatures.

10. Calculate the meter correction factor Y. Repeat the calibration two (2) more times at the same ΔH and

system vacuum settings and calculate the average Y for the three runs.

11. Calculate the percent change in the meter correction factor Y.

12. If the dry gas meter Y values obtained before and after the test series differ by more than 5%, either

void the test series or perform calculations for the test series using the lower Y value (which would

give a lower sample volume, and therefore higher concentration values).

2. Calibration of Thermocouples

Apex Instruments suggests the following procedures for calibrating thermocouples and temperature display

readouts:

● Check thermocouples for calibration at three temperatures. For example, ice-point and boiling point of

water and ambient temperature. Thermocouples that are used at higher temperatures than boiling water,

such as the stack gas thermocouples, can be checked for calibration using a hot oil bath.

83

● Another more modern technique is to use a Thermocouple Simulator Source (M5C-22), as shown in

Figure 3-5. The M5C-22 can calibrate without external compensation or ice baths, with a temperature

range from 0° to 2,100°F in divisions of 100°F, resulting in 22 precise test points.

A temperature sensor calibration form is provided in Appendix C.

Acceptable reference materials are:

● ASTM reference thermometers,

● NIST-calibrated reference thermocouples/potentiometers,

● Thermometric fixed points, e.g., ice bath and boiling water

● NIST-traceable electronic thermocouple simulators.

Thermocouple Calibration Procedure:

1. Prepare an ice-water bath in an insulated container (such as

the Cold Box).

a. Insert the thermocouple and a mercury reference thermometer into the bath.

b. Allow the readings of both to stabilize and record the temperatures on a thermocouple

calibration data sheet, as shown in Appendix C.

c. Remove the thermocouple and allow it to stabilize at room temperature.

d. Reinsert the thermocouple into the bath and record another reading.

e. Repeat Steps c and d.

f. Calculate the average of the thermocouple readings and the average of the reference

thermometer readings. The averages should differ by less than 1.5% of the absolute temperature

(°K) for the stack thermocouple.

2. Place a beaker of distilled water on a hot plate, and then add a few boiling chips and heat to boiling.

a. Insert the thermocouple and a mercury reference thermometer into the beaker and repeat Step

1, b through f, above.

3. Set the thermocouple you are checking and a mercury reference thermometer side-by-side at ambient

temperature and allow the readings to stabilize.

a. Repeat Step 1, a through f, above.

4. Place a container of oil on a hot plate and heat to a temperature below the boiling point. DO NOT

BOIL.

a. Insert the thermocouple and a mercury reference thermometer into the container and repeat Step

1, b through f, above.

Figure 3-5:

Thermocouple Simulator for

Temperature Display Calibration Check

84

Calibrate Temperature Display:

The

temperature display requires additional calibration procedures. To check the linearity of the temperature

display, use a thermocouple simulator (such as Apex Model M5C-22 pictured in Figure 3-5). Connect the

simulator to the temperature display and record the display reading at each temperature setting on a calibration

data sheet.

3. Calibration of Pitot Tube

Carefully check the construction details of the S-type (or Stausscheibe) pitot tube when you receive it and prior

to calibration. There are two options for calibrating a S-type pitot tube:

Option 1: Since few stack testers have access to a wind tunnel facility, the US EPA allows you to assign a co-

efficient of Cp = 0.84, if the pitot tube meets geometric specifications. Keep in mind that using the agency’s

standard co-efficient will likely bias your velocity and flow rate measurements high.

Option 2: When using a wind-tunnel calibration procedure, the pitot tube coefficient (Cp) will typically range

from 0.77 to 0.82. This means that your subsequent measurements of stack gas velocity will likely be between

2% and 8% lower due to increased accuracy associated with wind-tunnel calibration. Consequently, your

measurements of the stack gas volumetric flow rate and emission rate also will be lower. The procedures for

conducting a wind tunnel calibration are described in detail in US EPA Method 2.

Calibration Of

S-type Pitot Tube

Check that it meets

geometric

specifications and

assign Cp = 0.84

Calibrate against

standard p-type in a

wind tunnel and

calculate new Cp

OR

Did you know? Apex Instruments provides both geometric and wind tunnel

calibrations of type-S pitot tube assemblies for a reasonable fee. Contact us at (800)

882-3214 to learn more.

85

Geometric Specifications Pitot Calibration:

1. Before starting the calibration check, fill out a pitot tube

calibration data sheet as shown in Appendix C (or enter it

in a spreadsheet).

2. Clamp the pitot tube so that it is level, verify its level

position and record it.

3. Confirm that the pitot openings are not damaged or

obstructed and record it.

4. Using an angle indicator, measure the angles (α1 and α2)

between the pitot tube opening plane and the horizontal

plane when viewed from the end, and record the angles (see

third image in figure 3-6).

5. Measure the angles (β1 and β2) between the pitot tube

opening plane and the horizontal plane when viewed from

the side, and record the angles (see fourth image in the

figure).

6. Calculate the difference in length between the two pitot tube

legs (Z) by measuring the angle γ and record it (see the last

image in the figure).

7. Calculate the distance that the pitot tube legs are rotated (W)

by measuring the angle θ and record it (see the fifth image

in the figure).

8. Measure and record the vertical distances (PA and PB)

between the plane of each pitot tube opening and the center

line of the pitot tube (see the second image in the figure).

9. Measure and record the tube external diameter (DT) and

calculate the minimum/maximum values of PA and PB (see

first image in figure).

Figure 3-6

Probe Pitots measurements pertaining

to the geometric specifications

calibration check

86

4. Calibration of Sampling Nozzles

Inspect and calibrate probe nozzles in the field immediately before each use to verify that they were not

damaged in transport or shipment. We recommend the following procedure, illustrated in Figure 3-7:

1. Before starting the calibration check, fill out a probe nozzle calibration data sheet as shown in

Appendix C (or use a computer spreadsheet).

2. Using venier or dial calipers with at least 0.025 mm (0.001 in.) tolerance, measure the inside diameter

of the nozzle by taking three readings approximately 45-60° apart from one another, and record them.

3. Calculate the average of the three readings.

4. If readings do not fall within 0.1 mm (0.004 in.) of one another, the nozzle must be reshaped,

resharpened and recalibrated.

5. With a permanent marking tool, identify each nozzle with a unique number.

Figure 3-7: Calibration of Sampling Nozzle

87

5. Initial Calibration of Probe Heater

Apex Instruments calibrates the probe heater assembly before shipping according to procedures outlined in US

EPA APTD-0576. Probes are constructed according to specifications given in US EPA APTD-0581, which is

the original 1971 document entitled “Construction Details of Isokinetic Source-Sampling Equipment,” by

Robert M. Martin. (Available from National Technical Information Service (NTIS) as document PB-203 060.)

The procedure outlined in APTD-0576 involves passing heated gas at several known temperatures through a

probe assembly, and monitoring and verifying that the probe assembly is capable of maintaining 120°C ±

14°C, as shown in Figure 3-8.

Figure 3–8: Set-up for Probe Heater Calibration

88

6. Calibration of Pressure Sensors

The gauge-oil inclined manometer and a mercury-in-glass manometer are primary measuring devices, and

thus do not require calibration. When using a differential pressure gauge (magnehelic gauge), U-tube

manometer, or electronic manometer, they must be calibrated against a primary measuring device.

To check the calibration of differential pressure sensors other than inclined manometers, use the following

procedure:

1. Connect the differential pressure sensor to a gauge-oil inclined manometer as shown in Figure 3-9.

2. Vent the vacuum side to atmosphere, and place a pressure on each system.

3. Compare Δp (velocity head of stack gas) readings of both devices at three or more levels that span

the range, and record on a calibration data sheet.

4. Repeat Steps 1 through 3 for the vacuum side. Vent the pressure side and for the vacuum side, place a

vacuum on the system.

5. The readings at the three levels must correspond within ± 5% of the reference sensor.

Magnehelic

1 2 4 .6

OR

Manometer

To vacuum system or

vented to atmosphere

To pressure source or

vented to atmosphere

Valve

Figure 3-9: Set-up for Differential Pressure Sensor Calibration Check

89

Maintenance Procedures

For maintenance procedures, check your appropriate user’s manual for the equipment that you are using for

your stack test.

If you are using Apex Instruments equipment, call 1 (800) 882-3214 to speak with a member of our

Technical Services Group (TSG) to aid you in your maintenance needs. Additionally, you may use our

website www.apexinst.com to find a user’s manual for your specific equipment that needs maintenance.

http://www.apexinst.com/

90

Appendix A

Equipment Lists for Isokinetic Sampling

91

Recommended Equipment for Isokinetic Sampling

Apex Instruments, Inc. Method 5 Source Sampling System recommended items:

Qty Part# Description

1 XC-5000 Automated Isokinetic Method 5 Meter Console includes DGM with Optical Encoder, Barometric

Pressure Transducer, Internal Flash Memory, Type K Thermocouples, PID, Standard or Metric Units

1 XE-0523 External Pump Assembly, Double Diaphragm Pump, SS Quick Connects, 5 FT Power Cord & Hoses,

240V (120V option), Black UHMW Polyethylene Case

1 SB-2M Miniature Heated Filter Oven with 2 Access Doors & Probe Clamp, 240V (120V option)

1 SBR-10 Riser for SB-2M, Impinger Box Adapter, 10 IN Riser with Insulated Reservoir

1 SB-3 Impinger Box / Insulated Coolant Reservoir, Holds 4 Impingers

1 PS-3H 3 FT Method 5 Probe Sheath with Tube Heater, 120V (240V option)



1 PL-3S 3 FT SS Probe Liner, 5/8” o.d. with #28 Grooved Ball



3 PLN-3G 3 FT Glass Probe Liner, 5/8” o.d. with Unground #28 Grooved Ball



1 US-30-10 30 FT Split Umbilical Cable, Method 5, with 1/4” Pitot QCs, Stainless Steel Quick Connects

1 US-60-10 60 FT Split Umbilical Cable, Method 5, with 1/4” Pitot QCs, Stainless Steel Quick Connects

1 USL-15-SST 15 FT Unheated Sample Line, PTFE with SS over braid, #28 Socket Elbow Fitting Both Ends,

Includes TCA-06F

1 SB-8 Modular Sample Frame with Probe Clamp & Impinger Box Slides

1 GA-107-12 Sample Line Adapter (for SB-2M), Includes Bracket and 1/2” ID Sample Line Clamp

1 GA-100 Umbilical Adapter (Gooseneck), #28 Socket with Thermocouple, Mounting Bracket, 1/2” Male QC

1 NS-SET Set of 7 Stainless Steel Nozzles - Sizes 4,6,8,10,12,14,&16, Includes Case and Four 5/8” tube nuts

1 NG-SET Set of 7 Glass Nozzles - Sizes 4,6,8,10,12,14&16, Includes Case & Three 5/8” Glass Filled PFA

Ferrules

1 GN-DGS Basic Method 5 Glassware Set with Unground Joints & 3” Filter Assembly

1 GF-3TPG 82mm PTFE Coated Glass Fiber Filters - Hydrophobic, Low Absorption of Acid Gases such as SOX,

or NOX, 50/box (MFS PG60)

1 GF-3 3” Glass Fiber Filters, 100/box (Whatman 934AH-82.6mm)

1 PBX-S Modular Probe Brush Extension Kit, Nylon Brushes with Stainless Steel Extensions

1 NB-SET Nozzle Brush Set (sizes 3, 5, & 8) in Carrying Tube

1 P1000-6 Monorail , 6 feet, with Chain, L-Bracket & Hardware

2 P1000-9 Monorail , 9 feet, with Chain, L-Bracket & Hardware

2 P2751 Swivel Frame Trolley with Eye-bolt, 12” Chain & Quick Link

1 TX-XC5 Transport Case, XC500 Series

1 M5CO-SET Calibration Orifice Set, 5 Calibrated Critical Orifices & Spreadsheet Diskette for Method 5

92

It is also recommended to have additional Probe Assemblies to best suit your testing needs. Apex

Instruments, Inc. recommends a 4 foot and 8 foot Probe Assembly in addition to the standard 6 foot which is

included in the above listed system.

Apex Instruments recommended method 17 additional accessories.


3 SFA-2590 Method 17 SS In-Stack Filter Unit

1 GFA-2590 Glass Fiber Thimble, 25X90mm Tapered, 10/box

1 PLS-6S-QCF6 Method 17 6 ft SS Probe Liner with 3/8” Male QC

1 USL-15-QST 15 ft Unheated Sample Line, PTFE with SS Overbraid

1 UA-3J Power Box Adapter, 3 Receptacles

1 SB-8 Sample Frame w/ Probe Clamp & Impinger Box Slides




2 GNM-HC Horizontal Condenser, #28 Socket both ends, Water Jacket Hose Barbs

2 GN-9AKS Knock-Out Impinger Assembly, Unground

8 GNM-T XAD Trap, #28 Unground Socket & O-Ring Ball, Water Jacket Hose Barbs

4 TL-7/5 Surgical Tubing, 3/8 IN (2 FT.)

1 MM5-P220 Submersible Coolant Pump, 220V (120V option)

1 PBC-6 6 ft Extendible Aluminum Probe Brush with PB-5/8 Nylon Brush

1 NTG-10U 5/8” Glass-Filled Teflon Union with Nuts and Ferrules

1 PBT-5/8 Teflon Probe Brush, 5/8” Diameter, 4” Length, 8-32 Thread

1 PBX-8T 8 FT Flexible TFE Probe Brush Extension, Brush Not Included

1 T-TFE24 Teflon Tape, High Density, 1.5” x 520” per roll


93




1 GN-9AK Knock-Out Impinger, Short Stem, 500ml, Unground O-Ring Joints

1 GF-3QH 3” Quartz Fiber Filters, 100/box (MFS QR100 82 mm)

1 PBT-5/8 Teflon Probe Brush, 5/8” Diameter, 4” Length, 8-32 Thread

1 PBX-10T 10 FT Flexible TFE Probe Brush Extension, Brush Not Included

1 NBT-1/2 Nozzle Brush, Teflon, ½”

1 NTG-10U 5/8” Glass-Filled Teflon Union with Nuts and Ferrules

1 T-TFE24 Teflon Tape, High Density, 1.5” x 520” per roll

1 NG-SET Set of 7 Glass Nozzles - Sizes 4,6,8,10,12,14&16, Includes Case & Three 5/8” Glass Filled

PFA Ferrules

Apex Instruments recommended method 201A (PM10) additional accessories.


1 PM2.5-10K PM 2.5/10 Cyclone Kit, Includes PM10 Kit, PM2.5 Cyclone Body, Adapters, Pitot & Case

1 UA-3J Power Box Adapter, Includes 1/2 IN Mounting Clamp and 4 Pin Amphenol to 3 Receptacle

1 MPT-6-421-OFF Extended Pitot Tip for PM10/2.5 Sampling, Tube Diameter 3/8 IN, Length 421mm, Offset

1 GF-47Q 47mm Quartz Fiber Filters, 25/box (Pallflex 47mm).

1 PM2-K PM2.5 Cyclone Set, 12 Nozzles, (PM2-NS), Filter (SFA-47), Cyclone Body, Manual and Case.

94

Recommended Spare Parts for Isokinetic Sampling

Apex Instruments, Inc. recommends stocking the following spare parts:

Qty Part # Description

Console Meter Parts (MC-572)

1 TC-765KF Thermocouple Display, panel mount, LED, 120V/240V

1 M313102A Thermocouple Switch, 7-Channel

1 M-31302K Knob for 7-Channel Selector Switch

1 M-1400 Temperature Controller, analog, Love Model 140EF

2 SSR-330-25 Relay, SSRT, 25A, 120/240V

1 M-CB10A Electrical Circuit Breaker, 10A, 120V, panel-mount

2 M-CB3A Electrical Circuit Breaker, 3A, 120V, panel-mount

1 M-49BK Electrical Receptacle, snap-in, screw-term, 120V

1 AM-MCP Amphenol Connector, MC Panel, pre-wired sub

1 M-SV3131 Solenoid Valve, 3-way, brass, 120V

1 DGM-SK25 Dry Gas Meter, SK-25, Metric

1 QC-BHF4-B Quick Connect, bulkhead, ¼”- ¼” tube, female, brass

1 QC-F8-B Quick Connect, ½”- ½ ” tube, female, brass

1 QC-M6-B Quick Connect, 3/8”- 3/8 ” tube, male, brass

1 QC-BHF6-B Quick Connect, bulkhead, 3/8”- 3/8 ” tube, female, brass

1 M-42210 Dual Column Manometer, inclined vertical

1 QC-MAN-F3 Quick Connect, Manometer, female, 1/8” MNPT, stainless steel

2 QC-MAN-M2 Quick Connect, Manometer, male, 1/4” HB, P/C, PVC

2 M-422DS Manometer Displacer, with knob

1 HC83314SS Cabinet Spring Catch for Meter Console

1 HS83314SS Keeper Latch, short shank for Meter Console

External Pump Parts (E-0523)

1 GP-BL50-2 Mini Lubricator

4 AK731 Gast Vanes, Model E-0523 (4 Required)

1 QC-M6-B Quick Connect, 3/8” – 3/8” tube, male, brass

1 QC-F6-B Quick Connect, 3/8” – 3/8” tube, female, brass

Sample Case Parts (SB-1)

1 AM-SBP Amphenol Connector, SB panel, wired

1 TC-PJK Thermocouple Jack, Type K, panel

1 AM-SB500W Hot Box Heater, 500W, 240V

1 PC-1 Hinged Probe Clamp, stainless steel, (2.54 cm OD probes)

96

Recommended Spare Parts for Isokinetic Sampling

(continued)

Qty Part # Description

Umbilical Cable Parts (UC-60)

1 QC-F4-B Quick Connect, ¼” – ¼” tube, female, brass

1 QC-F8-B Quick Connect, ½ ” – ½ ” tube, female, brass

1 QC-M4-B Quick Connect, ¼” – ¼” tube, male, brass

1 QC-M8-B Quick Connect, ½ ” – ½ ” tube, male, brass

4 TC-LPS-K Thermocouple Plug, Type K, cord

4 TC-LJ-K Thermocouple Connector, Type K, female

1 AM3101A Amphenol Body, 4-pin cable

1 AM3106B Amphenol Body, 4-socket, cable

2 AM3057 Amphenol Body, strain relief, cable

10 EXP-20 Expando, 1-1/4 inch 500 black

25 PT24004BK PE Tubing, ¼ inch OD, weathered, black, 1000’ roll

25 PT24004NA PE Tubing, ¼ inch OD, weathered, Natural, 1000’ roll

25 PT24004YW PE Tubing, ¼ inch OD, weathered, yellow, 1000’ roll

General Repair and Supply Parts

50 WK-PP-24S Wire, Thermocouple extension, yellow, feet

25 WK-TT-24 Wire, Thermocouple, Type K, TFE insulation, feet

10 4F-B Ferrule, ¼ inch tube, brass

10 6F-B Ferrule, 3/8 inch tube, brass

10 8F-B Ferrule, ½ inch tube, brass

10 10F-B Ferrule, 5/8 inch tube, brass

1 O-113-DZ Silicone O-ring, 5/8 inch, 12 per pack

3 NTG-10F Single Ferrule, 5/8 inch

1 3M-69 Glass Tape, Scotch 69, ¾”. 66 ft. roll

97

Equipment Checklist

98

Appendix B

Calibration Data Sheets

107

Appendix C

Stack Testing Field Data Sheets

118

Appendix D

Calculation Worksheets

119

FEDERAL REFERENCE METHOD 1

Sample and Velocity Traverses for Stationary Sources Plant __________________________________________ Date _______________________ Location __________________________________________ Test No. _______________________

INPUT PARAMETERS

Sketch of Stack Geometry

Circular Stack:

Interior duct cross-section diameter = _______________ m or ft. Sampling port diameter = _______________ cm or in. Sampling port nipple length = _______________ cm or in. Stack cross-sectional area = _______________ m2 or ft2 Rectangular Stack: Length of stack location (L) = _______________ m or ft. Width of Stack location (W) = _______________ m or ft.

Equivalent diameter WL

LWDe

2 = _______________ m or ft.

Sampling Site: Diameter downstream of disturbance = _______________ m or ft. Diameter upstream of disturbance = _________________ Minimum number of sampling points = _________________ Total sampling time = ______________ min Individual point sampling times = ______________ min

120

Sample and Velocity Traverses for Stationary Sources

(continued) Location of Sampling Points:

CIRCULAR

Sample point number

Circular stack % diameter

Distance from sample port opening, in.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

RECTANGULAR

FEDERAL REFERENCE METHOD 2

121

Determination of Stack Gas Velocity and Volumetric Flow Rate (Type S Pitot Tube)

Plant ______________________________________ Date _________________________ Location ______________________________________ Test No. _________________________

INPUT PARAMETERS

Area of stack (m2) or (ft2) = r2 or (D/2)2 or L x W = As = _________________ Pitot tube coefficient = Cp = _________________ Stack gas temperature (K) = °C + 273° or (°R) = °F + 460° = Ts = _________________ Average of square root of velocity head (mm. H2O)1/2 or (in. H2O)1/2 = (√∆p)avg = _________________ Barometric pressure (mm. Hg) or (in. Hg) = Pbar = _________________ Stack gas static pressure (mm. H2O) or (in. H2O) = Pg = _________________ Absolute stack gas pressure (mm. Hg) or (in. Hg) = Ps = _________________ Note: Ps = Pbar + Pg (mm. H2O)/13.6 or (in. H2O)/13.6 Stack gas moisture (fraction) = Bws = _________________ Stack gas dry molecular weight (g/g-mole) or (lb/lb-mole) = Md = _________________ Stack gas wet molecular weight (g/g-mole) or (lb/lb-mole) = Ms = _________________ Note: Ms = Md (1 – Bws) + 18.0 Bws

CALCULATIONS

vS = Stack gas velocity, m/s or ft/s

ss

avgs

avgppsMP

TxpxCxKv

)()(

xxxxKv ps )( = __________________________m/s or ft/s

Kp = 34.97 (Metric Units) = 85.49 (English Units)

Qa = Volumetric flow rate, acmm or acfm

ssa AxvxQ 60

)()(60 xxQa = _____________________acmm or acfm

Determination of Stack Gas Velocity and Volumetric Flow Rate

(continued)

122

Qd = Dry volumetric flow meter, scmm or scfm

sswsd AxvxBxQ )1(60

xxxQd 160 = ____________________scmm or scfm

Qsd = Volumetric flow rate, dscmm or dscfm

std

s

s

std

sswssdP

Px

T

TxAxvxBxQ )1(60

std

std

sdP

xT

xxxxQ )1(60

= ____________________dscmm or dscfm

123

FEDERAL REFERENCE METHOD 3 Gas Analysis for the Determination of Dry Molecular Weight

Plant ___________________________________________ Date _____________________

Location ____________________________________________ Test No. _____________________

INPUT PARAMETERS

Percent Oxygen (O2) by volume, dry basis = %O2 = ______________________ Percent Carbon Dioxide (CO2) by volume, dry basis = %CO2 = ______________________ Percent Carbon Monoxide (CO) by volume, dry basis = %CO = ______________________ Percent N2 = 100 – (%O2 + %CO2 + %CO) = %N2 = ______________________

CALCULATIONS

Md = Dry molecular weight, g/g-mole or lb/lb-mole

)%(%28.0)(%32.0)(%44.0 222 CONOCOM d

)(28.0)(32.0)(44.0 dM = __________g/g-mole or lb/lb-mole

Ms = Wet molecular weight, g/g-mole or lb/lb-mole

)(0.18)1( wswsds BBMM

)(0.18))(1( sM = __________ g/g-mole or lb/lb-mole

%EA = Excess Air, %

100

)%5.0(%)(%264.0

%5.0)(%%

22

2 xCOON

COOEA

100)5.0()(264.0

5.0)(% xEA

= ______________________________%

124

FEDERAL REFERENCE METHOD 4 Determination of Moisture Content of Stack Gases

Plant _______________________________________________ Date _______________________ Location _______________________________________________ Test No. _______________________

INPUT PARAMETERS

Volume of gas sampled through dry gas meter = Vm = ________________ Dry gas meter (DGM) calibration factor = Y = ________________ Average DGM temperature (K) = °C + 273° or (°R) = °F + 460° = Tm = ________________ Average DGM orifice pressure differential (mm H2O) or (in. H2O) = ∆H = ________________ Volume of water collected, condensed, [Vf - Vi], ml = Vlc = ________________ Volume of water collected in silica gel (W f – Wi), g = Vwsg = ________________ Barometric pressure (mm. Hg.) or (in. Hg) = Pbar = ________________

CALCULATIONS

Vm(std) = Volume of gas sampled at standard conditions, dscm or dscf

m

bar

std

std

mstdmT

HP

xP

TYVV

6.13)(

6.13)(

std

std

stdmP

TV = _____________dscm or dscf

Vwc(std) = Volume of water vapor condensed at standard conditions, scm or scf

ifstdwc VVKV 2)(

2)( KV stdwc = _______________scm or scf

K2 = 0.001333 (Metric Units) 0.04706 (English Units)

125

Determination of Moisture Content of Stack Gases

(continued) Vwsg(std) = Volume of water vapor collected in silica gel

ifstdwsg WWKV 3)(

3)( KV stdwsg = ______________scm or scf

K3 = 0.001333 (Metric Units) 0.04706 (English Units) Bws = Mole fraction of water vapor

)()()(

)()(

stdmstdwsgstdwc

stdwsgstdwc

wsVVV

VVB

wsB = ________________________

%H2O = Percent moisture

wsBxOH 100% 2

xOH 100% 2 = _______________________%

126

FEDERAL REFERENCE METHOD 5 Nozzle Size Selection Worksheet

Note: The most commonly used equation for estimating isokinetic sampling nozzle diameter is the following (assumes that moisture fraction at dry gas meter equals zero.):

avgs

ss

wspm

mmestn

pP

MT

BCT

PQKD

1

1)(

K1 = 0.6071 (Metric Units) = 0.03575 (English Units)

Source Name ________________________________________ Date _______________________ Facility ________________________________________ Calculated by ___________________

INPUT DATA

Barometric Pressure (mm. Hg) or (in. Hg) = Pbar = ________________ Stack Static Pressure (mm. H2O) or (in. H2O) = Pg = ________________ Stack Gas Pressure (mm. Hg) or (in. Hg)

6.13

g

bars

PPP

6.13sP = Ps = ________________

Dry Gas Molecular Weight (g/g-mole) or (lb/lb-mole) = Md = ________________ assume 30.0 for combustion of coal, oil or gas assign 29.0 if mostly air assign 28.0 if mostly purge nitrogen or use preliminary Orsat® or Fyrite® data Stack Gas Moisture (fraction) = Bws = ________________ use preliminary moisture data use wet bulb/dry bulb if < 212°F BE CAREFUL: fraction Bws = %H2O/100 Wet Gas Molecular Weight (g/g-mole) or (lb/lb-mole)

wswsds BBMM 0.181

0.181 sM = Ms = ________________

Stack Gas Temperature (K) or (°R) = Ts = ________________ °C + 273° = K or °F + 460 = °R Pitot Tube Coefficient = Cp = ________________

127

Nozzle Size Selection Worksheet (continued)

Average Velocity Head (mm. H2O) or (in. H2O) = ∆pavg = ________________ v = calculation of inside square root term

avgs

ss

pP

MTv

x

xv = v = ________________

Sampling Flow Rate (cfm or lpm) = Qm = ________________ assume 0.75 cfm assume 21.24 lpm Dry Gas Meter Temperature (K or °R) = Tm = ________________ use ambient temp + 25°F + 460 = °R Dry Gas Meter Pressure (mm Hg or in. Hg) = Pm = ________________ use Pbar + (∆H@)/13.6

CALCULATION OF NOZZLE SIZE

Estimated Nozzle Diameter (mm or inches)

avgs

ss

wspm

mmestn

pP

MT

BCT

PQKD

1

1)(

1

1)(

xx

xxxKD estn = Dn(est) = ________________


Actual Nozzle Diameter Chosen (mm or inches) = Dn = ________________

128


K-FACTOR CALCULATION

∆H = Isokinetic Rate Orifice Pressure Differential

pKxH

mss

smd

wspnPTM

PTMBCHDK

p

HK

22

@

4

6 1

224

6 1

K

p

HK = _________________

K6 = 8.038x10-5 (Metric Units) = 846.72 (English Units) CHECK CALCULATIONS FOR SUFFICIENT SAMPLE VOLUME AND ISOKINETIC RATE 90-110%

Stack Gas Velocity (m/s or ft/sec) = vs = ________________ from preliminary velocity run convert to m/min or ft/min vs x 60 sec/min = vs(fpm) or(mpm) = ________________ Estimated Sampling Time (minutes) = θ = ________________

multiply number of traverse points by minutes/point = _________total min.

CALCULATION OF ACTUAL SAMPLING RATE

Qm(std) = Actual Sampling Rate (dscmm or dscfm)

s

nmpmorfpmssws

stdmT

DvPBQ

1039

1100 2

)()(

)(

1039

11002

)(

stdmQ = ________________

Vm(std) = Total Gas Sample Volume to be Collected (dscm or dscf)

xQV stdmstdm )()( = ________________

Based on applicable regulations for this source: Will there be sufficient sample volume (dscf)? yes no Will there be sufficient sampling time (minutes)? yes no

129


Check Intermediate Isokinetic Sampling Rate

wsnss

stdms

wssnsstd

stdstdms

iBAvP

VTK

BPAvT

PVT

1160

100I%

)(4)(

1

I% 4Ki = ________________

K4 = 4.320 (Metric Units)

= 0.09450 (English Units) Check Final Isokinetic Sampling Rate

An = Nozzle Area 2

4nD

= __________in2 or mm2

nsavgs

bar

avgm

totm

lcavgs

APv

HP

T

VVKT

)(

)(

)(

3)(

f60

6.13100

I%

60

6.13100

I%

3

f

K

= ________________


APEX INSTRUMENTS, INC. Isokinetic Source Sampling Handbook

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Transcript of APEX INSTRUMENTS, INC. Isokinetic Source Sampling Handbook