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Method 5 Manual - Apex Instruments, Inc.

1. gizz AN Plug into the Sample Port of the Meter Console Figure 3 2 Set up for Calibrating the Source Sampler Console Against Wet Test Meter lt of ke Gas Meter Thermocouple ie Il Secondary Reference Dry Gas Meter J fj DGM if Vacuum Adjustment i Valve Plug into the Sample Port of the Meter Console Figure 3 3 Illustration of Console Meter Calibration with Secondary Reference Dry Gas Meter Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 66 ISOKINETIC SOURCE SAMPLER MANUAL Post Test Calibration of the Source Sampler Console Sapphire Orifice pii L h Figure 3 4 Critical Orifice Used for Calibration A post test or 3 point calibration of the Source Sampler Console should be conducted after each trip to and from the field or test series to ensure that the dry gas meter correction factor Y has not changed by more than 5 With a critical orifice set as shown in Figure 3 4 this can be done in the field before departing the test site Follow the same directions below except substitute the critical orifice for the wet test meter and ensure that the vacuum is 25 50 mm Hg 1 2 inc
2. 11x3 HALIH Ino Yala I8OHA ho xju dd0ud cd Wooo INNVHO NAdO WHITE 5 Jo e ofr jno oD C lt re 6 re 3LIHM t com INS info apex www apexinst com e mail 919 557 7300 Fax 919 557 7110 Web Apex Instruments Inc Phone ISOKINETIC SOURCE SAMPLER MANUAL N3349 REV DATE 095 02 ITEM ZED PARTS LEGEND P N DESCRIPTION M 498K ELECTRICAL RECEPTACLE 120V W HOT BOX 120V HOT BOX 240V TC PJK TC JACK TYP K PNL SNAP IN REVISION HISTORY BY DESCRIPTION KR ADDED 240V HEATER TO LEGEND NOTES AMPHENOL ALI EX INSTRUMENTS TITLE SB 2 Electrical Schematic FILE NAME SB2SCHEM DWG DATE 8 21 98 INITIALS PLR REVISION 0 PART SB 2 Apex Instruments Inc Phone
3. Checked by ee ee eer Personnel Signature Date Team Leader Signature Date Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com C 6 ISOKINETIC SOURCE SAMPLER MANUAL PROBE NOZZLE DIAMETER CALIBRATION DATA SHEET Nozzle Diameter mm Calibrated by NozzlelD D1 D2 Dn Where P2 P3 Di D2 D3 Three different nozzle diameters at 60 degrees to each other each PA measured to the nearest 0 025mm AD Maximum distance between any two diameters must be s 0 100mm MEASUREMENT PLANE Dav D1 D2 D3 3 INSTRUCTIONS 1 Inspect the nozzie for nicks dents and corrosion If these are found they should be corrected before calibration 2 Place a reference mark on the nozzle Place the nozzie at the center of figure aligned with point P1 Measure and and record D1 3 Rotate the nozzle so that the reference mark is aligned with point P2 Measure and record D2 4 Rotate the nozzle so that the reference mark is aligned with point P3 Measure and record D3 5 Calculate AD and Dyyg Checked by Personnel Signature Date Team Leader Signature Date Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com C 7 ISOKINETIC SOURCE SAMPLER MANUAL EX SOURCE TESTING EQUIPMENT INSTRUMENTS Type S Pitot Tube Inspection Form Allowable Range assempytoverr ves ror
4. As the solenoids switch from orifice valve to ambient valve a light click should be heard Allow a few seconds for the AH manometer pressure to equalize to atmospheric Level the manometer by adjusting the leveling screw located in the lower left of the manometer body while viewing the built in level bubble e Zero both manometers bv turning the manometer zero displacer knobs When the manometer is zeroed the fluid level plunger should have about 3 to 6 mm 1 8 to 1 4 travel inward If fluid needs to be added remove the manometer fill screw on the left side toward the top of the manometer Fill to appropriate level and re zero If the fluid is faded or contaminated drain from the bottom drain screw and refill Both oils red and orange have a specific gravity of 0 826 to match scale calibration Troubleshooting e Valve fails to operate Check electrical supply with voltmeter Voltage should agree with nameplate or label rating at the valve Check coil with ohmmeter for shorted or open coil Verify supply pressure is equal to or less than nameplate rating Valve is sluggish or inoperative Electrical and Pressure OK Disassemble valve operator see Disassembly instructions Clean extraneous matter from inside valve Plunger must be free to move without binding e External leakage at sleeve to bodv joint Check that sleeve is torqued to the bodv with 30 40 inch pounds and that O ring seal inside the bodv is not
5. Recalibrate repair or replace Recalibrate repair or replace Recalibrate reshape or resharpen when dented or corroded Repair or replace and verify calibration Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 62 ISOKINETIC SOURCE SAMPLER MANUAL Dry Gas Meter and Orifice Tube The dry gas meter and Orifice Tube are calibrated simultaneously In USEPA Method 5 Section 5 3 contains the calibration procedure An initial or full calibration is conducted at five 5 selected flow rate AH settings and should occur 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 Quarterly or post test calibrations use an abbreviated calibration procedure described in Section 5 3 2 of Method 5 with three calibration runs at a single intermediate AH setting In calibrating the Source Sampler Console the operator is determining the dry gas meter calibration factor Y which is the ratio of measurement of the wet test meter s volume to the dry gas meter volume The Orifice Tube calibration factor AHe is the pressure drop across the orifice for a sampling flow rate of 21 2 Ipm 0 75 cfm It is related to the true Orifice Tube calibration factor by the equation AHe 0 9244 K n where Km is the orifice calibration factor The sampling ra
6. 21 Stack Sampling Sliderule and Laptop Computer with IsoCalc 2 2 The following preliminary information is first required to select the nozzle size and to calculate the K factor gt gt gt Average stack gas velocity head Apavs This is measured before the sample run or from a previous test Stack gas moisture fraction Bws or percent H20 This may be determined from a preliminary run previous test or calculated see Method 4 Stack gas dry molecular weight Ma This may be determined from a preliminary run previous test or estimated see Method 3 Stack gas pressure Ps This is measured before the sample run or if the static pressure of the stack is very low sample ports near stack exit the barometric pressure is used Source Sampler Console orifice calibration factor AH This is determined from the laboratory calibration and should be readily available on site see Calibrations Meter temperature Tm Temperature at the meter rises about 14 C 25 F above ambient temperature due to heat from the vacuum pump The ambient temperature should be measured at the Source Sampler Console site Meter pressure Pm Same as barometric pressure Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 46 ISOKINETIC SOURCE SAMPLER MANUAL The equation most commonly used for calculating the probe nozzle size is D eh KOL TM n est LCA B PAP a
7. Uy m __ sttw inwy Diameter of Stack D m C oono Area of Stack A mi _ p DistanceUpstreami B m o Diameters Upstream B di Aa o os Distance Downstream taD Diameters Downstream Number of Traverse Points Required Diameters to Minimum Number of Flow Disturbance Traverse Points Downstream Disturbance Stream Stream Points Points 2 00 4 99 0 50 1 24 24 16 5 00 5 99 1 25 1 49 20 16 6 00 6 99 1 50 1 74 16 12 7 00 7 99 1 75 1 99 12 12 gt 8 00 gt 2 00 80r12 8or12 UpstreamSpecj L DownstreamSpecj Traverse Pts Reguiredi Check Minimum Number of Points for the Upstream and Downstream conditions then use the largest 8 for Circular Stacks 12 to 24 inches 12 for Circular Stacks over 24 inches Upstream Disturbance Location of Traverse Points in Circular Stacks Distance Including 1 2 3 4 5 6 7 8 9 10 ll 12 PEX SOURCE TESTING EQUIPMENT LX INSTRUMENTS Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 3 ISOKINETIC SOURCE SAMPLER MANUAL METHOD 1 SAMPLE AND VELOCITY TRAVERSES FOR RECTANGULAR SOURCES PlantName SSS at Sampling Location Project Operator SCC Pts Available Stack Type of Ports Used StackSize Port
8. i 60T a Vs OA P l B P V A o l B l si Kik AA X i TI IC AE Ka 4 320 Metric Units 0 09450 English Units Check Final Isokinetic Sampling Rate VA n Nozzle Area inf or mm A 7 D 2 f V F AH LOOT we K Ve men A F l ir 13 6 91 60 0 Viar te A K3 0 003454 Metric Units 0 002669 English Units Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 12
9. 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 from the inlet of the first impinger inlet or if applicable the filter holder see Leak Check Procedures for non isokinetic or isokinetic sampling trains 4 Position the probe tip well into the stack Sample at a constant 10 flow rate of 2 Ipm until about 0 031 m 1 1 cf or until visible liquid droplets are carried 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 lt 20 C 68 F at the silica gel impinger exit 6 Mandatory Leak check the sampling train as in step B3 C Sample Recovery 1 Disassemble the impinger glassware and weigh each impinger or drying tube to 0 5 g Record weighing data on a field data sheet 2 Verify constant sampling rate 3 Calculate the stack gas moisture percentage Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 43 ISOKINETIC SOURCE SAMPLER MANUAL Large Impinger Train A Preparation 1 B Sampling 6 Transfer about 100ml of water into the first two impingers Leave the third impinger
10. Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 2 ISOKINETIC SOURCE SAMPLER MANUAL System Description The Apex Instruments isokinetic source sampling system consists of five 5 main components shown in Figure 1 1 1 Source Sampler Console includes a dual column manometer sample flow control valves with orifice flow meter dry gas meter and electrical controls External Vacuum Pump Unit includes pump hoses with quick connect fittings and lubricator Probe Assembly includes a removable probe liner removable tube heater encapsulated in a protective probe sheath with pitot tubes stack temperature orsat line quad assembly Modular Sample Case includes hot box for filter assembly cold box for impinger glassware and electrical connections Umbilical Cable includes all electrical and pneumatic lines to connect the Modular Sample Case with the Source Sampler Console Source Sampler Console External Vacuum ini Unit Modular Sample Case gt Tt Probe Assembly Umbilical Cable 1 5 Figure 1 1 Apex Instruments Isokinetic Source Sampling Equipment Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 3 ISOKINETIC SOURCE SAMPLER MANUAL Source Sampler Console The Source Sampler Console is the operator s control station that monitors gas velocity and tempe
11. Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 35 ISOKINETIC SOURCE SAMPLER MANUAL Static Pressure Static Pressure can be measured any of three ways gt Using a static tap gt Using a straight piece of tubing and disconnecting one leg of the manometer gt Using the S type pitot tube and disconnecting one leg of the manometer or The easiest way is to use a piece of metal tubing inserted into the approximate middle of the stack connected to a U tube water filled manometer with the other end open to atmosphere If the manometer deflects toward the stack it is recorded as negative static pressure less than barometric pressure If the manometer deflects away from the stack it is recorded as positive static pressure If an inclined manometer is used then the connection to the tubing must be placed on the negative right hand side of the manometer to read a negative static pressure and switched to the positive left hand side to read a positive static pressure If a stack static tap is used the procedure is identical If an S type pitot is used to measure static pressure the following procedure will work 1 Insert the S type pitot tube into the stack near the middle 2 Rotate the pitot about 90 until zero or null reading is obtained 3 Holding the pitot in place disconnect the positive side of the manometer and read the deflection of the oil in the manometer Record the static pre
12. modern combustion source CO concentrations Second the molecular weight of CO is the same as N2 28 g g mole and the balance of gas can be assumed to N2 without any change in calculation of molecular weight For a more detailed discussion of gas analysis using an Orsat Analyzer please refer to Apex Instruments Combustion Gas ORSAT Analyzer Model VSC 33 User s Manual and Operating Instructions or the operating instructions provide with the Fyrite Analyzer Figure 2 18 Illustration of Orsat Analyzer and Gas Sample Bag Container The equation used to calculate dry molecular weight of a stack gas is M 9 44 CO 0 32 O 0 28 N CO Where COr Percent CO by volume dry basis O2 Percent O by volume dry basis N2 Percent N by volume dry basis CO Percent CO by volume dry basis 0 28 Molecular weight of N or CO divided by 100 0 32 Molecular weight of O2 divided by 100 0 44 Molecular weight of CO divided by 100 Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 39 ISOKINETIC SOURCE SAMPLER MANUAL Method 4 Moisture Content of Stack Gas There are two separate procedures for determining moisture content in stack gases gt The first is a Reference Method for accurate measurements of moisture such as are needed to calculate emission data an
13. turning off the pump except when changing ports Do not bump the probe nozzle into the stack walls Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 51 ISOKINETIC SOURCE SAMPLER MANUAL a Maintain the temperature of the Hot Box probe outlet or filter outlet at the proper level b Monitor the Ap during each point and if the Ap changes by more than 20 another set of readings should be recorded c Periodically check the level and zero of the manometers and re adjust 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 AH temps vacuum at least once each sample point during each time increment maintaining the AH Ap isokinetic ratio f Add more ice and if necessary salt to maintain a temperature lt 20 C 68 F at the silica gel impinger exit 10 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 11 Mandatory Leak Check the sampling train at the maximum vacuum achieved during the sample run Record leak check results on field data sheet 12 Mandatory Leak Check the pitot lines Record on the field data sheet 13 Allow the probe to cool Wipe off all external particulate material near the tip of the probe nozz
14. 33 cm 13 inches This means that in traversing the stack the sampling equipment needs 33 cm of clearance below the port level so as not to bump into guardrails or other structures The dimensions needed for clearance along the sample port plane include the effective probe length stack diameter plus port nipple length PLUS at least 91 cm 36 inches to accommodate the sample case Hot Box Cold Box and probe clamp length Figure 2 2 illustrates the clearance zones required Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 20 ISOKINETIC SOURCE SAMPLER MANUAL NOTE The cable must be attached to the stack so that the cable angle to the monorail is a minimum of 30 45 is recommended gt 30in or gt 76cm pe fa gt 12 5in l or gt 32cm lin or gt 35cm is KU gt 36in or gt 92cm Figure 2 2 Clearance Zones at Stack for Isokinetic Sampling Train Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 21 ISOKINETIC SOURCE SAMPLER MANUAL Where sampling train clearance problems cannot be overcome Apex Instruments offers a non rigid Method 5 sampling train with separate and or miniature heated Filter Box SB 2M to allow the Cold Box to be placed on the sampling platform connected by the sample line and Umbilical Adapter GA 104 Another option is to use the Com
15. 5 000 to 15 000 hours operation depending upon application Remember The pump is designed for pumping clean dry air It is built of cast iron and steel Protect it against entrance of dirt excessive moisture and chemical contamination lubricate it and you will receive years of trouble free service Maintenance and troubleshooting procedures for the rotary vane pump is as follows Inspection Regular inspection and flushing may prevent excessive repairs Dirty or clogged filter felts can be responsible for failure of pump to build up vacuum and eventually causes overheating of pump WARNING THE MOTOR IS THERMALLY PROTECTED AND WILL AUTOMATICALLY RESTART WHEN PROTECTOR RESETS ALWAYS DISCONNECT POWER SOURCE BEFORE SERVICING PERSONAL INJURY AND OR PROPERTY DAMAGE MAY RESULT Remove the felts and wash in Flushing Solvent see Flushing If there is overheating or excessive noise stop pump immediately for repairs It may be quickest and least expensive to send the pump unit for repair Starting If motor fails to start or slows down when under load turn off and unplug Verify that the voltage agrees with the motor post terminals and motor data nameplate Also examine plug and switch If pump unit is extremely cold bring to room temperature before starting If trouble appears to be in motor it may be cheaper to return unit to pump manufacturer than to call an electrician especially within the guarantee period NOTE ALL DUAL VOLTAGE MOTORS ARE
16. 6 C and ambient pressure for 2 24 hr and then weigh at intervals of 2 6 hr to a constant weight lt 0 5 mg change from previous weighing Record results to 0 1 mg During each weighing do not expose the filter to the laboratory atmosphere for gt 2 minutes and a relative humidity gt 50 3 Optional If condensable or back half particulate matter is to be measured 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 Nozzles should be kept 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 de ionized water followed by reagent grade acetone and then allow to air dry Cover all exposed openings with parafilm plastic caps serum caps ground glass stoppers or aluminum foil not for metals to avoid contamination Note Special cleaning procedures may be
17. 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com ISOKINETIC SOURCE SAMPLER MANUAL Low Pressure High Pressure To Manometer AH Low Pressure Side High Pressure Side AP 4 Pitot 4 To Manometer AH High Pressure Side 4 Pitot AP Manometer gt High Pressure Side hel yy i l l i HEHHE lt To Sample Line ty Course Control Valve Vacuum Gauge G H i Pump Suction LU Fine Control Valve _ f Orifice Tube l HHO lt Pump Pressure LU t Dry Gas Meter TITLE MC522 Plumbing Schematic REVISION HISTORY PART DATE BY DESCRIPTION P EX SOURCE TESTING EQUIPMENT INSTRUMENTS I MATERIAL FILE mc522 plumbing schem cdr INITIALS kr Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com B 4 ISOKINETIC SOURCE SAMPLER MANUAL Appendix C Calibration Data Sheets Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com C 1 ISOKINETIC SOURCE SAMPLER MANUAL USING WET TEST METER 8 o 3 ha 3 z 8 b E d a p a 2 fn z miil kiri f TWITTI which is traceable to the National Bureau of Standards N 1 S T Apex Ins
18. ALUM FOIL REAGENTS RAILS SQUEEZE BOTTLES H20 TAP__DD__ ROLLERS PETRI DISHES ____ ACETONE DUCTIAPE PARAFILM OTHER penne RUBBER GLOVES SILICA GEL JANE ORSAT CHEM METER OPERATORS CASE MOC BOX NOMOGRAPH TOOLS MULTIMETER COMPUTER CALCULATOR BAROMETER WRENCHES PENS PROGRAMS STOP WATCH VAC GAUGE SCREWDRIVER CLIP BOARD DATA SHEETS CFR METHODS SERUM CAPS TAPE MEAS PROJECT FILE PRELIM DATA ELEC TAPE MAP DIRECTIONS A 5 Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com ISOKINETIC SOURCE SAMPLER MANUAL Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com A 6 ISOKINETIC SOURCE SAMPLER MANUAL Appendix B Electrical and Plumbing Schematics Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com B 1 ISOKINETIC SOURCE SAMPLER MANUAL ZEO TA AE NO aera dLVO NI ALa X cE sezopdn s buoy3 sequin d DIVNY JLVLS HITIOHL L YSZ AYY OvvOL9 8 OJIJYAS HIWIL WG WSL HIHVINS Z OWVAOZL IK SIL IL l 9W MA6L LL6VH W NOILHIHDSIQ Dd Add I NLVAZJWAL qa LV4H
19. DAA Double Headed Diaphragm Pump Motor 370 watts 1 2 hp 120 VAC 60 Hz 1 2 Amp Measured Flow 82 Ipm 0 25 kPa 2 9 cfm 1 inch Hg 40 Ipm 3 73 kPa 1 4 cfm 15 inches Hg Maximum Vacuum 89 7 kPa 26 5 inches Hg Weight 13 6 kg 30 Ib E DAAV Optional 240 VAC 50 Hz Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com Optional Unit 8 ISOKINETIC SOURCE SAMPLER MANUAL Probe Assembly The Probe Assembly consists of the following Figure 1 4 illustrates a standard Probe Assembly and a Probe Assembly with the optional 50 8mm 2in Oversheath and Packing Gland The Figure 2 4 also details the connection between the nozzle and probe using fittings from the Small Parts Kit Probe lengths vary from 0 914 m 3 ft to 4 877 m 16 ft nominal length Note Effective probe length in stack 0 305 Probe Liner 15 9mm 5 8in OD tubing made from either Borosilicate Glass Quartz Stainless Steel Inconel or Teflon Probe Heater Removable rigid tube heater with coiled heating element electric thermal insulation and thermocouple Max Recommended Temperature 260 C 500 F Probe Sheath 25 4mm lin OD tube with quad assembly attached that includes a replaceable modular S type pitot tube stack thermocouple and a 6 35 mm 1 4 inch OD stainless steel tube to collect a gas sample for Orsat analysis Small Parts Kit Fittings to attach Nozzle t
20. Direction j l Figure 3 11 GP BL50 2 Lubricator Assembly Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 76 ISOKINETIC SOURCE SAMPLER MANUAL Flushing Most pump trouble can be corrected by flushing rather than disassembly A noisy or inefficient pump is frequently nothing more serious than a vane or vanes stuck in rotor slot due to excessive oil or foreign material inside pump e Disconnect the power to the pump unit The inlet and outlet couplers need to be disconnected also Exercise extreme caution as the pump head and motor may be extremely hot e Remove the filter insert See Figure 3 12 from the muffler jar Reinstall the muffler jar and tighten HAND TIGHTEN ONLY e Wrap the end of the pressure hose in newspaper or disposable rags This will catch the oil mist that is dispersed e Turn on the pump and add several teaspoons of solvent Gast Flushing Solvent AH255 or non flammable solvent WD 40 is commonly used by most stack testers directly into the vacuum hose This should be done until the oil coming from the pressure hose looks clean The pump should be run for another five minutes in order to clear out any remaining oil DO NOT USE KEROSENE GASOLINE OR ANY OTHER FLAMMABLE LIQUID PERSONAL INJURY AND OR PROPERTY DAMAGE MAY RESULT Flush the pump in a well ventilated area Eye protection is rec
21. P it Ps ii 13 6 Dry Gas Molecular Weight g g mole or Ib ib mole Mg 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 lt 212 F BE CAREFUL fraction Bws H20 100 Wet Gas Molecular Weight g g mole or Ib ib mole M M 1 B 18 0 B M HI8 0 M Stack Gas Temperature K or R Ts C 273 Kor F 460 R Pitot Tube Coefficient Cp Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 9 ISOKINETIC SOURCE SAMPLER MANUAL Nozzle Size Selection Worksheet continued Average Velocity Head mm H20 or in H20 APavg v calculation of inside square root term T M y ee ae a SS F AP avg m JED e VC ki Sampling Flow Rate cfm or lpm Qm assume 0 75 cfm assume 21 24 Ipm 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 Phar AH 13 6 CALCULATION OF NOZZLE SIZE Estimated Nozzle Diameter mm or inches _ katt NA Puo GIA TAT sl K4 0 6071 Metric Units 0 03575 English Units Actual Nozzle Diameter Chosen mm or inches Dn Apex Instruments Inc Ph
22. Run Procedure 1 Open and clean the portholes of dust and debris 2 Level and zero the Ap and AH manometers 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 pitot tube temperature gauge and probe alignments and clearances 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 Ap on the manometer and determine AH from the nomograph Immediately start the pump and adjust6 the flow to set the AH 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 6 When the probe is in position block off the openings around the probe and porthole using duct tape rags gloves or towels or flameproof materials for hot stacks Figure 2 27 Blocking off the Porthole During Sampling 7 Record the AH pump vacuum and temperatures for stack gas DGM filter box probe and impinger exit Record the ID numbers for DGM thermocouples pitot tube and Sample Box 8 If simultaneously running Method 3 gas bag collection turn on the Orsat pump Turn Orsat pump off during port changes 9 Traverse the stack cross section for the same time period at each point without
23. Trango a mem Wash Beaker Estimated Volume Fintor Acetone Date Time Humiaity Temp Cel Audit mer i te EL Measurement 2 mama __ __ measurement 3 ms im _ L L 0 Measurement 4 mam __ Acetone Wash mg madman mdm lg Bottle Wt with Wash a Additional Rinse Wt mg Bottie Tare Weight m p mw ne Blank Adjustment Net Wash Weight Total Particulates ma Ca Analytical Data Placed in Dosiccator OOOO O O Run Number O 181 o f Number Date f Tims Run Start Timel OOOO O Fitter Leakage T A estore Wash Beaker Estimated Volume Fitter Acetone Date Time Humidity Temp Cal Audit Measurement impima o Measurement 2 ma m _ _ _ A a Measurement 4 mma a ee ee Acetone Wash moma C Tare Weight mom 7 WeightGainf mime OOO Total Particulates m Da aa J Ta Bottie wewith Wash Mad o Additional Rinse wt ma mg Bottle Tare Weight me mg f NetWash Weight ma _ mg Blank Concentration CJ Mg average of last two filter measurements Mi average of last two acetone measurements P EX SOURCE TESTING EQUIPMENT L X INSTRUMENTS Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 11 IS
24. _ or_ ____ SiGar_ Fm wow __ initia Vatwe vy _ __ Net Vatue vis _ Total voume v mi Water Vol Condensed Vossa som nan Number OO Run Start Time Run Stop Time Total Meter Volumel Wa L Barometric Press mmHg Avg Meter Temp Ma C Stack Static Press Pama __ mmH 0 Avg Stack Temp lea _ Avg Orifice Press Hina mmr lem om om g m m m D AW A or Sica S SO l Fmivaw wow __ rime i KANA ENGAANIEI KRETA FKGREBTI NGO neva vane o 2 can Sid Meter Volumel Vaea deom Sat Moisture Content Gea Calc Moisture Content Bw Final Moisture Content Bw O o O RunStartTime RunStopTime Fotai Meter Volume WI am Sarometic Press FI mmr T Avg Meter Temp taen Stack Static Press Cug mmr Avg Stack Temp Wee C Avg Orifico Press Ha mH 0 77 Finalvalef Vow __ 7 wavae w _ T O Ntvawe vow O O i o Total Volume v mi Water Voi Condensed Wens _ som Calc Moisture Content B Final Moisture Content Bm Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 7 ISOKINETIC SOURCE SAMPLER MANUAL P EX SOURCE TESTING EQUIPMENT INSTRUMENTS ISOKINETIC SAMPLING DATA Sample
25. com 36 ISOKINETIC SOURCE SAMPLER MANUAL Stack Gas Molecular Weight and Moisture To calculate the average stack gas velocity values for the molecular weight and moisture must be obtained See the sections on Method 3 and Method 4 The stack gas molecular weight dry basis Ma is corrected to the wet basis Ms using the moisture fraction Bws by the equation M M B 18 0B After the average stack gas velocity V has been calculated the volumetric flow rate can be calculated The area of the stack A is calculated for circular stacks as 2 sek l 2 For rectangular stacks The stack gas volumetric flow rate is calculated using the following equations Q 60v A P KVA Q S T P Qa K a z B V A Where Qa Volumetric flow rate actual m min acfm Q Volumetric flow rate standard sm min scfm Qsa Volumetric flow rate dry standard dsmm min dscfm K Constant to convert time to minutes and P T to standard conditions 21 553 for metric units 1058 8 for English units Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 37 ISOKINETIC SOURCE SAMPLER MANUAL 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 From this data the stack ga
26. in Method 4 and other isokinetic methods they can be replaced with a stainless steel equivalent coil condenser S 4CN making a rugged and reliable system without the fragility of the traditional glass assembly Figure 2 19 Set up of Cold Box with Sample Frame and Probe Clamp Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 40 ISOKINETIC SOURCE SAMPLER MANUAL Reference Method 4 Use the following procedure for accurate measurements of moisture content A Preparation 1 Use at least the following number of traverse points and locate them according to Method 1 a 8 for circular ducts lt 60 cm 24 inches diameter b 9 for rectangular ducts lt 60 cm 24 inches equivalent diameter c 12 for all other cases 2 Transfer about 100 ml of water into the first two impingers Leave the third impinger empty and weigh each impinger to 0 5 g 3 Transfer about 200 300 g of silica gel into the fourth impinger and weigh to 0 5 g 4 Determine the sampling rate to collect 2 0 741 sm 21scf at lt 21 Ipm 0 75 cfm 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 Section D B Sampling 1 Assemble and set up the sampling tr
27. next sampling run as well as the average isokinetic rate To calculate the stack gas moisture content Buy the following equations are used to compute the sample gas volume V me and gas moisture volume V salad AH ata T a Vin std E KY T where AH Average orifice tube pressure during sampling mm H O in H O Va Dry gas volume measured by dry gas meter dem dcf Ta Absolute temperature at dry gas meter K CR Y Dry gas meter calibration factor K 0 3858 K mm Hg metric units 17 64 R in Hg English units Vvetstd K W W where W Final weight of water collected g Wi Initial weight of water collected g K 0 001335 m g metric units 0 04715 ft g English units and Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 58 ISOKINETIC SOURCE SAMPLER MANUAL _ Voge std ws V nista Vive std where B Proportion of water vapor by volume in the gas stream Next the average stack gas velocity is calculated The equation for average gas velocity in a stack or duct is skoll ie PM where v Average stack gas velocity m sec ft sec C Pitot tube coefficient dimensionless VAP avg Average of the square roots of each stack gas velocity head le Absolute average stack gas temperature K R P Absolute stack gas pressure mm Hg in Hg Ppa P 13 6 Bis Barometric Pressure at
28. plug ground pin Ohmmeter should read less than ohm Modular Sample Case Check the probe heater plug with a check light for continuity Probe Assembly Tube Heater Inspect electrical connections to the tube heater and power cord for visible shorts or burned spots in the high temperature insulation Connect power cord into suitable power source and monitor temperature Probe should become warm to touch over its entire length in a few minutes If probe does not heat check power source for proper voltage and loose connections in plug Shorts are indicated by partial heating in rear section of probe Breaks in heating element and connections can be checked with an ohmmeter or a battery light system Replace probe tube heater if necessary Sample Vacuum and Pitot Pressure Lines on Umbilical Cable Check the quick connects and lines on the Umbilical Cable as follows Quick Connects Wipe vacuum line and pitot line quick connects clean before attaching to Source Sampler Console Mating quick connects should be joined together when not in use to prevent damage and dirt A drop of penetrating oil on each keeps them in good working condition Vacuum Line Test vacuum line for leaks by plugging inlet with a 12 7 mm quick connect plug and connect line to Source Sampler Console Conduct leak check by pulling vacuum If leakage is noted check all connections first and then if necessary inspect the tubing look for crimps If cause c
29. 0 Raleigh NC North Carolina State University 1995 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 Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 60 ISOKINETIC SOURCE SAMPLER MANUAL Chapter Calibration amp Maintenance Setting up and adhering to a routine maintenance program will help to ensure trouble free operation of the isokinetic sampling system In addition a carefully documented maintenance and calibration system will help to assure that accurate results are obtained during stack testing activities The following text describes maintenance and troubleshooting procedures for the various subsystems of the isokinetic sampling system Calibration Procedures Test results from a stack emission test are meaningless without calibration of the equipment components The creation and maintenance of a regularly scheduled calibration and record keeping program are c
30. Ball Viton Th O ring ri 0 126V 1 Impinger O ring l l Top 0 123V Impinger O ring GN 2 Bottom Cyclone Body optiional GN 3 Cyclone Flask optiional GN 9A GN 9AO GN 9A GN 9A Figure 1 9 Glassware Sampling Train Schematic Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 15 ISOKINETIC SOURCE SAMPLER MANUAL Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 16 ISOKINETIC SOURCE SAMPLER MANUAL Chapter Operating Procedures There are many elements to consider before testing for particulate matter which includes Set up and check of source sampling system Test design Site preparation Sampling equipment calibrations Described in Chapter 3 Assembling sampling equipment and accessories reagents sample recovery equipment and sample storage containers e Preliminary measurements of stack dimensions gas velocity dry molecular weight and moisture Set up and Check of Source Sampling System Carefully unpack the contents saving the packing material until the parts have been examined for shipping damage and the sampling system has been completely assembled Check each item against the packing list If any item is damaged or missing notify Apex Instruments immediately at 800 882 3214 or email at info apexinst com Appendix A lists the items i
31. C 500 F Exposure to elevated temperatures can damage the insulation and shorten the life of the heater Table 1 5 lists the probe heater wattage required for probe nominal length Table 1 5 Probe Heater Wattage Requirements Length m ft 0 914 3 1 22 4 1 52 5 Probe Sheath Apex Instruments stainless steel Probe Sheaths feature a one inch diameter sheath constructed from corrosion resistant stainless steel alloy modular 3 8 inch pitot tip with inch stainless steel quick connects stack temperature thermocouple and an orsat line Inconel Sheaths are available for gas temperatures up to 1800 F Small Parts Kit Apex Instruments Small Parts Kit PK SP includes15 9mm 5 8in union nut and ferrules along with o rings and backer ring as shown in Figure 1 4 The Probe Assembly connects to the Modular Sample Case with the following connections e The probe sheath is mounted to the Modular Sample Case using a probe clamp that is attached to the probe holder of the sample case e Extending from the probe assembly is a thermocouple male connector which connects to female thermocouple connector of the Umbilical Cable e Anelectrical plug connects to the electrical receptacle on the Modular Sample Case Hot Box e The outlet ball of the Probe Liner is inserted 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 e The pitot tube quick connect
32. Case Oven Leak Checks L Stack Static Pressure Paas mm HO _ Absolute Stack Pressurej P mm Hg Absolute Meter Pressure P 1 mm Hg Leak C Orsat OK Dry Gas Desired Actual Meter Traverse Sampling Clock Meter Velocity Orifice Orifice Probe Outlet Filter Point Time Time Reading Head AH AH Temp Temp e Vind Ap AH AH t tra P min hh mm ss m HA PTT i Cs ee EOR AAMT SOMES eS TRE d k OK Celele v 3 3 Temp Vacuum i v c 3 ki Q o 3 v Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 8 ISOKINETIC SOURCE SAMPLER MANUAL P EX SOURCE TESTING EQUIPMENT INSTRUMENTS METHOD 5 SAMPLE RECOVERY AND INTEGRITY DATA SHEET PlantName ate Sampling Location JI Project SSS Operator Acetone Lot Number O o Run History Data Run Start Time Run Stop Time Train Prepared B aay GEW Sane peo 4 TrainRecoveredBy ea aes aac ee Recovery Date Relinquished B Received B Relinquished Date Relinquished Time TULL LL FIEX Equipment Identification Num eee a p Acetone Wash JI J Silica Gel f p ImpingerCasej J o Sample Boxf o o ieee es R Moisture Content Data Impingers 1 2 and 3 Water Volume Final Volume Initial Volume Net Volume Comment
33. IPMENT INSTRUMENTS Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 4 ISOKINETIC SOURCE SAMPLER MANUAL METHOD 2 DETERMINATION OF STACK GAS VELOCITY AND VOLUMETRIC FLOW RATE Diameteror Length of Stack D m OOo Widthofstae w m Area of Stack A Tm mmHg Velocity Traverse Data Run Time Stack Local Temp Velocity Pressures Barometric Pressure Py _ Static Pressure Pan Absolute Stack Pressure P _ Composition Data Acts L Estimata II l Carbon Dioxide Concentration CO Oxygen Concentration 0 carbon Monoxide Concentration 00 Nitrogen Goncentration Np __ EE a TA EEN g Stack Moisture Content Stack Dry Molecular Weight Ma Stack Wet Molecular Weight Avg Stack Gas Velocity w msec l Ag Stack Dry Std Flow Rate Q dsomihr EN Eee Avg Stack Dry Std Flow Rate Q 4 dsem min Avg Stack Wet Flow Rate Qa ascm min Stack Cross Section Schematic Average of the square roots of Ap where Ap 799 b ap Formulas Used A DWIK for Rectangular Stacks Taavo In Et Tu A 1 D 2 IK for Circular Stacks where T 273 K for metric units where K 1 for metric units where T 460 R for English units where K 144 i
34. Inside Diameter Rectangular Stacks or Ducts Length to Far Wall of Stack tw R a Ltw Lw Length of Stack L ee O aa en WidthofStacki w 2uwaLewy Equivalent Stack Diam D Lwicunits Area of Stack Distance from Port to Disturban Distance Upstream 8 ceon Diameters Upstreamf B diameters EM ps Downstreom JIDisturbonce ra Meosuremen Distance Downstream A sADe Diameters Downstream Number of Traverse Points Required Diameters to Minimum Number of Flow Disturbance Traverse Points Up Down jParticulate Velocity Stream Points Points Upstream isturbonce wn 3 2 00 4 99 0 50 1 24 25 16 Number of Traverse Points Used 5 00 5 99 1 25 1 49 20 f 16 JPorisov Across 6 00 6 99 1 50 1 74 16 12 JPtsUsed Required 7 00 7 99 L LI Particulate l Velocity Upstream Spec f Downstream Spec Distance Traverse Pts Required Including Check Minimum Number of Points for the Upstream and Downstream conditions then use the largest 9 for Rectangular Stacks 12 to 24 inches 12 for All Stacks over 24 inches Location of Traverse Points in Rectangular Stacks raverse Fraction of Stack Dimension fram inside Wall to Traverse Point umber of Traverse Points Across the Stack e L10 13 12 0560 045 042 PEX SOURCE TESTING EQU
35. MANUAL Although the Isokinetic Source Sampling System was designed to fit into a 6 35 cm 2 inch sample port 7 6 cm 3 inch or larger holes allow easier entry and removal without damaging the nozzle or picking up deposited dust There are basically two ways to mount the isokinetic sampling system Hot Box Cold Box for testing on a stack 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 When no mounting support for a monorail system exists it can be easily fabricated using the Apex Instruments Monomount P501 around the stack as shown in Figure 2 6 Monorail mounting can be accomplished when an angle iron with a hole or an eyehook has been welded to the stack Alternatively a tee bracket system such as that shown in Figure 2 5 may be used with the load bearing calculations described Figure 2 7 and Figure 2 8 illustrate a complete stack set up using the Hot Box Cold Box together SB 1 and Hot Box and Cold Box separated SB 2M and SB 3 Chain Fo included with P1000 0 Cee Ce a P1000 29 L i unistrut nut mo PA Pp Se o BI f A See 12 5 in oN Ts p 32 cm N i porst Q AL l pe Figure 2 5 Illustration of Monorail System for Sampling Train a Chain Pes Sy i
36. Method APEX INSTRUMENTS INC Isokinetic Source Sampler 500 Series Models P EX SOURCE TESTING EQUIPMENT INSTRUMENTS Apex Instruments Inc 204 Technology Park Lane Fuquay Varina NC 27526 USA Phone 919 557 7300 e Fax 919 557 7110 Web www apexinst com E mail info apexinst com Revision No 4 Revision Date February 2003 ISOKINETIC SOURCE SAMPLER MANUAL TABLE OF CONTENT INTRODUCTION ssssnsnsensanezzznsanezzznsaneneznenneneee L SYSTEM DESCRIPTION pps serensnnnenennznnenenenznnn na 3 Source Sampler Console seen 4 Electrical Subsystem s ssseseseeesznzonanzenzazenzonnaneranzanenza Thermocouple Subsystem Vacuum Subsy stein sas sisiu pesii ieitet iba gas rati 7 External Vacuum Pump Unit seen 6 Probe Assembly nare senser onn sms 9 Probe Liner is Probe Heater asri ara EOR 11 ProberSheathi 4 eee el See Ee Ge eel su lise 11 Smalt Parts Kitsas iena ien sa 11 Modular Sample Case nsss 12 Umbilical Cable with Umbilical Adapter 14 Glassware Sample Train sse 15 OPERATING PROCEDUREG cccsssssssrseeee 17 SET UP AND CHECK OF SOURCE SAMPLING SYSTEM Initial Set up Procedure System Check sireni tnia Re an Initial Sampling System Leak Check TEST DESIGN arinen ioaea d l SITE PREPARATION ccccccccececececececececececececeseceeece ASSEMBLING SAMPLING EQUIPMENT AND REAGENT Si iii e E a l e 25 PRELIMINARY MEASUREMENTS OF GAS VELOCI
37. OKINETIC SOURCE SAMPLER MANUAL METHOD 5 DETERMINATION OF PARTICULATE EMISSIONS RESULTS Plant Namej 00 Date Sampling Locationp 77777777 L Projectii EE IK Stack Type Historical Data Po Run Number JI P Run Start Time II RunStoprim PI p MeterCalibrationFactori V ey ey Sa Stack Test Data Initial Meter Volume Vendy Total Meter Volume Total Sampling Time n l Average Stack Temperature Stack Static Pressure Absolute Stack Pressure P Average Orifice Pressure Drop AH wa Absolute Meter Pressure Avg Square Root Pitot Pressure Ap juq gt kal gt e a gl S falam 3 8 3 8 2 3 el EE 8 3 3 8jels 2 8 8 Blele AHHA 5I515131313 PEPER ap al Data 2 a gt g 3 O o 3 2 8 3 gt Impingers 1 3 Water Volume Gain Impinger 4 Silica Get Weight Gain W Total Water Volume Collected Standard Water Vapor Volume Standard Meter Volume L Calculated Stack Moisture Braicate _ Saturated Stack Moisture Busi Reported Stack Moisture Content Bws Gas Analysis D Carbon Dioxide Percentage Oxygen Percentage Carbon Monoxide Percentage CO Nitrogen Percentage N2 Dry Gas Molecular Weigh Wet Stack Gas Molecular Weigh Calculated Fuel Factor Fa Percent Excess Air Volumetric FI Average Stack Gas Velocity Stack Cross Sectional Area Actual Stack Flow Rate Qm Wet Standard Stack Flow Rate Dry Standard Stack Flow
38. PLS LIGN a U specify nozzle size Figure 1 5 Diagrams of Probe Liner Configurations Table 1 3 Maximum Stack Gas Temperatures for Probe Liner Materials Maximum Material Temperature Teflon Liners and Fittings 177 C 350 F Mineral Filled Teflon Fittings 315 C 600 F Borosilicate Glass Liners 480 C 900 F Stainless Steel Liners 650 C 1200 F 900 C 1650 F Table 1 4 Probe Configuration Temperature Ratings Maximum Probe Assembly Configuration Temperature Stainless Steel Sheath and Glass Liner 480 C 900 F Stainless Steel Sheath and Liner 650 C 1200 F Inconel Sheath and Liner 980 C 1800 F Inconel Sheath and Quartz Liner 980 C 1800 F Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 10 ISOKINETIC SOURCE SAMPLER MANUAL Probe Heater Apex Instruments Probe Heaters are designed to maintain the temperature of the sample traveling through the probe at 120 C 14 C 248 F 25 F Our design features a rigid tube heater with coiled heating element electrical thermal insulation with integrated thermocouple and power cord sealed in silicone impregnated glass insulation This mandrel type heater design allows for liner replacement without removing the heating element Standard heaters are configured for 120VAC operation and 240VAC configuration is available The maximum recommended stack exposure temperature is 260
39. Rate Percent of Isokinetic Rate Emission Rat ole 3 a jeje 3 als 3 Fi JEM TI 2 i S Ej L E Mass of Particulate on Filter mM Mass due to Acetone Blan Fl ieee p G a Particulate Emission Ra g g 3 d a d x ta b Pl i b wie o 2 8 05 g EJ AA aKa 31815 oja 5 HEHHE sisjej 2S o e 818123 S 175 App F Sect 5 21 Heat Inpu P EX SOURCE TESTING EQUIPMENT INSTRUMENTS Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 12 ISOKINETIC SOURCE SAMPLER MANUAL Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 13 ISOKINETIC SOURCE SAMPLER MANUAL Appendix E Calculation Worksheets Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 1 ISOKINETIC SOURCE SAMPLER MANUAL 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 m or ft Rectangular Stack Length of stack location L m or ft Width of Stack location W m or ft 2LW Equ
40. SHIPPED FROM FACTORY SET FOR HIGH VOLTAGE Muffler Assembly AB609B Gast Pump GP 0523 Lubricator GP BL50 2 Figure 3 10 Diagram of E 0523 Rotary Vacuum Pump Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 75 ISOKINETIC SOURCE SAMPLER MANUAL Lubrication Use of correct oil and proper amount of oil will ensure years of operation A film of oil provides the seal for the vanes to ride on and fill any tolerance clearance Use Gast AD220 Oil order Part AD220 or a high detergent SAE 10 or SAE 5 automotive engine oil may be used as an equivalent to Gast AD220 In ambient locations with temperatures over 38 C 100 F SAE 20 oil should be used The Lubricators may be filled only under no pressure For proper lubrication fill oil jar to level indicated on outside of jar To check lubrication hold a thumbnail or small mirror near the pump exhaust A heavy film indicates over lubrication Lubrication rate should be adjusted by raising and lowering wick HAND TIGHTEN ONLY To Add Oil 1 Unscrew reservoir 2 Add oil to reservoir approximately 3 4 full See Figure 3 11 3 Replace reservoir Hand tighten only To Adjust Oil Flow 1 Loosen nylon screw as in Figure 3 11 2 Move wick up for more oil or down for less oil as in diagram Be careful Wick is fragile and breakable 3 Re tighten nylon screw 4 Replace reservoir TO
41. SOURCE SAMPLER MANUAL Appendix D Stack Testing Field Data Sheets Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 1 ISOKINETIC SOURCE SAMPLER MANUAL SOURCE SAMPLING TITLE PAGE PlantNamef S __SamplingLocation SS Fuelor Source Type gt oS O FuelF Factor d o o T Test Information Starting Test Date Standard Temperature Test Equipment Information Meter Box Number Meter Calibration Factor Cp Dan Pitot identification Pitot Tube Coefficient C Orsat Identification Nozzle Number _ Nozzle Diameter D Probe Number _ Probe Length SS Glass Liner Material Sample Case Oven Number Impinger Case Number _ Acetone Lot Number Company Name SS Address o City State Country Zip o Project Manager S e eee Phone Number P EX SOURCE TESTING EQUIPMENT INSTRUMENTS Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 2 ISOKINETIC SOURCE SAMPLER MANUAL METHOD 1 SAMPLE AND VELOCITY TRAVERSES FOR CIRCULAR SOURCES C PlantNamef Cate Sampling Location d rojo Operator of Ports Available StackType tof Ports Used Stack Size Cort Inside Diameter Distance to Far Wall of stack i fm Distance to Near Wall of stack
42. Stack Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 29 ISOKINETIC SOURCE SAMPLER MANUAL 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 Table 2 3 Cross Section Lavout for Rectangular Stacks Number of Traverse Points Matrix Lavout 9 3x3 12 4x3 16 4x4 20 5x4 25 5x5 30 6x5 36 6x6 42 7x6 49 7x7 e e e e e e e e e e e e This is an example of a rectangular stack cross section divided into 12 equal areas with a traverse point at centriod of each area Figure 2 12 Traverse Points Located in Centroids for Rectangular Stack Tips from an Old Stack Tester After calculating the traverse point locations before adding sample port nipple length vou 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 then if the third and third from last and so on Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apex
43. TY MOLECULAR WEIGHT AND MOISTURE 0065 25 METHOD DETERMINING SAMPLE AND VELOCITY TRAVERSE POINTS cccccccecececececeseeeeeseseseseseeeeees 26 METHOD 1A SAMPLE AND VELOCITY TRAVERSES FOR SMALL STACKS OR DUCTS c0cesseeeeeeeeeeeeee 32 METHOD 2 STACK GAS VELOCITY AND VOLUMETRIC FLOW RATE nenenenezznnnezznnnzn 33 Sane PLS SUP e siis a i hosel iver Ree cote Aah 36 Barometric Pressure ooer 36 Stack Gas Molecular Weight and Moisture 37 METHOD 3 GAS ANALYSIS FOR DRY MOLECULAR WEIGH a na e a R RS 38 METHOD 4 MOISTURE CONTENT OF STACK GAS40 Reference Method 4 41 Approximation Method 43 METHOD 5 DETERMINATION OF PARTICULATE EMISSIONS oaran aas a ee ass METHOD 5 TEST PROCEDURE RECOMMENDED READING LIST FOR ISOKINETIC SAMPLING iii pi e ctuccocewvelasevatocscosvei ear eS 60 CALIBRATION PROCEDURES s ccessseesseseeeseseees Dry Gas Meter and Orifice Tube Metering System Leak Check Procedure Vacuum Side 63 Metering System Leak Check Procedure Pressure Side 64 Initial or Semiannual Calibration of Dry Gas Meter and OTIS TUBE i se is e qa a Fa 65 Post Test Calibration of the Source Sampler Console 67 Calibration of Thermocouples 68 Calibration of Pressure Sensors ss 70 Calibration of Pitot Tube 71 Calibration of Sampling Nozzles 73 Initial Calibration of Probe Heater 74 MAINTENANCE vereis h a a nn sana snanar External Pum
44. Tube Thermocouples and Digital Indicator Pitot Tube Sampling Nozzles Probe and Filter Box Heater System 1 Wet Test Meter 2 Secondary Reference DGM 1 Wet Test Meter 2 Reference DGM 3 Critical Orifices Measured during DGM calibration Certified Hg in glass thermometer in ice slush and boiling water 1 Standard pitot tube in wind tunnel and calculate C 2 Measure with angle indicator to demonstrate meeting geometry specifications and assign C 0 84 Micrometer with at least 0 025 mm 0 001 inch scale Gas thermocouple Y Y 0 05Y Y Y 0 05Y ive AHe 46 7 6 4 mm H O 1 84 0 25 in H 0 Stack 1 5 K DGM 3 C Probe 3 C Filter 3 C Exit 1 C If part of Probe Assembly calibrate with assembly G lt 0 001 for side A and side B a 10 az 10 B 5 B2 5 Z lt 0 125 W lt 0 031 Pa Pg lt 0 063 0 188 SD7S0 375 Average of three inner diameter measurements AD 0 1 mm 0 004 inch Capable of maintaining 120 C 14 C at 20 Ipm flow rate Semiannually After each field test With DGM After each field test Quarterly or after each field test Quarterly or after each field test Before each field use Initially Table 3 1 Sampling System Equipment Calibration and Frequency Recalibrate repair or replace Recalibrate at 5 points Repair or replace Recalibrate repair or replace
45. a wind tunnel facility USEPA allows the assignment of a C 0 84 if the pitot tube meets geometric specifications because the error is in the regulatory agency s favor biases velocity and flow rate high The procedure shown on next page describes how to conduct the geometric specifications calibration check Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 71 ISOKINETIC SOURCE SAMPLER MANUAL BOTTOM VIEW 2 Orsat Line G il Oe Before starting the calibration check fill out ee amare SEL i a pitot tube calibration data sheet as shown Ko Dr Tue 0D in Appendix C or a computer spreadsheet Clamp the pitot tube so that it is level verify haan aa and record ERN am SS E A SS S Verify that the pitot openings are not as Tipe S Piot Tubo a damaged or obstructed and record THE IMPACT PRESSURE OPENING PLANE OF THE PITOT TUBE SHALL BE EVEN WITH OR ABOVE THE NOZZLE ENTRY PLANE Using an angle indicator measure the angles a and a2 between the pitot tube opening plane and the horizontal plane when viewed from the end and record DEGREE INDICATING LEVEL DETERMINING 1 AND a2 Measure the angles f and B2 between the pitot tube opening plane and the horizontal plane when viewed from the side and record IS e fa DEGREEWOICATING LEVEL f Calculate the difference in l
46. ain 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 from the inlet of the first impinger or if applicable the filter holder see Leak Check Procedure 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 lt 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 2D through 2F 8 At the completion of sampling disconnect the probe from the first impinger or from the filter holder 9 Mandatory Leak check the sampling train as in step B3 Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 41 ISOKINETIC SOURCE SAMPLER MANUAL C Sample Recovery 1 Disassemble the impinger glassware and weigh each impinger to 0 5 g Record weighing data on a field data sheet 2 Verify constant sampling rate 3 Calculate the stack moisture percentage D Saturated or Moisture Droplet Laden Gases 1 M
47. ain completely in the Hot Box and Cold Box and 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 Cold Box Do not load the Filter Assembly with a filter and do not fill the impingers because this is a dry set up 9 Connect the Umbilical Cable to the Modular Sample Case Connect the Umbilical Cable circular connector plug to the receptacle on the side of the Hot Box see Figure 1 6 Connect the labeled Umbilical Cable thermocouple plugs into the receptacles on the Hot Box Probe Assembly and Umbilical Adapter Insert the Umbilical Cable sample line female quick connect into the Umbilical Adapter male quick connect Insert the Umbilical Cable female pitot line quick connects onto the Probe Assembly male quick connects Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 18 ISOKINETIC SOURCE SAMPLER MANUAL 10 Connect the Umbilical Cable to the Source Sampler Console Connect the Umbilical Cable circular connector plug to the receptacle on the front panel of the Source Sampler Console Connect the labeled Umbilical Cable thermocouple plugs into the receptacles on the Source Sampler Console front panel Insert the Umbilical Cable sample line male quick connect into the Source Sampler Console female quick connect Insert the Umbilical Cable pitot line male quick connects onto the Sour
48. an not be readily identified slightly pressurize the line and check for leaks using soapy water Pitot Lines Connect one end of pitot line to manometer and pull vacuum of 250 mm 10 inches seal tubing at the pump end and check for leaks by noting loss in manometer level Do same for other side If leakage is noted check connections and tubing same way as for vacuum line Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 84 ISOKINETIC SOURCE SAMPLER MANUAL Appendix A Equipment Lists for Isokinetic Sampling Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com A 1 ISOKINETIC SOURCE SAMPLER MANUAL Recommended Equipment for Isokinetic Sampling Apex Instruments Inc Intermediate Method 5 Source Sampling System SY5 CIS includes the following items Qty Part Description 1 MC 572 Model 572 Source Sampler Console with External Pump 1 SB 50 Modular Sample Case Includes SB 2M SBR 10 amp SB 3 1 PA 6S 6 Foot Stainless Steel Lined Probe Assembly 3 PLN 6G 6 Foot Borosilicate Glass Probe Liner 1 UC 60 15 60 Foot Umbilical Cable with 15 foot Sample Line Cut Back 1 U 15 SLE 15 Foot Umbilical Sample Line Extension 1 USL 15 SS 15 Foot Flexible Sample Line with Socket Elbow Fittings 1 GA 107 12 Mini Hot Box Sample Line Strain Relief
49. 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 AH Suggested AH values are 13 26 39 52 65 and 78 mm H20 0 5 1 0 1 5 2 5 3 5 and 4 5 in H20 recording the same data as before 10 At the conclusion of the five calibration runs calculate the average Y ratio of accuracy of the wet test meter to the dry gas meter and AHe values The tolerance for individual Y values is 0 02 from the average Y The tolerance for individual AH values is 6 4 mm 0 25 in H20 from the average AHe If a value in this range is not obtained the orifice opening should be adjusted or the Orifice Tube replaced If the Y and AHe are acceptable record the values on a label on the front face of the Console Meter Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 65 ISOKINETIC SOURCE SAMPLER MANUAL Ne Primary Reference N Wet Test Meter N a wW a WTM W A ka
50. arbon Carbon Carbon Dry Analysis Dioxide Monoxide Dioxide Molecular Weight l 1 ST a l Average Calculated Fuel Factor Fay Molecular Wt Deviation lt 0 3 L EA wg percent Fuel Factor in Handbook Range i LI Fueltype Minimum Maximum Coal Lignite 1 016 1730 Coal Bituminous 1 083 112307 0 f 1 01 08 Oil Distillate 1 260 1 413 Gas Natural 1600 1 836 Gas Propane 1434 1 586 1 553 1 120 Gas Butane 1 405 Wood 1000 1 120 Wood Bark S 1003 1130 CO Veoz 03 Voz Veoz CO Veo Vee N 100 CO O2 CO Ma 44 CO 32 O 28 N CO AMg Mg Mans F 20 9 03 5 COW CO CO Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com ISOKINETIC SOURCE SAMPLER MANUAL P EX SOURCE TESTING EQUIPMENT INSTRUMENTS METHOD 4 DETERMINATION OF MOISTURE CONTENT IN STACK GASES p PlantName tof L Sampling Locationf Project p Operatori of Ports Used S pStack Type Meter Box Number L Train Leak Check 1 Pretest L PostTest MeterCalFactor vji P Run umbejp dT RunStartTime Ru StopTime Total Meter Volumel Wa am Barometric Press P3 _ Avg Meter Temp tag _ C Stack Static Press Puc _ Avg Stack Temp iss C Avg Orifice Press Whim l contents r
51. as it passes through the impingers to condense the water vapor This enables measurement of stack gas moisture volume so that stack gas density can be calculated Most testers have multiple Cold Boxes and sets of impingers for rapid turnaround between test runs Cold Box features include e Durable polyethylene foam insulation plus pre punched foam inserts for holding the impingers in place e Slide on off guides plus spring loaded latch to prevent accidental slippage e Fold down handle with rope centering guide e High strength plastic bracket for supporting the Umbilical Adapter and e Four different removable insulated Cold Boxes Impinger Cases are available SB 3 holds 4 impingers SB 4 holds 8 impingers SB 5 holds up to 14 impingers and the SB 3C accepts inexpensive removable liners See Figure 1 7 Figure 1 7 SB 3C Impinger Box Caddy SB 3 Impinger Box SB 4 Impinger Box SB 5 Impinger Box Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 13 ISOKINETIC SOURCE SAMPLER MANUAL Umbilical Cable with Umbilical Adapter The Umbilical Cable connects the Modular Sample case and Probe Assembly section of the isokinetic source sampling system to the Source Sampler Console The Umbilical Cable contains g The primary gas sample line 12 7 mm 12 inch with male quick connect to the Source Sampler Console and at the opposite end a 12 7 mm 12 inch female quick con
52. at standard conditions scm or scf LA K v NIE V TAR K K2 0 001333 Metric Units 0 04706 English Units Phar dscm or dscf scm or scf Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 7 ISOKINETIC SOURCE SAMPLER MANUAL Determination of Moisture Content of Stack Gases continued Vwsg sta Volume of water vapor collected in silica gel V sg std K w W W Vaea K scm or scf Ks 0 001333 Metric Units 0 04706 English Units Bws Mole fraction of water vapor B a Veca T Lew std ws V ve std ag Vasea V nesa po C W H20 Percent moisture H O 100 x B H O 100 x Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 8 ISOKINETIC SOURCE SAMPLER MANUAL 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 K Q P kasi Ta C I B K1 0 6071 Metric Units 0 03575 English Units SourceName_ Date Facility es a Calculated by INPUT DATA Barometric Pressure mm Hg or in Hg Phar Stack Static Pressure mm H20 or in H20 Pg Stack Gas Pressure mm Hg or in Hg P s bar 13 6
53. ate the Source Sampler Console s dry gas meter Use the following procedure 1 Before starting the calibration fill out a meter calibration data sheet can be a computer spreadsheet as shown in Appendix C Record barometric pressure at the start of calibration the Source Sampler Console and wet test meter identification numbers date and time of calibration and 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 Turn on the Vacuum Pump and adjust the Coarse and Fine control valves on the Source Sampler Console until a AH of 12 7 mm 0 5 in H20 is obtained at a vacuum of between 8 and 15 kPa 2 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 Record initial settings of AH 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 AH to the desired setting Start the Elapsed Timer on the Source Sampler Console at the same time that the pump is started 7 Let the Vacuum Pump run until a dry gas volume of approximately 140 liters 5 cubic feet is indicated by the dry gas meter Allow the calibration run to continue until the next minute elapses then stop the Vacuum Pump
54. ated Orifice Tube located on the outlet of the Dry Gas Meter to indicate the sample flow rate The orifice pressure drop is measured on the AH front or orange side of the dual column manometer The stack gas velocity pressure drop is measured on the Ap back or red side of the manometer By observing the orifice reading AH on the manometer the operator can quickly adjust the sample flow rate using the Fine Increase Valve so that the sample is extracted under isokinetic conditions The Manometer Zero switch on the front panel enables the operator to adjust the AH manometer before or during a sampling run By switching to ON solenoid valves are actuated to vent the pressure lines to atmosphere and the operator can adjust the manometer s fluid level using the knobs located at the bottom of the manometer To zero the pitot tube manometer the pitot lines can be disconnected at the quick connects on the Source Sampler Console Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 7 ISOKINETIC SOURCE SAMPLER MANUAL External Vacuum Pump Unit The External Pump Unit provides the vacuum that draws the sample from the stack The pump assembly attaches to the Source Sampler Console by non reversible 9 525 mm 3 8 inch quick connects and an electrical receptacle Two interchangeable pump styles are available the E 0523 lubricated rotary vane pump and the E DAA dual diaphragm non lubr
55. averse points for each site and choose the highest of the four numbers for traverse point number 3 For PM steady flow or velocity steady or unsteady flow measurements select one location and use the same criterion as Method 1 4 For PM steady flow conduct velocity traverses before and after PM sampling to demonstrate steady state conditions i e within 10 v v lt 1 10 5 For PM unsteady flow monitor velocity and sample PM at two separate locations simultaneously A and B Velocity port disturbances distances B and C Sampling port disturbances distance Flow disturbance Velocity A A sampling port port Flow disturbance NOTE Velocity port must be downstream from sampling port All distances A B and C must be shown on sampling location schematic Figure 2 14 set up of EPA Method 1A Small Duct Sampling Locations Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 32 ISOKINETIC SOURCE SAMPLER MANUAL 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 There are two instances where Method 2 would be used gt Prior to a particulate stack test series to determine the size of the nozzle and length of the sampling run preliminary velocity determination gt During each stack test run to ensure that the particulate sample is extracted from the s
56. ce Sampler Console female quick connects labeled and The pitot lines are colored to differentiate the positive and negative lines and keep the connections consistent between the pitot tube and Source Sampler Console 11 Connect the Vacuum Pump Assembly to the Source Sampler Console 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 Connect the power cord of the Vacuum Pump Assembly to the receptacle on the Source Sampler Console labeled PUMP 12 Plug the Source Sampler Console into an appropriate electrical power source System Check Follow the set up procedure in the previous section before starting system check procedure Initial Sampling System Leak Check The system leak check is a dry run as described l Close the Coarse Valve on the Source Sampler Console 2 Insert a rubber stopper into the nozzle inlet 3 Turn on the Vacuum Pump switch PUMP POWER ON 4 Slowly open the Coarse Valve and increase fully 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 For 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 press
57. cribe techniques underpinning the sampling activities associated with Method 5 Together these methods outline the basic protocols for determining particulate concentrations and mass emission rates Method Description Method 1 Determination of Sampling Location and Traverse Points Method 2 Determination of Stack Gas Velocity and Volumetric Flowrates 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 The basic Method 5 sampling train is easily adapted to test for many other gaseous and particulate parameters of interest from stationary sources Parameters of interest may include metals polychlorinated biphenyls PCBs dioxins furans polycyclic aromatic hydrocarbons PAHs particle size distributions and an ever increasing group of pollutants by adaptations of basic test methods While the different methods are designated by other US EPA or agency method numbers they are variations of Method 5 procedures such as using different impinger solutions organic resin traps different filter media sampling temperatures or a range of other alternative procedures Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 1 ISOKINETIC SOURCE SAMPLER MANUAL The Model MC 500 Series Sampling System is applicable for the fol
58. ctorv configured for 120VAC 60Hz electrical power Configuration for 240VAC 50Hz operation is an available option The Electrical Schematics for the Source Sampler Console are presented in Appendix B All circuits are protected by three 3 front panel mounted circuit breakers These circuit breakers detect and interrupt overload and short circuit conditions providing an important safety factor If the circuit breaker opens or trips indicating interruption of the circuit investigate and repair the electrical fault Then reset the breaker by pressing the circuit breaker switch The circuit breaker can also nuisance trip making it difficult to complete a test To reduce the probability of nuisance tripping the circuit start up sequence can reduce the power surge The optimum start up sequence is to power up the pump first as this has the highest current and start up surge demand The filter and probe heaters can be powered seconds after the pump has started The electrical subsystem provides switched power to several circuits which are MAIN POWER PUMP POWER MANOMETER ZERO TIMER PROBE heater and OVEN heater e The MAIN POWER switch controls all power to all circuits within the source sampler Also when this switch is on the cabinet cooling fan should operate e To activate the pump unit plug the pump power cord into the Source Sampler Console receptacle and turn on the PUMP POWER switch e The MANOMETER ZERO switch operate
59. d gt The second is an approximation method which measures percent moisture to a good enough estimate to aid in setting isokinetic sampling rates prior to a pollutant emission run The approximation method is only a suggested approach Alternative ways for approximating moisture content are also acceptable for example e Wet bulb dry bulb techniques applicable to gas streams less than 100 C e Stoichiometric calculations applicable to combustion sources e Condensation techniques e Drying tubes and e Previous experience testing at a stack The Reference Method is almost always conducted simultaneously with a pollutant emission measurement run The Reference Method is also used when continuous monitoring for pollutants such as SO2 NO or O2 need to be corrected to a dry basis The equipment set up for the Reference Method can consist of either of these sampling trains gt The isokinetic source sampling system Hot Box and Cold Box equipped with Probe Assembly with no nozzle and a filter bypass GN 13 piece of glassware instead of a Filter Assembly filter may be used if particulate levels are high or gt The Basic Method 4 Test Kit 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 Either a standard heated Probe Assembly or a heated CEM probe no pitot tube can be used Although glass impingers are typically used as the condenser section
60. damaged e Internal leakage at sleeve port energized or de energized Remove sleeve Examine surface of rubber seals in bottom and top of plunger Clean or replace plunger as required Inspect orifices in body and sleeve for nicks Damage may require installing a new valve if problem not solved by repair kit component Return spring must not be broken Disassembly WARNING Depressurize system and turn off electrical power to valve before attempting repair Valve needs to be removed from line for disassembly or repair To remove the coil Unscrew nut on top of sleeve The enclosure coil and flux plate or integrated coil may now be removed e To disassemble pressure vessel e Placing pliers on sleeve of valve remove sleeve from the bodv of the valve Pliers should be positioned 90 from centerline of sleeve to avoid sleeve damage Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 81 ISOKINETIC SOURCE SAMPLER MANUAL Temperature Controllers The temperature controllers for probe and filter box heat after setting temperature to the desired setpoint receive a signal from the thermocouple subsystem and maintain these temperatures within a close range of the setpoint The standard temperature controllers are solid state analog devices with a dial control as shown in Figure 3 12 Figure 3 12 Analog Temperature Controller 1 Check Operation e Adjust the red poi
61. e Additional calibration procedures are performed on the temperature display To check the linearity of the temperature display a thermocouple simulator Apex Model M5C 22 is used Connect the simulator to the temperature display as illustrated in Figure 3 5 and record on a calibration data sheet the display reading at each temperature setting Figure 3 5 Thermocouple Simulator for Temperature Display Calibration Check Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 69 ISOKINETIC SOURCE SAMPLER MANUAL 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 a differential pressure gauge magnehelic gauge U tube manometer or electronic manometer is used they must 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 6 2 Vent the vacuum side to atmosphere and place a pressure on each system 3 Compare Ap 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 sys
62. e Orsat gas collection line built onto the Probe Assembly Sample volume and rate recommendations are the same Gas samples can be analyzed using either an Orsat or Fyrite analyzer Figure 2 17 depicts the options for sample collection and analysis Sampling Options Gas Analysis Options Single point Grab Sampli Analvzer Single Point Integrated Sampling Fvrite Analvzer Multi Point Integrated Sampling Figure 2 17 Sampling and Analvsis Options of Method 3 Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 38 ISOKINETIC SOURCE SAMPLER MANUAL Both the Orsat Analyzer and a Fyrite Analyzer are gas absorption analyzers and measure the reduction in liquid volume when a gas sample is absorbed and mixed into a liquid solution 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 CO 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 Figure 2 18 illustrates an Orsat Analyzer connected to a bag sample collection enclosure The CO concentration is typically not measured by the Orsat analyzer for two reasons First the detection limit of the analyzer is 0 2 by volume 2 000 ppmv which is well above most
63. easure the stack gas temperature at each traverse point Calculate the average stack gas temperature 2 Determine the saturation moisture content by a using saturation vapor pressure tables or equations or b using a psychrometric chart and making appropriate corrections if stack pressure is different from that of the chart 3 Use the lower of this value or the value from Section C Tips from an Old Stack Tester Make sure to wipe off moisture from the outside of each impinger before weighing Do not weigh with U tubes connected Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 42 ISOKINETIC SOURCE SAMPLER MANUAL Approximation Method The Method 4 approximation method specifies use of midget impingers and a Source Sampler Console sized for midget impinger trains such as that used for Method 6 for SO Many stack testers perform preliminary moisture measurements for input to their isokinetic calculations nomograph by using a full size sampling train and collecting about 0 283 sm 10scf of gas sample These runs take about 15 to 20 minutes Use the following procedures for approximate measurements of moisture content Midget Impinger Train A Preparation 1 Transfer about 5ml of water into each impinger 2 and weigh each impinger to 0 5 g Assemble the sampling train 2 Connect a pre weighed drying tube to the back of impinger train B Sampling 1
64. eck continuity of TC by subjecting it to a change in temperature for example remove from stack and touch an ice cube If the temperature goes the wrong way then polarity of the TC has been reversed Check each connection for proper polarity The red wire is negative and yellow wire is positive TC Reads Lower Value Than Expected Under reading is usually caused by second unintended junction in TC circuit such as a short in one wire TC display reads average of two junctions Most common place for the short is in connectors with unintended junction reading ambient temperature Quick check is to disconnect TC at connection farthest away from Source Sampler Console If display reads 1 for an open circuit then there is NOT a short in the extension circuit Check connector on the measuring device TC Display Susceptible to Static Electricity When sampling hot dry gas across probe ground with a grounding strap to either the Probe Assembly to the stack or make sure the Umbilical Cable is always connected TC Selector Switch Clean contacts of accumulated dust periodically with electrical switch spray cleaner Check switch connections by connecting TC simulator to each receptacle on faceplate and verifying that each channel reads temperature selected by simulator Note TCs attached to inlet and outlet of DGM are wired directly to selector switch and should read ambient temperature Electrical Power Circuits Electrical power c
65. ed to the Hot Box The outlet ball of the Probe Liner is carefully inserted through the hole into the Hot Box and the back of the sheath is even with the inside of the Hot Box Plug the Probe Heater electrical plug into the probe receptacle on the Hot Box 6 To install a Nozzle to the Probe Assembly consult Figure 2 1 Slide the ferrule system onto the plain exposed end of the Probe Liner High temperature braided glass cord packing should be substituted for the o ring when stack temperatures are gt 260 C 500 F The Probe Assembly Spare Parts Kit 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 with different liner options are detailed below a Stainless Steel Liner Stainless Steel Single Ferrule or Backer Ring with O Ring b Glass Liner Backer Ring with R Ring Teflon Single Ferrule Optional Mineral Filled Teflon Single Ferrule Optional O Ring Backer Ring Probe Sheath Ferrule PT Tube 5 8 Liner Tube Nut Union Nut Figure 2 1 Installation of Probe Nozzle Connectors 7 Thread the 15 875 mm 5 8 inch union onto the nut welded to the probe sheath This is a compression fitting which is tapered to seal the ferrule system inserted on the Probe Liner Tighten the fitting until the liner has a leak tight seal but DO NOT OVERTIGHTEN 8 Connect the glassware sampling tr
66. eliminary Measurements for Isokinetic Sampling No Symbol Value Needed Obtain from 1 APavg Average stack gas velocity pressure head 1 Before the sample run best or 2 A previous test often erroneous 2 Pe Stack gas pressure 1 Before the sample run best or 2 A previous test very small error 3 Pu 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 Ma Stack gas molecular weight 1 Before the sample run best or 2 A previous test very small error 8 AHe Orifice meter calibration factor Determined previously from laboratory calibration Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 25 ISOKINETIC SOURCE SAMPLER MANUAL USEPA Methods 1 through 4 are used to gather the preliminary values for Method 5 sampling Then when sampling using Method 5 the procedures of Methods 1 through 4 are completed to perform Method 5 sampling and calculations Method 1 Determining Sample and Velocity Traverse Points Method 1 is the first step towards collect
67. empty and weigh each impinger to 0 5 g Transfer about 200 300 g of silica gel to the fourth impinger and weigh to 0 5 g Assemble and set up the sampling train 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 Optional Leak check the sampling train from the inlet of the first impinger inlet or if applicable the filter holder see Leak Check Procedures for non isokinetic or isokinetic sampling trains Position the probe tip well into the stack Sample at a constant 10 flow rate of lt 21 lpm 0 75 cfm until about 0 283 m 10 cf Record initial and final data on a field data sheet Add more ice and if necessary salt to maintain lt 20 C 68 F at the silica gel impinger exit Mandatory Leak check the sampling train as in step B3 C Sample Recovery 1 Disassemble the impinger glassware and weigh each impinger or drying tube to 0 5 g Record weighing data on a field data sheet Verifv constant sampling rate 3 Calculate the stack gas moisture percentage Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 44 ISOKINETIC SOURCE SAMPLER MANUAL To calculate the stack gas moisture content Bws the following equations are used to compute the sample gas vo
68. ength between the two pitot tube legs Z bv measuring the le y and record SANA weon le 2 Calculate the distance that the pitot tube legs FORDETERMNNG E i are rotated W bv measuring the angle 9 and record AL lt Measure and record the vertical distances a ee PA and Pg between each pitot tube opening eZ RUNN nes BAN plane and the center line of the pitot tube Figure 3 7 Calibration of the Probe Measure and record the tube external Pitots diameter Dr and calculate the minimum and maximum values of Pa and Pg Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 72 ISOKINETIC SOURCE SAMPLER MANUAL Calibration of Sampling Nozzles Probe nozzles should be inspected and calibrated in the field immediately before each use to verify that they were not damaged in transport or shipment The following procedure illustrated in Figure 3 8 is recommended 1 Before starting the calibration check fill out a probe nozzle calibration data sheet as shown in Appendix C can be a computer spreadsheet Using venier or dial calipers with at least 0 025 mm 0 001 inch tolerance measure the inside diameter of the nozzle by taking three readings approximately 45 60 apart from one another and record Calculate the average of the three readings If readings do not fall within 0 1 mm 0 004 inches of one another nozzle must be reshaped resharpened and
69. enter on the filter support Assemble the Filter Holder and tighten the clamps around the Filter Holder to prevent leakage around the O ring Record filter number on the field data sheet 7 Connect the Filter Holder and Cyclone Bypass GN 1 in the Hot Box to the Probe Liner ball joint and to the L Adapter using Ball Joint Clamps Close the Hot Box doors and fasten shut A pex B B Figure 2 26 Assembled Sampling Train Before Umbilical Hookup 8 Connect the Umbilical Cable electrical and pitot tube line connections to the assembled sampling train and to the Source Sampler Console If used connect the Orsat line also 9 Place the assembled sampling train near the first sample port either on the monorail or 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 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 Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 50 ISOKINETIC SOURCE SAMPLER MANUAL 11 Optional Leak check the sampling train see Leak Check Procedure for Isokinetic Sampling Trains in Method 4 and Pitot Tube and Line Leak Check in Method 2 D Sampling
70. erature 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 tA 14 tube female brass 1 QC F8 B Quick Connect 1 2 1 2 tube female brass 1 QC M6 B Quick Connect 3 8 3 8 tube male brass 1 QC BHF6 B Quick Connect bulkhead 3 87 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 pr
71. ext by following the directions in the next section The Rockwell dry gas meter in the MC 522 English version of the MC 572 will run backwards if there is a leak on the Pressure Side when completing the Vacuum Side Leak Check The Kimmon dry gas meter in the MC 572 will not run backward thus requiring a Pressure Side Leak Check Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 63 ISOKINETIC SOURCE SAMPLER MANUAL To Manometer AH High Pressure Side Low Pressure Side AP SE DT pt A 4 Pitot iE a at EEE TC MM of water ERRA z 4 To Manometer nina OEE ERE RR 5 da Uo H 188 High Pressure Side lt Pitot AP Manometer gt High Pressure Side SAA l 4 7o Sample Line Course Control Valve Vacuum Gauge gt S 4 Pump Suction Orifice Tube as Fine Control Valve LHH i HHI lt Dry Gas Meter 4 Pump Pressure Figure 3 1 Source Sampler Console Plumbing Diagram for Leak Check Metering Svstem 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 USEPA recommendation contained in Section 5 6 of Method 5 1 Ze Connect the Vacuum Pump to the Source Sampler Console Plug the outlet of the Orifice Meter with a rubber stopper Insert both pitot Ap
72. follows A Measure the stack diameter to within 0 3175 cm 1 8 inch B C D wa E 1 2 3 4 5 Insert a long rod or pitot tub e into the duct until it touches the opposite wall Mark the point on the rod where it meets the outside of the port nipple Remove the rod measure and record this length to the far wall Ly With a tape measure or rod if stack is hot measure the distance from the outside of the port nipple to the near wall and record this length to the near wall Lay Calculate the diameter of the duct from this port as D Ley Law Repeat for the other port s and then average the D values Measure the distance from the sample port cross sectional plane to the nearest downstream disturbance designated Distance A Measure the distance from the sample port cross sectional plane to the nearest upstream di sturbance designated Distance B Calculate the number of duct diameters to the disturbances by dividing Distance A by D and Distance B by D F Use Figure 5 in Method 1 for particulate traverses or Figure 12 for velocity traverses determine where Distance A diameters meets the graph then where Distance B diameters meets the graph and select the higher of the two minimum numbers of traverse points Tips from an Old Stack Tester Measure the stack diameter from each sampling port not all circular stacks are round And not all rectangular stacks are perfectly rectangular By Measu
73. g FROM POINT OF ANY TYPE OF DISTURBANCE l l BEND EXPANSION CONTRACTION ETC STACK DIAMETER 0 30 TO 0 61 m 12 24 in l 0 i 2 3 4 5 6 T 8 9 10 DUCT DIAMETERS DOWNSTREAM FROM FLOW DISTURBANCE DISTANCE B Minimum number of traverse points for particulate traverses DUCT DIAMETERS UPSTREAM FROM FLOW DISTURBANCE DISTANCE A 0 5 1 0 1 5 2 0 2 5 50 a i HIGHER NUMBER IS FOR l E RECTANGULAR STACKS OR DUCTS 2 Disturbance 5 40 7 A fe l Measurement a 1 T Site LU l b i i l B 1 i i l Disturbance e 1 A a 4 1 m i 8 20 I 2 16 s STACK DIAMETER 20 61 m 24 in 2 12 z i a 10 8or9 FROM POINT OF ANY TYPE OF DISTURBANCE l J A BEND EXPANSION CONTRACTION ETC STACK DIAMETER 0 30 TO 0 61 m 12 24 in i l 2 3 4 5 6 T 8 9 10 DUCT DIAMETERS DOWNSTREAM FROM FLOW DISTURBANCE DISTANCE B Minimum number of traverse points for non particulate traverses Figure 2 10b Example of Determining Number of Traverse Points Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 28 ISOKINETIC SOURCE SAMPLER MANUAL For circular stacks with diameters greater than 60 cm 24 inches the minimum number of traverse points required is twelve 12 or six 6 in each of two directions 90 apart when the duct diameters from disturbances are eight 8 or more upstream and two 2 or more downstream For circular stacks wit
74. h diameters between 30 and 60 cm 12 and 24 inches the minimum number of sample points required is eight 8 or four 4 in each of two directions 90 apart For stacks less than 30 cm 12 inches in diameter refer to Method 1A for calculating traverse points For rectangular stacks or ducts an equivalent diameter must first be calculated using the following equation _ 2LW L W where De equivalent diameter of rectangular stack L length of stack W width of stack The minimum number of traverse points required for rectangular stacks is nine or 3 x 3 After the number of traverse points has been determined the location of each traverse point must be calculated The traverse points and their locations are designated as the sample point matrix For circular stacks the stack cross section is divided into concentric rings of equal area based on the number of traverse points divided by four 4 the rings are bisected twice and the sample points are located in the centroid center of mass of each equal area as shown in Figure 2 11 For rectangular stacks the centroids are much easier to determine as shown in Figure 2 12 gt TRAVERSE DISTANCE POINT of diameter 4 4 14 6 29 6 70 4 85 4 95 6 ouahonhd This is an example of a circular stack cross section divided into 12 equal areas with location of traverse points indicated Figure 2 11 Traverse Points Located in Centroids for Circular
75. h your pocketknife Various tapes and black marking pens do not hold up against stack conditions nearly as well Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 31 ISOKINETIC SOURCE SAMPLER MANUAL Method 1A Sample and Velocity Traverses for Small Stacks or Ducts This procedure is the same as that in Method 1 except for the special provisions that apply to small stacks or ducts where 10 2 cm 4 in lt D lt 30 5 cm 12 in or for small rectangular ducts where 81 1 cm 12 57 in lt A lt 729 cm 113 in A standard type pitot tube must be used for the velocity measurements and must NOT be attached to the sampling probe In these small diameter stacks or ducts the conventional Method 5 stack assembly consisting 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 and causes inaccurate measurements Therefore for particulate matter sampling in small ducts the gas velocity is measured either gt Downstream of the sampling nozzle for unsteady flow conditions or gt Inthe same sample port alternately before and after sampling for steady flow conditions The procedure for determining sampling location traverse points and flow rate preliminary or other in a small duct is as follows 1 Select a site as shown in Figure 2 14 2 Use Method 1 to locate tr
76. her filter assembly rather than changing the filter itself Before installing a new filter conduct a leak check Add the filter assembly catches for the total particulate matter weight Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 53 ISOKINETIC SOURCE SAMPLER MANUAL 10 Use a single train for the entire sampling run except when simultaneous sampling is required in two or more separate ducts or at two or more different locations within the same duct or in cases where 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 two or more trains are used analyze separately the front half and if applicable impinger catches from each train unless identical nozzle sizes were used on all trains In this case the front half catches may be combined as may the impinger catches and one analysis of front half catch and one analysis of impinger catch may be performed Consult with the regulatory agency for details concerning the calculation of results when two or more trains are used 12 If a flexible line is used 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 d
77. hermocouples potentiometers e Thermometric fixed points e g ice bath and boiling water or e NIST traceable electronic thermocouple simulators Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 68 ISOKINETIC SOURCE SAMPLER MANUAL Calibration of Thermocouples 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 Insert again 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 Place a beaker of distilled water on a hot plate add a few boiling chips and heat to boiling a Repeat Steps a through f as above Set both the thermocouple to be checked and a mercury reference thermometer side by side at ambient temperature a Repeat Steps a through f as above Place a container of oil on a hot plate and heat to a temperature below the boiling point DO NOT BOIL a Repeat Steps a through f as abov
78. hes Hg above the critical vacuum A post test calibration check is conducted at the average AH and highest system vacuum observed during the test series Use the following procedure 1 Before starting the calibration fill out a meter calibration data sheet can be a computer spreadsheet as shown in Appendix C Record barometric pressure at the start of calibration the Source Sampler Console and wet test meter or secondary DGM or critical orifice identification numbers date and time of calibration and confirmation of acceptable leak checks on the Source Sampler Console Connect the outlet of the wet test meter to the inlet SAMPLE of the Source Sampler Console as depicted in Figure 4 2 Insert a valve between the wet test meter and the inlet of the Source Sampler Console to adjust the vacuum to 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 Turn on the Vacuum Pump and adjust the Coarse and Fine control valves on the Source Sampler Console until a AH equivalent to the average AH observed during the test series is attained Set the calibration system vacuum to the highest vacuum observed during the test series 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 If using a Critical Orifice select an orifice with AH properties similar t
79. icated pump with specifications shown in Table 1 2 The E 0523 is a rotary vane pump that requires lubrication The pump is shipped from the factory without oil Thus the lubricator jar will need to be unscrewed and filled approximately 4 full with lightweight lubricating oil Gast AD220 SAE 10 or SAE 5 Both pump assemblies are available in either 120VAC or 240VAC operation Please see Chapter 6 Maintenance and Troubleshooting for additional information on Apex Instruments pump units The External Pump Unit contains e The Vacuum Pump e Adjustable Lubricator E 0523 only e Two 2 1 524 m 5 ft hose extensions with 9 525 mm 3 8 inch quick connects configured with male connector on the pressure side and female connector on the suction side e arigid aluminum frame that protects the pump and allows easy access for service A hinged enclosure is available for either pump style f81 oe i oe L iwi al ka p e z far TE lt as Figure 1 3 Picture of E 0523 Lubricated Vane Vacuum Pump and optional E DAA Table 1 2 Features and Specifications of Apex Instruments Model MC 500 Series Vacuum Pumps Model No E 0523 Lubricated Vane Pump Motor 250 watts 1 3 hp 120 VAC 60 Hz 1 2 Amp Measured Flow 88 Ipm 0 25 kPa 3 1 cfm 1 inch Hg 42 5 Ipm 3 73 kPa 1 5 cfm 15 inches Hg Maximum Vacuum 86 4 kPa 25 5 inches Hg Weight 15 9 kg 35 Ib E 0523V Optional 240 VAC 50 Hz Standard Unit E
80. id level Label the container 5 Container No 3 Silica Gel a Determine whether silica gel has been completely spent and note on data sheet its condition and color b Either reuse in the next run using the final weight as the initial weight for the new sampling run or discard and reload impinger 6 Impinger Water a Note on the data sheet any color or film in the liquid catch b Discard the liquid unless analysis of the impinger catch is required Store as is appropriate 7 Whenever possible ship sample containers in an upright position Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 56 ISOKINETIC SOURCE SAMPLER MANUAL 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 the following equations are used to compute the sample gas volume Vista and gas moisture volume V wecsta Val Po A Vines K a el where AH Average orifice tube pressure during sampling mm H20 in H20 Vm 7 Dry gas volume measured by dry gas meter dem dcf iex Absolute temperature at dry gas meter K R Y Dry gas mater calibration factor K3 0 3858 dK mm Hg metric units 17 64 R in Hg English units V sc sta K W W where W Final weight of water collected g W Initial
81. inst com e mail info apexinst com 30 ISOKINETIC SOURCE SAMPLER MANUAL The procedure for locating each traverse point along the diameter for a circular stack and then marking the probe assembly or pitot tube is as follows e Ona Method field data sheet data sheet can be computer or calculator generated multiply the stack diameter by the percentage taken from the appropriate column of Table 2 2 e Add the port nipple length to each value for each traverse point e Convert the decimal fraction to 1 8 0 125 of an inch for each point English units only e For stacks 2 60 cm 24 inches in diameter relocate any traverse points that are closer than 2 5 cm 1 00 inches from the stack wall to 2 5 cm and label them as adjusted points You may combine two successive points to form a single adjusted point which must be sampled twice e For stacks 60 cm 24 inches do the same except the adjusted distance is 1 3 cm 0 5 inch e Measure each traverse point location from the tip of the pitot tube and mark the distance with heat resistant fiber tape or whiteout correction fluid as illustrated in Figure 2 13 Figure 2 13 Illustration of Marking Traverse Points on Probe Assembly Tips from an Old Stack Tester White Out correction fluid used on paper has amazing properties for stack testing It dries quickly and withstands stack heat and moisture very well To remove from a probe or pitot tube simply scrape it off wit
82. ion of a representative sample for measuring particulate concentration and mass emission rate from a stack The velocity and particle concentration in the stack are not uniform so the cross section must be traversed The basic premise is that for straighter lengths of stack or duct flow streamlines are more uniform and fewer traverse points are needed to obtain a representative sample Conversely the closer the sampling site is to bends and flow disturbances the more traverse points are needed to obtain a representative sample This method describes procedures to e Select an appropriate sampling location on the stack if sample ports do not already exist e Calculate the number of traverse points for velocity and particulate sampling within the stack e Calculate the location of the traverse points Sampling sites are measured in terms of number of stack or duct diameters away from flow disturbances Disturbances can be bends transitions expansions contractions stack exit to atmosphere flames or presence of internal installations such as valves or baffles Figure 2 9 depicts the relationship of stack diameters and a flow disturbance such as a bend Figure 2 9 Visualizing Stack Diameters from Flow Disturbances Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 26 ISOKINETIC SOURCE SAMPLER MANUAL The procedure for calculating the minimum number of traverse points is as
83. ircuits include the Probe Assembly Modular Sample Case Umbilical Cable and Source Sampler Console connections Circular Connector Outlet on Source Sampler Console Check the Circular connector outlet with a voltmeter or check light by connecting the leads to the different terminals see Electrical Schematic in Appendix B When connected across heater lines voltmeter or check light should respond correspondingly Solid state temperature controller circuits should be tested with a resistant load such as test lamp or heater Umbilical Cable Check the electrical lines of the Umbilical Cable for continuity using an ohmmeter or battery light system If there is no continuity in any of the lines check the circular connector connections If this not the problem replace the cord Connect the Umbilical Cable to the Source Sampler Console Check the Umbilical Cable outlet with a voltmeter by connecting the leads to a combination of the four pins Pin A is Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 83 ISOKINETIC SOURCE SAMPLER MANUAL 120 240 VAC for auxiliary power Pin B is common neutral Pin C is 120 240 VAC for filter heat and Pin D is 120 240 VAC for probe heat Voltmeter should respond properly when circular connector is wired correctly and appropriate switches are thrown Check ground continuity wire with an ohmmeter between Circular connector body and electrical
84. ivalent diameter D 7 L EW 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 Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 2 ISOKINETIC SOURCE SAMPLER MANUAL Sample and Velocity Traverses for Stationary Sources continued Location of Sampling Points CIRCULAR Sample point Circular stack Distance from number diameter sample port opening in 1 2 3 4 5 6 7 8 9 10 11 12 RECTANGULAR era aia ncn cp ete a a cs pee f i a Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 3 ISOKINETIC SOURCE SAMPLER MANUAL FEDERAL REFERENCE METHOD 2 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 ft nr or x D 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 H20 or in H20 VAP avwg Barometric pressure mm Hg or in Hg Phar Stack gas static pressure mm H20 or in H20 Pg Absolute stack gas
85. l selector switch and a digital temperature display with internal compensating junction There are automatic temperature controllers for probe and filter oven heat which receive an input signal from the electrical subsystem and maintain these temperatures within a close range of the set point The temperature controllers are solid state analog devices with a dial control Digital programmable temperatures controllers are optional The thermocouple electrical diagram is presented in the Electrical Schematic Vacuum Subsystem The vacuum subsystem consists of an external vacuum pump assembly quick connects internal fittings two 2 control valves Coarse and Fine an orifice meter and a dual column inclined manometer The external vacuum pump assembly provides the vacuum for extracting the gas sample from the stack and then through the various components of the isokinetic source sampling system The sample flow rate is controlled by 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 blocks the flow from the SAMPLE inlet quick connect to the Vacuum Pump inlet 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 recirculate from the pump outlet back to the pump inlet This dual valve configuration enables very precise control of the sample flow rate A calibr
86. le and cap the nozzle to prevent contamination or loss of sample Hint Open the Hot Box doors to allow the filter holder to cool 14 Before moving the sampling train to the cleanup site disconnect the probe from the Cyclone Bypass inlet and cover both ends Do not lose any condensate that might be present Disconnect the Filter Holder from the L Adapter and cap off the Filter Holder 15 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 The Probe nozzle Assembly Filter Holder and impinger case are ready for sample recovery 16 Transfer the probe and filter impinger assembly to a cleanup area that is clean and protected from the wind E Variations and Alternatives 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 can be useful for cross sections over 3 m 10 ft in diameter Whenever practical make every effort to use borosilicate glass or quartz probe liners Metal liners will bias particulate matter results high 2 For large stacks consider sampling from opposite sides of the stack to reduce the length of probe Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 52 ISOKINETIC SOURCE SAMPLER MANUAL 3 Use either borosilicate
87. lines probe heater thermocouple stack thermocouple and Orsat gas sample line are connected to the Source Sampler Console by the Umbilical Cable Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 11 ISOKINETIC SOURCE SAMPLER MANUAL Modular Sample Case The Modular Sample Case is used for support protection and environmental control of the glassware in the sampling train Figure 1 6 illustrates the major components and accessory connections on the Modular Sample Case The Modular Sample Case consists of an insulated heated filter compartment Hot Box and insulated impinger case Cold Box The Hot Box features e Insulated 1 2 inch ceramic filter box with dimensions 24 x 24 x 60 cm 9 x 9 2 x 23 inches e 500 watt heating element e Oven thermocouple with external thermocouple receptacle e Dual access doors e Handle and SS bail clip monorail attachment e Removable stainless steel hinged probe clamp 19 cm length 7 2 inches and e Stainless steel slides for connection removal of impinger case PEX iF INSTRUMENTS Figure 1 6 Modular Sample Case Components and Accessories Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 12 ISOKINETIC SOURCE SAMPLER MANUAL The Cold Box holds the sampling train impingers in an ice bath so that the stack gas sample is cooled
88. lowing isokinetic test methods and pollutants Method No SA 5B 5D SE SF 5G 5H 8 12 13A amp 13B 17 23 26A 29 101 101A 104 108 111 201A 202 206 207 306 315 316 Method No 0010 0011 0023A 0050 0060 0061 Pollutants PM from Asphalt Roofing Non sulfuric Acid PM PM from Positive Pressure Fabric Filters PM from Fiberglass Plants Non sulfate PM from Fluid Catalytic Cracking Units PM from Wood Stoves Dilution Tunnel PM from Wood Stoves Stack Sulfuric Acid Mist Sulfur Dioxide and PM Inorganic Lead Pb Total Fluorides Particulate Matter Polychlorinated Dibenzo p Dioxins and Dibenzofurans Hydrogen Halides and Halogens Multiple Metals Mercury Hg from Chlor Alkali Plants Mercury Hg from Sewage Sludge Incinerators Beryllium Be Inorganic Arsenic As Polonium 210 PM Particulate Matter Constant Sampling Rate Condensable Particulate Matter Ammonia Tentative Isocyanates Tentative Hexavalent Chromium from Electroplating and Anodizing Operations PM and Methylene Chloride Extractable Matter MCEM from Primary Aluminum Production Formaldehyde from Mineral Wool and Wool Fiberglass Industries Proposed Waste Combustion Source Methods in EPA SW 846 Pollutants Semivolatile Organic Compounds Formaldehyde Other Aldehydes and Ketones Polychlorinated Dibenzo p Dioxins and Dibenzofurans Hydrogen Chlorine and Chlorine Multiple Metals Hexavalent Chromium Apex Instruments
89. lume V mesta and gas moisture volume V we sta Val Par tie V nista KAY where AH Average orifice tube pressure during sampling mm H2O in H20 Vm Dry gas volume measured by dry gas meter dem def Tm Absolute temperature at dry gas meter K R Y Dry gas meter calibration factor K3 0 3858 K mm Hg metric units 17 64 R in Hg English Units V c std T K W W Wi where W Final weight of water collected g W Initial weight of water collected g K 0 001335 m g metric units 0 04715 ft g English units and Vreca ws V std Vive std m where B Proportion of water vapor by volume in the gas stream Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 45 ISOKINETIC SOURCE SAMPLER MANUAL Method 5 Determination of Particulate Emissions There are several techniques for calculating the probe nozzle size and K factor ratio of AH Ap needed for isokinetic sampling rate These include gt gt gt gt Calculating by hand or on a worksheet see worksheets in Appendix D Using a specially designed stack testing slide rule nomograph M5A 1M or MSA 1 as shown in Figure 2 21 Using a pre programmed hand held calculator M5A C or Using a personal or laptop computer equipped with specialized spreadsheets for data collection and reduction ISOCALC2 0 as shown in Figure 2 21 Figure 2
90. manometer plastic connectors onto the right side of the dual column manometer Insert both orifice AH manometer plastic connectors onto the left side of the dual column manometer To pressurize the system remove one the of the AH plastic connectors and then blow lightly into the tubing until the AH reads 177 8 to 254 mm 7 to 10 inches H2O Pinch off the tubing securely and insert the AH plastic connector back into the manometer Allow the manometer oil time to stabilize Observe for one minute Any loss of pressure during this minute indicates leakage which must be corrected Check all connections and tubing for leaks Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 64 ISOKINETIC SOURCE SAMPLER MANUAL Initial or Semiannual Calibration of Dry Gas Meter and Orifice Tube The Source Sampler Console dry gas meter and Orifice Tube is calibrated 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 A series of five 5 calibration runs are conducted at differing flow rates AH settings which bracket the range of expected sampling rates during particulate sampling tests If a wet test meter is used as the calibration standard it should have a meter correction factor of 1 000 Alternatively a properly calibrated secondary reference dry gas meter may be used to calibr
91. measurement site mm Hg in Hg P Stack static pressure mm H O in H O Molecular weight of stack on wet basis g g mole Ib Ib mole M B 18 0B M Molecular weight of stack on dry basis g g mole Ib Ib mole K Constant 34 97 for metric system 85 49 for English system The average percent isokinetic sampling rate is calculated as pis KTV na Pv A O 1 B where A Cross sectional area of the nozzle m ft 0 Sampling time minutes K 4 320 metric units 0 09450 English units Tips From an Old Stack Tester During port changes many stack testers scan or quickly average values for VAp AH stack gas temperature and DGM temperature to calculate lI before the sampling run is finished this all assumes that B will not change substantially Some sophisticated calculator programs and most laptop computer programs monitor I for each point and Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 59 ISOKINETIC SOURCE SAMPLER MANUAL 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
92. n an Isokinetic Source Sampling System that are recommended for a system check Initial Set up Procedure These instructions are for a dry run set up of the complete US EPA Method 5 sampling train Do not load a glass fiber filter into the filter assembly or charge liquids and silica gel in the impingers The objective is to set up the equipment to verify everything works 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 compartment Hot Box using the steel slide guides Check the fit and height of the Sample Case and Umbilical Adapter The slides are adjustable for obtaining the desired fit Engage the spring latch that locks the Cold Box 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 if necessary replace or repair Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 17 ISOKINETIC SOURCE SAMPLER MANUAL 4 Slide the Probe Liner into the probe sheath The plain end no ball joint of the liner should come out approximately 1 27 cm 1 2 inch at the pitot tube end of the Probe Assembly 5 Insert and tighten the Probe Assembly into the probe clamp that is attach
93. n7 ft for English units Va KCl Ap nvg Tseng PM Py Paar Puras 13 6 where K 34 97 for metric units JEN 100 CO 0 CO where K 85 49 for English units Mg 44 COz 32 O2 28 N2 CO Qsa 3600 1 BLJVALT sta T sjavi PJ P sia M M 1 Bws 18B ys where Tsa 293 K Pag 760 mm Hg for metric units Ap Pm Elp where Taa 528 R Paa 29 92 in Hg for English units Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 5 ISOKINETIC SOURCE SAMPLER MANUAL P EX SOURCE TESTING EQUIPMENT INSTRUMENTS METHOD 3 GAS ANALYSIS FOR THE DETERMINATION OF DRY MOLECULAR WEIGHT ea Se of Ports Used ooo Gas Analysis Data RunNumber RunStatTime RunStopTime Sample Carbon Carbon Carbon Dry Molecular Analysis Dioxide Monoxide Dioxide Weight Time Volume Volume Conc b A Deviation TT i a WANT ce aT Average Calculated Fuel Factor Fa Molecular Wt Deviation lt 0 3 O Average Excess Air EA percent Fuel Factor in Handbook Range Gas Analysis Data Do RunNumberj Run Start Time RunStopTimel Sample Carbon Carbon Dry Analysis Dioxide Oxygen Dioxide Volume Average Calculated Fuel Factor Fao Molecular Wt Deviation lt 0 3 Average Excess Air EA a percent Fuel Factor in Handbook Range L Do RunNumberi Run Start Time Run Stop Time _ Sample C
94. ncluded with P1000 0 P1000 SSS a ea Figure 2 6 Illustration of Apex Instruments Monomount Monorail System Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 23 ISOKINETIC SOURCE SAMPLER MANUAL Figure 2 8 Stack Set up with Hot Box on Monorail Separated from Cold Box Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 24 ISOKINETIC SOURCE SAMPLER MANUAL Assembling Sampling Equipment and Reagents The use of checklists for assembling the sampling equipment reagents and auxiliary supplies for a test is highly recommended Appendix A contains the recommended equipment for isokinetic sampling Appendix A also contains the recommended spare parts for isokinetic sampling although not all of the list may be needed at a test site Section 3 of USEPA Method 5 contains the list of reagents required to perform an isokinetic particulate test A standard equipment and reagent checklist used by stack testers is provided in Appendix A Preliminary Measurements of Gas Velocity Molecular Weight and Moisture Before attempting to calculate the parameters needed for isokinetic sampling probe nozzle size ratio of AH Ap K factor needed for isokinetic sampling rate gas sample volume several preliminary values are required Table 2 1 Pr
95. nd allow the temperature reading to stabilize 7 Move to each traverse point reseal the port and record the velocity head and temperature Switch to the next port and repeat traverse Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 34 ISOKINETIC SOURCE SAMPLER MANUAL 8 Conduct a post test leak check mandatory to prove that no leakage occurred as described in Step 4 and record on field data sheet 9 Measure the static pressure in the stack One reading is adequate 10 Determine the barometric pressure at sample port level 11 Calculate the average stack temperature from the traverse readings and record 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 number of traverse points then record on the field data sheet It is important to ensure that the proper manometer or pressure gauge is being used for the range of Ap values encountered If it is necessary to change to a more sensitive gauge do so and remeasure the Ap and temperature readings at each traverse point using the above procedures METHOD 2 VELOCITY TRAVERSE SET UP WAKE TEMP DISPLAY PRESSURE o TS APR IMPACT PRESSURE P FLOW Figure 2 16 Apparatus for Preliminary Velocity Measurement Apex Instruments Inc
96. nect to the Umbilical Adapter Two 2 pitot lines 6 35 mm 4 inch with female quick connects to the Probe Assembly and 6 35 mm 14 inch male quick connects to the Source Sampler Console The pitot lines are color coded black and white for convenience Another yellow line 6 35 mm 14 inch which is intended for collecting a gas sample for Orsat analysis can be used as a spare pitot line Five 5 thermocouple extension cables for type K thermocouples which terminate with full size connectors for durability The connectors have different diameter round pins to maintain 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 AC power lines for the heaters in the filter compartment Hot Box and Probe Assembly The power cable terminates with a circular connector military style connector on each end The body of the circular connector is the ground conductor 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 The Umbilical Adapter connects the outlet of the glass impinger train to the Umbilical Cable and c
97. ning fittings or replacing damaged parts The manometer screws have sealing washers DO NOT OVER TIGHTEN them which can cause stress cracks in the manometer bodv 4 Pitot Tube Lines e Blow through the pitot quick connects there should be free movement of air and the manometer should respond bv fluid moving awav from the side vou blow Check that there are no crimps in the tubing that would affect pressure reading Pull all AP and AH lines out as far as possible before installing panel back into cabinet 5 Orifice Tube Lines e Turn on the vacuum pump and carefullv adjust the Coarse and Fine Increase valves Xou should see response on the orifice manometer e If it does not respond check that the Manometer Zero Switch is in the OFF position and that the solenoids are working properly Check that there are no crimps in the tubing Manometer Zero Solenoid Valve The Manometer Zero Switch operates the solenoid valve assembly which contains two 3 way solenoid valves and operates only on the Orifice Tube manometer When the valve switch is turned ON the two valves close and flow into the manometer is blocked and vented to atmosphere allowing the pressure to equilibrate Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 80 ISOKINETIC SOURCE SAMPLER MANUAL 1 2 3 Inspection e To check the Manometer Zero AH solenoid valve turn the switch to ON
98. nst com 33 ISOKINETIC SOURCE SAMPLER MANUAL Velocity measurements in a duct are made using a pitot tube that is connected to an inclined manometer Alternatively a magnehelic pressure gauge or an electronic manometer can replace the inclined manometer but each of these devices must be calibrated periodically against an oil filled inclined manometer see Section 4 The S type pitot tube is most often used in stack testing because it is compact size makes it easy to attach to a Method 5 probe assembly it is relatively easy to manufacture it is relatively insensitive to plugging in stack gas streams it is relatively insensitive to yaw and pitch errors and it has a fixed pitot coefficient of 0 84 if manufactured and maintained to meet the geometric specifications of Method 2 A standard or p type Prandl pitot tube with coefficient 0 99 can also be used for these measurements VVVVV The S type pitot tube is inserted into the stack so that one leg hole opening of the pitot tube is pointing into the direction of gas flow as shown in Figure 2 16 The leg pointing into the flow streamline measures impact pressure P and the opposite leg pointing away from the flow measures wake pressure Pw of the gas stream The velocity pressure Ap is the difference between the impact and wake pressures Ap P P U w The procedure for determining flow rate preliminary or other in a stack gas stream is as follows 1 Fill out the t
99. nt on the glass probe liner covered until the assembly of the train is complete and sampling is about to begin 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 amp 2 100 ml water in each b Impinger 3 Empty c Impinger 4 200 to 300 g of silica gel Note More than one sampling run can be prepared with 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 JZ z 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 Figure 2 24 Top View of Assembled Impingers Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 49 ISOKINETIC SOURCE SAMPLER MANUAL Glass Filter Inlet Glass Filter Outet i Filter Teflon Frit Ri fl fi it O Ring f N f R O Ring yi KE i N3 AN ZA Inlet side of Outlet side of Teflon Frit Teflon Frit Figure 2 25 Exploded View of Filter Assembly 6 Using tweezers or clean disposable surgical gloves place the tared filter on the grooved side of the TFE filter support in the Filter Holder Check the filter for tears after placement and c
100. nter on dial to desired setpoint The setpoint LED upper left corner should respond as follows When GREEN the temperature is within 1 5 of setpoint When RED the temperature is below or above setpoint by more than 1 5 2 Repair Do not attempt to repair unit Remove and replace Thermocouple Wiring and Thermocouple Display The most commonly used thermocouple TC in stack testing applications is the Type K Calibration guidance is given by the USEPA in Emission Measurement Technical Information Center EMTIC Guidance Documents GD 024 and GD 028 A Type K TC even with large wire gauge sizes will eventually fail if subjected to sustained temperatures gt 1 090 C 2 000 F Even short excursions will shorten the useful life of the TC Other types of TCs should be considered for sustained temperatures above 1 090 C 1 TC Wire Not Functioning Properly Check to see if TC leads have not detached from screw posts inside TC plugs or receptacles This causes an open TC circuit when there is NO junction and reads 1 on the temperature display This condition occurs when there is no device connected to that channel or when one of the wires in the circuit has broken or become disconnected Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 82 ISOKINETIC SOURCE SAMPLER MANUAL 2 3 4 5 Temperature On Display Goes Down When It Should Go Up Ch
101. o Probe Assembly Fittings include 15 9mm 5 8in union nut and ferrules along with o rings and backer ring m 1 ft less than nominal length Nominal Length O Ring Backer Ring Probe Sheath Nag Ferrule Mea 5 8 Tube 5 8 Liner Tube Nut Union Nut Method 5 Probe with Optional Oversheath and Packing Gland Figure 1 4 Diagrams of Probes and Probe Assembly Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 9 ISOKINETIC SOURCE SAMPLER MANUAL Probe Liner Standard Probe Liners are constructed from 15 9mm 5 8in OD tubing and have 28 ball joints attached Liner materials available are borosilicate glass quartz stainless steel inconel and Teflon Teflon liners straight liners and liners with integrated nozzles require a ball joint adapter Various configurations are available as shown below in Figure 1 5 Table 1 3 and Table 1 4 list the temperature limits for Probe Liner Materials and Probe Configurations respectively Standard Probe Liner PLN LIG D 4 1111 Nominal Length gt Plain Probe Liner PLS Probe Liner with Male 14 35 Taper Joint and 28 Ball Joint PLN LIGT FS 1c D or i PL OQT NO OT Probe Liner with Nozzle eat oF shown with optional 28 ball adapter
102. o the average AH observed during the test series Also the vacuum will be independent of the vacuum observed during the test series This is 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 max vacuum with the Coarse Valve fully opened and the Fine Valve fully closed Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 67 ISOKINETIC SOURCE SAMPLER MANUAL 10 11 Turn off the Vacuum Pump Record initial settings of AH dry gas meter volume reading wet test meter volume reading dry gas meter temperature and wet test meter temperature Start the Vacuum Pump and quickly adjust the AH to the desired setting Start the Elapsed Timer on the Source Sampler Console at the same time that the pump is started Let the Vacuum Pump run until a dry gas volume of approximately 140 liters 5 cubic feet is indicated by the dry gas meter Allow the calibration run to continue until the next minute elapses then stop the Vacuum Pump and Elapsed Timer 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 a
103. obes Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com A 3 ISOKINETIC SOURCE SAMPLER MANUAL Recommended Spare Parts for Isokinetic Sampling continued Qty Part Description Umbilical Cable Parts UC 60 1 QC F4 B Quick Connect 14 14 tube female brass 1 QC F8 B Quick Connect 12 77 1 2 tube female brass 1 QC M4 B Quick Connect 14 4 tube male brass 1 QC M8 B Quick Connect 2 1 2 tube male brass 4 TC LPS K Thermocouple Plug Type K cord 4 TC LJ K Thermocouple Connector Tvpe 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 14 inch OD weathered black 1000 roll 25 PT24004NA PE Tubing 1 4 inch OD weathered Natural 1000 roll 25 PT24004YW PE Tubing 14 inch OD weathered yellow 1000 roll General Repair and Supply Pa rts 50 WK PP 24S Wire Thermocouple extension yellow feet 25 WK TT 24 Wire Thermocouple Type K TFE insulation feet 10 4F B Ferrule 4 inch tube brass 10 6F B Ferrule 3 8 inch tube brass 10 8F B Ferrule 12 inch tube brass 10 10F B Ferrule 5 8 inch tube brass 1 O 113 DZ Silicone O ring 5 8 inch 12 pe
104. ommended Keep face away from exhaust port and do not flush with flammable solvents e Clean the lubricator and replace the oil See Figure 3 11 Use Gast Oil AD220 or SAE 10 Oil e Remove the muffler jar again and clean thoroughly Clean or replace the filter insert as necessary See Figure 3 12 Re install the muffler jar and hand tighten Muffler Jar Seal A404 p Muffler Filter Insert AJF 0523 AN 7 Aluminum Muffler Jar AJ 0523 Figure 3 12 AB609B Muffler Assembly Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 77 ISOKINETIC SOURCE SAMPLER MANUAL Disassembly If foreign matter has entered pump try flushing If this does not eliminate foreign matter remove ONLY the end plate and the four vanes as in Figure 3 13 DO NOT at any time remove the rotor or loosen any of the electrical motor thru bolts Wash vanes end plate and pump chamber with Flushing Solvent AH225 Dry and re lubricate lightly When replacing vanes be sure angled ends are oriented properly See drawing in Figure 3 13 If pump fails to produce proper vacuum the top clearance between the rotor and body may have increased A metallic clanging could mean that the rotor and the body are touching Remove end plate loosen body bolts and set top clearance at 0 051 mm 0 002 This can be done by lightly tapping with a miniature hammer on the pump body either to
105. one 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 10 ISOKINETIC SOURCE SAMPLER MANUAL Nozzle Size Selection Worksheet continued K FACTOR CALCULATION AH Isokinetic Rate Orifice Pressure Differential AH KxAp AH M T P K K D AH C 1 B Ap i M T P Ke 8 038x10 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 preliminarv velocitv run convert to m min or ft min vs x 60 sec min Vs fpm or mpm 6 Estimated Sampling Time minutes multiply number of traverse points by minutes point total min CALCULATION OF ACTUAL SAMPLING RATE Qmista Actual Sampling Rate dscmm or dscfm _100 1 B P v D S fpmjor mpm n TE 10397 2100 l JC X JE Y l Qnn 1039 l Vinista Total Gas Sample Volume to be Collected dscm or dscf V nisa Q nisa x 0 zi Based on applicable regulations for this source Will there be sufficient sample volume dscf 2 CI yes CJ no Will there be sufficient sampling time minutes CI yes CI no Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 11 ISOKINETIC SOURCE SAMPLER MANUAL Nozzle Size Selection Worksheet continued Check Intermediate Isokinetic Sampling Rate 1007 V Std Pay K T V nista
106. ontains the exit thermocouple This adapter serves as a strain relief between the Umbilical Cable and the glassware train Figure 1 8 Circular Connector and Electrical Pin Designations Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 14 ISOKINETIC SOURCE SAMPLER MANUAL 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 illustrates the glassware of the USEPA Method 5 sampling train The order in which a typical USEPA Method 5 glassware train is constructed is as follows 1 2 Se eae E Cyclone Bypass GN 1 Optional Cyclone GN 2 and Cyclone Flask GN 3 3 inch 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 3C Double L Adapter GN 8 Ist Impinger Modified Greenburg Smith GN 9A U Tube GN 11 2nd Impinger Greenburg Smith with Orifice GN 9AO U Tube GN 11 3rd Impinger Modified Greenburg Smith GN 9A U Tube GN 11 10 4th Impinger Modified Greenburg Smith GN 9A 11 Sample Case Umbilical Adapter GA 100 C il 4 ha j amp GNFA 3 GN 8 15K 1 jA JA yh GN 1 GN 11 GN 11 GN 11 o 116V T Tp P 7 TP P p jid 28
107. op section of a Velocity Traverse field data sheet 2 Have the pitot tube marked for traverse points according to Method 1 3 Assemble the apparatus for flow velocity measurement a Pitot tube with thermocouple pitot and thermocouple extension lines inclined manometer temperature display deviceor b Use Probe Assembly Umbilical Cable and inclined manometer on Meter Console 4 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 H O 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 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 off to hold the pressure 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 Make periodic checks of zero and level between ports 6 Insert the pitot tube into the stack to a marked traverse point seal off the port opening with a rag or towel to prevent ambient effects Measure the velocity head and temperature and record on the field data sheet It is suggested that the farthest point be measured first a
108. or quartz glass probe liners for stack temperatures up to 480 to 900 C 900 1 650 F The softening temperature for borosilicate glass is 820 C 1 508 F and for quartz it is 1 500 C 2 732PF 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 6 If a different type of condenser other than impingers is used 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 empty the silica gel after the run back into the container for weighing at another time Figure 2 28 Recovering Silica Gel for Weighing Figure 2 29 Determining Moisture Volumetrically 8 If the total particulate catch is expected 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 high pressure drops across the filter high vacuum on the gauge causing difficulty in maintaining isokinetic sampling replace the filter Suggestion Use anot
109. own as this would create a vacuum in the Filter Holder which may draw water from the impingers into the Filter Holder F Sample Recovery Sample Recovery is extremely important because that is where sample loss can occur bias results low due to sampler errors or blunders or contamination can be introduced bias results high 1 Place 200 ml of acetone from the wash bottle being used for cleanup 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 filter from the Filter Holder and place it in its identified petri dish container If necessary fold the filter such 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 PM and or remaining pieces of filter or filter fibers that adhere to the filter support or gasket 4 Container No 2 Acetone Rinses Recover any particulate matter from the internal surfaces of the Probe Nozzle swaged union fitting probe liner use a glass funnel to aid in transferring liquid washed to the container front half of the Filter Holder and if applicable the cyclone and recover all rinses in a single glass container as follows a Before cleaning the fron
110. p Assembly Source Sampler Console eee Diy Gas Metera orun neien en Eni ea ia raiter ASS Dual Column Inclined Manometer Manometer Zero Solenoid Valve Temperature Controllers ss esenenenznnznnzznnnzznaza Thermocouple Wiring and Thermocouple Displav gi Electrical Power Circunits Circular Connector Outlet on Source Sampler Console 83 Umbilical Cable Modular Sample Case Probe Assembly Tube Heater ss mmmmmmnnnnnn 84 Sample Vacuum and Pitot Pressure Lines on Umbilical Cable w ceccccesccesscecesecesnceenseceeneeenseeees 64 Quick Connects Vacuum Line i Pitt Lines oriei kasu red A 84 APPENDIX Accre Al RECOMMENDED EQUIPMENT FOR ISOKINETIC SAMPLING i see a aa BA gada A 2 RECOMMENDED SPARE PARTS eeceeeeeeees A 3 EQUIPMENT CHECKLIST 0cccccceeeeeeeeeeees A 5 APPENDIX B cecsecesesecececescvcveessceeebn ELECTRICAL amp PLUMBING SCHEMATICS B 2 APPENDIX C cccecececcecscecscecececscesse Onl CALIBRATION DATA SHEETS C 2 APPENDIX D ccececseccsececccevevcvesese D 1 STACK TESTING FIELD DATA SHEETS D 2 APPENDIX E cccccsecececececececscescecececetun CALCULATION WORKSHEETS E 2 Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com ISOKINETIC SOURCE SAMPLER MANUAL Chapter Introduction The purpo
111. p or bottom depending on whether clearance is too large or too small The rotor should be turned while setting clearance so that all points on the circumference of rotor will clear End clearance total for both sides of rotor may vary from 0 0635 mm to 0 0889 mm 0 0025 to 0 0035 Replacement Vane AK731 Figure 3 13 Vane Replacement Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 78 ISOKINETIC SOURCE SAMPLER MANUAL Source Sampler Console To inspect the inside components of the Source Sampler Console make sure the power cord is disconnected Remove the front panel and tray from the cabinet by turning the four panel latches in corners of front panel counterclockwise with a flathead screwdriver until the latch releases Slide out the panel using the handle at the bottom center of the faceplate Once the panel is partially pulled out reach inside and disconnect the fan wire from the fan assembly Visually inspect all of the mechanical and electrical components Clean any accumulated dust off the components Dry Gas Meter The dry gas meter shown in Figure 3 11 is not field adjustable The routine maintenance consists of performing the required periodic calibrations and calibration checks If the dry gas meter fails repeatedly to calibrate against a wet test meter then return the meter to the factory for repair Valve Mechanism Reverse Flo
112. pact Method 5 with our Heated Filter Assembly SFA 82H and Power Box Adapter UA 3J Figure 2 3 illustrates the Non Rigid Isokinetic Sampling Train The midget hot box allows for less clearance between the monorail and guardrail of the stack Figure 2 4 illustrates the Compact Method 5 The small heated filter assembly allows greater flexibility in small sampling areas Mini Heated a Filter Box l Strain Relief IA GA 107 O SB 2M Flexible Unheated Sample Line USL L SST o D H a we _ Strain Relief ne Il GA 09 D H a l i Jl a g Impinger Outlet AM Ef GA 100 i To Meter Console REAREA AARDE Cut Back Umbilical Cord O O mm ai Af Figure 2 3 Schematic of Non Rigid Isokinetic Sampling Train IE Power Adapter ae UA 3J lu 4 Strain Relief GA 109 ra igi ona l mpinger Outle sil ff GA 100 N mo a A Heated Stainless Steel j AN Filter Assembly KA Exploded View SFA 82H SFA 82HV f A Heated Stainless Steel i k Unheated Sample Line kel Filter Assembly for A USL O QST X 240VAC To Meter Console Cut Back Umbi uc U 0 mi ae F Figure 2 4 Schematic of Compact Isokinetic Sampling Train Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 22 ISOKINETIC SOURCE SAMPLER
113. pressure mm Hg or in Hg Ps Note Ps Pyar Pg mm H20 13 6 or in H20 13 6 Stack gas moisture fraction Bws Stack gas dry molecular weight g g mole or Ib Ib mole Ma Stack gas wet molecular weight g g mole or Ib ib mole Ms Note Ms Ma 1 Bws 18 0 Bws CALCULATIONS vs Stack gas velocity m s or ft s v K xC x Ap dak x v K x eat Ie mis or ft s Kp 34 97 Metric Units 85 49 English Units Qa Volumetric flow rate acmm or acfm Q 60 xv x A OQ 60 x x acmm or acfm Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 4 ISOKINETIC SOURCE SAMPLER MANUAL Determination of Stack Gas Velocity and Volumetric Flow Rate continued Qa Dry volumetric flow meter semm or scfm Q 60x 1 B x v x A Q 60 x I x x scmm or scfm Qsa Volumetric flow rate dscmm or dscfm T P Q 60 x B xv x A x x l l l l T Pa Q 0x0 Jx x jal dscmm or dscfm Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 5 ISOKINETIC SOURCE SAMPLER MANUAL 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 02 Percent Carbon Dioxide CO2 b
114. r Console The Series 500 Source Sampler Console includes e Double Column Inclined Vertical 250 mm 10 inch Manometer and Flow Control Valves to monitor stack gas velocity pressure head and orifice pressure to achieve isokinetic sampling e Dry Gas Meter that reads gas sample volume in cubic meters or cubic feet to three decimal places e Automatic Solid State Temperature Controllers with individual circuit breakers for filter hot box oven and probe heat e Digital Temperature Display and 6 channel Thermocouple Selector Switch enable the operator to monitor all sampling system temperatures e Vacuum Gauge reads system vacuum 0 100 kPa 0 30 in Hg e Digital Elapsed Timer monitors sampling time by the on off toggle switch e Manometer Zero switch enables the operator to zero the Orifice Tube manometer at any time before or during sampling using direct acting solenoid valves Table 1 1 Features and Specifications of Apex Instruments Model MC 500 Series Console Meters MC 522 MC 572 Gas Meter Rockwell 110 direct read index 0 1 cubic Kimmon SK 25 with direct read numeric index feet revolution res 0 001 cubic feet 68 Lpm rated capacity 0 1 liter res with flow indicator for leak checks Meter Display Direct reading numeric totalizer with 9999 999 Direct reading numeric totalizer with 9999 999 cubic feet capacity cubic meter capacity Temperature Analog solid state controllers with solid state Analog solid state controller
115. r pack 3 NTG 10F Single Ferrule 5 8 inch 1 3M 69 Glass Tape Scotch 69 34 66 ft roll Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com A 4 ISOKINETIC SOURCE SAMPLER MANUAL Equipment Checklist CLIENT SOURCE PROJECT ORSAT EQUIPMENT SAMPLING EQUIPMENT SAFETY EQUIPMENT _ METER BOX QTY S N ORSAT ANALYZER HARD HAT PROBE QTY FT ORSAT PUMP PERISTALTIC GLOVES PROBE BRUSH FT TUBING RESPIRATOR NOZZLE BOX GLASS SS_ FYRITE EAR PLUGS SAMPLE BOX QTY SQUEEZE BULB SAFETY GLASSES IMPINGER BOX QTY SAMPLE BAGS BUCKETS QIV RAIN GEAR UMBILICAL QTY FT ORSAT REAGENTS SAFETY BELT REAGENT BOX SPARE GLASSWARE BAGS FILTERS EXTENSION CORD QTY FT SAMPLE RECOVERY SUPPLIES amp REAGENTS et BALANCE BRUSHES ROPE FILTERS FUNNELS PULLEY amp STAND GRAD CYL 250 ML TFE TAPE SOEMES TWEEZERS TRAY w ERS
116. ratures at the sampling location and controls system sampling rate and system temperatures Figure 1 2 illustrates the Apex Instruments Model MC 572 Source Sampler Console s front panel The Model 572 is the metric version of the Model 522 Filter amp Probe Temperature Controllers Temperature Display Rocker Switches Manometer Quick Connects Elapsed Timer Dual Column Inclined Manometer Vacuum Gauge Coarse Control Valve Temperature Selector Switch Dry Gas Meter Color Coded Thermocouple Fine Control Valve Jacks Umbilical Cable Manometer Zero Power Connection Adjust Knobs Vacuum Pump Manometer Connections Level Adjust Sample Pitot Quick Connect Quick Connects Lubricated Rotary Vane Pump Figure 1 2 Model MC 572 Source Sampler Console Front Panel Assembly in the field is simple The connections for sample line pitot tube lines vacuum pump non reversible and electrical 4 pin and thermocouple are located on the front panel for easy access The front panel has four 4 latches one in each corner that unscrew and enable the operator to pull out the Source Sampler Console from the cabinet using the convenient handle Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 4 ISOKINETIC SOURCE SAMPLER MANUAL Table 1 1 presents a comparison of the features and specifications of each Apex Instruments Source Sample
117. recalibrated With a permanent marking tool identify each nozzle with a unique number Figure 3 8 Calibration of Sampling Nozzle Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 73 ISOKINETIC SOURCE SAMPLER MANUAL 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 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 9 Figure 3 9 Set up for Probe Heater Calibration Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 74 ISOKINETIC SOURCE SAMPLER MANUAL Maintenance External Pump Assembly The Gast rotary vane pump E 0523 is a precision product with only 0 051 mm 0 002 clearance at the top and 0 0635 0 0889 mm 0 0025 0 0035 total at the ends of the rotor The vanes take up their own wear and should last
118. required for other test method for example metals or dioxin B 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 7 Select a nozzle size and determine the K factor for isokinetic sampling rate Note Do NOT change nozzle size during the sampling run Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 48 ISOKINETIC SOURCE SAMPLER MANUAL 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 2 minutes per traverse point C Preparation of Sampling Train 1 Mark the Probe Assembly with heat resistant tape or White Out to denote the proper distance into the stack or duct for each sampling point 2 Insert the Probe Nozzle into the probe sheath union and finger tighten the union fitting Avoid over tightening to prevent cracking the glass probe liner Keep the nozzle tip and the ball joi
119. ring in each port we can often find in stack obstructions and can check ourselves against erroneous measurements If possible shine a flashlight across the stack and check for obstructions or irregularities If possible with a glove on your hand reach into the sampling port and check that the port was installed flush with stack wall does not extend into the flow Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 27 ISOKINETIC SOURCE SAMPLER MANUAL Figure 2 10 illustrates determining the total traverse point number from the curve of Method 1 s Figure 1 1 For example if Distance A is 1 7 duct diameters and Distance B is 7 5 duct diameters then Distance A would indicate use of 16 traverse point and Distance B would indicate use of 12 traverse points You must choose the higher of the two Therefore the sampling site requires 16 total traverse points eight in each of two directions 90 apart DUCT DIAMETERS UPSTREAM FROM FLOW DISTURBANCE DISTANCE A 0 5 1 0 1 5 2 0 2 5 50 l a i HIGHER NUMBER IS FOR l P RECTANGULAR STACKS OR DUCTS a Disturbance 5 40 L A o i t Measurement a 1 i Site LU l o i ti B 30 rm 1 E 24 OR 25 i Vv Disturbance o 1 X 1 w i 8 20 I 2 I i STACK DIAMETER gt 0 61 m 24 in Di z 12 Zz H a 10 H 8 or
120. ritical to conducting any stack testing program Without calibration sampling cannot be verified as having been conducted isokinetically 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 USEPA has determined that the interlaboratory standard deviation is 12 1 Only through careful calibration maintenance and record keeping can the stack tester ensure that the data collected during the stack test program are representative of particle concentrations and mass emission rate Components of the particulate sampling system which 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 4 Sampling Nozzles 5 Probe and Filter Box Heater System Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 61 ISOKINETIC SOURCE SAMPLER MANUAL Table 3 1 presents a summary of the calibrations required equipment used for calibration acceptance limits calibration frequency and actions required if calibration fails to meet acceptance limits Acceptance Action If Component Calibrated Against Limits Frequency Unacceptable Dry Gas Meter Initial 5 point Post test 3 point Orifice
121. s Impinger 4 Silica Gel Weight p FinalWelghti w jj f g l Initial Weight w f f f g IT Net Weight Wa d f o Comments F Total Water Collected l toaiva 9 Formulas Used Va Vi V Wa Wi W Vic Vn Wilpw where p 9982 g mi PEX SOURCE TESTING EQUIPMENT INSTRUMENTS Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 9 ISOKINETIC SOURCE SAMPLER MANUAL Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com D 10 ISOKINETIC SOURCE SAMPLER MANUAL METHOD 5 SAMPLE ANALYTICAL DATA SHEET Plant Wamel io Sampling Location ____ Projects Operator Acetone Lot Number irc in Dosiccaor Ammi S Number dato Time Run Start Timo O OOOO rr ee ey acetone Wash Beaker Estimated Volume lt Pa l I l mammitilmima _ Measurement 2 ma m _ _ Measurement 3 momo _ Measurement 4 maim _ ___ El STEN ME ane Acetone Wash mm 9 Bottiowewith Wash mou 0 pare Weight mama 9 Additional Rinse wt mw o Weight Gain mam mo Bottle Tare Weight ma 9 Wa gt mo _Net Wash Weight me o Total Particulates m ma Bank Concentration Cy mo Analytical Data Placed in Desiccator o S Number Run Start Tim Dato rit
122. s Damages no Oo o a wea O e mwee oom o ee Oo e emos E jA i Pl zsa O ws oor DAMU INDIKA NI UL VEL POSTI FOR DETERMNIN Ba 1AMD 42 188 to 375 DEGREE INCCATING LEVEL POSITION FOR DETERMINING for 1 4 OD 525 to 750 for 3 8 OD 788 to 1 125 p Certification I certify that pitot tube probe number meets or exceeds all specifications criteria and or applicable design features and is hereby assigned a pitot tube certification factor of 0 84 See 40 CFR Pt 60 App A EPA Method 2 Certified by Personnel Signature Date Team Leader Signature Date Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com C 8 ISOKINETIC SOURCE SAMPLER MANUAL PRESSURE SENSOR CALIBRATION DATA SHEET If other than inclined gauge oil or mercury in glass Type of Pressure Sensor Differential Gauge Electronic Manometer U Tube Other Gauge A Reference B AIB 0 95 to 1 05 Low o T Reference Inclined oil gauge or mercury in glass Checked by Personnel Signature Date Team Leader Signature Date Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com C 9 ISOKINETIC SOURCE SAMPLER MANUAL Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com C 10 ISOKINETIC
123. s dry molecular weight or density is calculated and this data is used in the equation for stack gas velocity From the gas composition data the amount of excess air for combustion sources can be calculated In jurisdictions where the particulate emissions are regulated on a concentration basis such as mg m3 the gas composition data can be used to correct the concentration results to a reference diluent concentration for example 7 O or 12 CO2 There are three options for determining dry molecular weight 1 Sample and analyze 2 Calculate stoichiometrically for combustion sources the O and CO concentrations or 3 If burning fossil fuels Coal oil or natural gas assign a value of 30 0 for dry molecular weight The stack gas sample can be collected using one of three options 1 Grab sampling from a single traverse point a portion of the stack gas using a one way squeeze bulb and loading directly into the analyzer This technique can also be used 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 collection of at least 30 liters 1 00 cu ft however smaller volumes may be collected if desired Constant rate sampling is used 3 Integrated sampling from multiple points in a flexible leak free bag This technique is used when conducting a Method 5 particulate traverse and using th
124. s two 2 3 way solenoid valves These valves open both legs of the AH side of the dual column manometer to atmosphere so that the manometer fluid zero pressure level can be checked and if necessary adjusted by the operator When the MANOMETER ZERO switch is ON the valves should produce an audible click e 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 e To activate the heaters in the filter compartment Hot Box and the probe heater turn on the switches labeled FILTER and PROBE The indicator lights on the automatic temperature controllers will illuminate Adjust the dials to approximately 120 C 248 F and check the temperature display to verify if the heaters are working Allow time for the temperatures to stabilize and verify operation of the circuits Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 6 ISOKINETIC SOURCE SAMPLER MANUAL Thermocouple Subsystem The thermocouple subsystem displays measures and or controls temperatures critical to isokinetic sampling operation The thermocouple system consists of Type K thermocouples extension wires male female connectors receptacles a 6 channe
125. s with solid state Control power relay external relay 120 VAC SA or 240 power relay external relay 120 VAC SA or 240 VAC 3A resistive load VAC 3A resistive load Temperature 31 2 digit red LCD display 15 F to 1999 F 3 digit red LCD display 105 C to 1372 C Display range with external 7 channel selector switch range F available with external 6 channel selector switch Sample Pump Rotary Vane Pump Standard Rotary Vane Pump Standard Double Head Diaphragm Optional Double Head Diaphragm Optional See Descriptions Below See Descriptions Below Umbilical Electrical 4 pin circular connector Electrical 4 pin circular connector Connections Sample Line 12 7 mm 1 2 inch quick Sample Line 12 7 mm 1 2 inch quick connects connects Pitot Line 6 35 mm 1 4 inch QCs 3 8 inch Pitot Line 6 35 mm 1 4 inch QCs 3 8 inch Optional Optional Thermocouples Type K standard size Thermocouples Type K standard size Dimensions 19x19x1034 inches metric 49x49x26cm 19x19x10 inches metric 49x49x26cm Power 120 V 60 Hz 120 V 60 Hz aes V 50 Hz Beem 240 V 50 Hz Optional Weight 40 Ib 19 5 gomd9ske o 19 5 kg 40 Ib Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 5 ISOKINETIC SOURCE SAMPLER MANUAL The Source Sampler Console has Electrical Thermocouple and Vacuum sub systems Electrical Subsystem The Source Sampler Console is fa
126. se of this manual is to provide a basic understanding of the Apex Instruments Model MC 500 Series Source Sampler console and isokinetic sampling system Sections of the manual include System Description Calibration Procedures Sampling Procedures and Maintenance and Troubleshooting The manual is based on the procedures established by the United States Environmental Protection Agency USEPA in accordance with Reference Methods 1 through 5 Determination of Particulate Emissions from Stationary Sources The Apex Instruments isokinetic source sampling system enables the operator to extract a gas sample from a stack isokinetically The word isokinetic is comprised of two Greek root words iso meaning the same as and kinetic meaning relating to motion of material bodies Isokinetic sampling is therefore the extraction of a gas sample from a gas stream at the same velocity as the gas travels in the stack Isokinetic sampling is necessary because of the inertial effects of particulate matter in a gas stream The isokinetic sampling ratio or percent isokinetic 901 is the ratio of the sample velocity at the inlet of the sampling nozzle to the stack gas velocity Isokinetic testing requires a through understanding of the first five test methods presented in Title 40 Part 60 Appendix A of the Code of Federal Regulations 4OCFR60 App A Method 5 provides the general sampling train operation protocol but Methods 1 through 4 pres
127. ssure as negative 4 If the oil travels past the zero mark reconnect the positive side and disconnect the negative side and read the deflection of the oil in the manometer Record the static pressure as positive After the static pressure Pg is recorded the value must be converted from mm H20 to mm Hg inches H20 to inches Hg prior to use in the velocity equation as P The density of mercury is 13 6 times that of water so the conversion equation is P P Pray 13 6 Barometric Pressure The barometric pressure at the measurement site can be obtained by using a calibrated on site barometer or by contacting a local or nearby weather station within 30 km and obtaining the uncorrected station pressure weather stations report barometric pressure corrected to sea level so ask for the uncorrected pressure and their elevation above sea level You must also know the measurement site s elevation and correct by subtracting 0 832 mm Hg for every 100 m rise in elevation 0 1 in Hg for every 100 ft Calculate the sampling site barometric pressure Phar as follows B P 0 001 A B where P 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 Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst
128. t half of the Filter Holder wipe clean all joints of silicone grease Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 54 ISOKINETIC SOURCE SAMPLER MANUAL b Rinse with acetone brush with small nylon bristle brush and rinse with acetone until there are no visible particles Make a final acetone rinse c For probe liner repeat rinse brush rinse sequence at least three times for glass liners and six times for metal liners Figure 2 30 Sample Recovery from Probe Liner Tips from an Old Stack Tester Instead of trying to catch the probe rinse with a glass funnel and sample container likely step for sample loss clamp an Erlenmeyer flask outfitted with female ball joint on the probe liner ball joint and conduct the probe rinse procedure If the probe is short one person can perform the brushing and rinsing Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 55 ISOKINETIC SOURCE SAMPLER MANUAL Figure 2 31 Rinsing Probe Nozzle Figure 2 32 Brushing Probe Nozzle Figure 2 33 Front Half Acetone Rinse Samples d Make a final rinse of the probe brush with acetone e For Probe Nozzle use the nylon nozzle brush and follow the same sequence of rinse brush rinse as for the probe linger f After completing the rinse tighten the lid on the sample container Mark the height of the flu
129. tack at isokinetic conditions The equation for average gas velocity in a stack or duct is Where vs Average stack gas velocity m sec ft sec Cp Pitot tube coefficient dimensionless Ap Velocity head of stack gas mm H2O inches H20 Ts Absolute average stack gas temperature K R P Absolute stack gas pressure mm Hg in Hg Phar Pg 13 6 Piar Barometric pressure at measurement site mm Hg in Hg Ps Stack static pressure mm H2O in H20 M Molecular weight of stack on wet basis g g mole Ib Ib mole Ma 1 Bws 18 0 Bws Ma Molecular weight of stack on dry basis g g mole Ib Ib mole K Constant 34 97 for metric system 85 49 for English system To obtain all values for input to the equation values for molecular weight and moisture of the stack gas must be measured or estimated Figure 2 15 illustrates the relationship of Methods 1 3 and 4 to Method 2 Method 3 Method 1 Selection of Traverse Points Stack Gas Molecular Weight Options 5 Sample with Orsat analysis 6 Sample with Fyrite analysis 7 Assign 29 0 if air 8 Assign 30 0 if combustion 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 Figure 2 15 Determination of Preliminary Velocity Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexi
130. te of 21 2 Ipm 0 75 cfm is the standard sampling rate for solving the isokinetic equation and setting up the nomograph sets of equations for testing Both the initial and intermediate calibration procedures are described here Prior to conducting a calibration run the portion of the sampling train from the pump to the Orifice Tube in the Source Sampler Console should be leak checked Metering System Leak Check Procedure Vacuum Side Figure 3 1 shows a plumbing diagram of the MC 500 Series Source Sampler Console Connect the Vacuum Pump to the Source Sampler Console Close the Coarse Valve on the Source Sampler Console Insert a plugged male quick connect into the SAMPLE quick connect inlet Turn on the pump Open the Coarse Valve and fully close FINE INCREASE the Fine Increase Valve The Vacuum Gauge should read 92 kPa 27 in Hg for a barometric pressure of 100 kPa 30 in Hg D so a 7 After the AH manometer has returned to the zero mark using the dry gas meter gauge and a wristwatch or timer note whether the leak rate exceeds 0 28 lpm 0 01 cfm If the leak rate is greater turn off the pump and check connections of the tubing and piping on the Pump Vacuum Gauge and metering valves Check the tubing also for leaks 8 Close the Coarse Valve and observe the Vacuum Gauge If there is no loss of vacuum the vacuum side of the Source Sampler Console is leak free 9 The Pressure Side Leak Check will need to be performed n
131. tem 5 The readings at the three levels must agree within 5 of the reference sensor To pressure source or vented to atmosphere Magnehelic To vacuum system or vented to atmosphere Manometer Figure 3 6 Set up for Differential Pressure Sensor Calibration Check Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 70 ISOKINETIC SOURCE SAMPLER MANUAL Calibration of Pitot Tube The construction details of the S type or Stausscheibe pitot tube should be carefully checked when received and prior to calibration There are two options for calibrating a type S pitot tube Calibration Of S type Pitot Tube Check that it meets Calibrate against geometric standard p type in a specifications and wind tunnel and assign C 0 84 calculate new C Apex Instruments provides both geometric and wind tunnel calibrations of type S pitot tube assemblies at extra charge The procedures for conducting a wind tunnel calibration are described in detail in US EPA Method 2 When using this procedure a pitot tube coefficient C will typically range from 0 77 to 0 82 Subsequent measurement of stack gas velocity will be more accurate and from 2 to 8 lower Consequently stack gas volumetric flow rate and emission rate will be lower The cost of purchasing or building a wind tunnel is too high for many stack testers and few have access to
132. truments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com C 2 ISOKINETIC SOURCE SAMPLER MANUAL S 6 3 2 a 3 i i 8 18 i g FM S al l FA p 8 jg z ji a A 3L3W 1S31 13M NISN NOILVHBITWO 3IOSNO9 1S3AL 1SOd S QOHLIW SINIWNULSNI X3dV Ce Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com C 3 ISOKINETIC SOURCE SAMPLER MANUAL SIHAYO TWILLIHOI QILVHBNWI DNISN NOLLVU8 MV2 STOSNOD 1S31 34d S QOHLIW SLNSWNYLSNI Xadv BMIEUBIS CL STN SPJEPUBIS JO NEBAB JEVOIJEN Sup 0 DIQBDJEJN SI LIAM Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com ISOKINETIC SOURCE SAMPLER MANUAL APEX INSTRUMENTS METHOD POST TEST CONSOLE CALIBRATION USING CALIBRATED CRITICAL ORIFICES 3 POINT METRIC UNITS Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com ISOKINETIC SOURCE SAMPLER MANUAL TEMPERATURE SENSOR CALIBRATION DATA SHEET DATE THERMOCOUPLE NO PERSONNEL REFERENCE AMBIENT TEMPERATURE C ASTM MERCURY IN GLASS ID NIST REFERENCE TC ID Reference Thermocouple Absolute Thermometer Display Temperature Temperature C Temperature C Difference Reference Point Number g 8 G 3 S
133. ure differential AH 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 Ipm 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 Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 19 ISOKINETIC SOURCE SAMPLER MANUAL Test Design Before testing the operator should know the following e Why the test is to be conducted e Who will use the data e What stacks or emission points are to be tested and what process data is to be collected and correlated with test results e Where the sample ports are located and type of access e When the test is scheduled and deadlines for reporting e How the method or procedure is followed and how many test runs or process conditions will be tested Site Preparation Preparing the site so that sampling equipment can be positioned is frequently the most difficult part of sampling When the sample ports do not have a platform or catwalk then scaffolding must be erected to reach the sampling site At many sites the operator must use his ingenuity to get the sampling equipment to the sample ports When selecting the site for sample ports the operator should keep in mind that the distance form the probe to the bottom of the sample case is about
134. verage dry gas meter and wet test meter temperatures Calculate the meter correction factor Y Repeat the calibration two 2 more times at the same AH and system vacuum and calculate the average Y for the three runs Calculate the percent change in the meter correction factor Y If the dry gas meter Y values obtained before and after the test series differ by more than 5 the test series shall be either voided or calculations for the test series shall be performed using the lower Y value gives lower sample volume therefore higher concentration values Calibration of Thermocouples Apex Instruments suggests the following procedures for calibrating thermocouples and temperature display readouts Thermocouples should be checked for calibration at three temperatures for example ice point and boiling point of water and ambient temperature Thermocouples such as the stack gas thermocouples which are used at higher temperatures than boiling water can be checked for calibration using a hot oil bath 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 for 22 precise test points A temperature sensor calibration form is provided in Appendix C Acceptable reference materials are e ASTM mercury in glass reference thermometers e NIST calibrated reference t
135. vg where Ks 0 6071 metric units 0 03575 English units After selecting the appropriate nozzle from the Nozzle Set shown in Figure 2 22 the K factor ratio of AH Ap such that AH KAp used to maintain isokinetic sampling rate at each traverse point is calculated for the sampling test run using the following equation x 54 x pt aH Ca n Y Milk Ap M T P where Dn Nozzle diameter mm inches Tia Average DGM temperature K R Ts Average stack gas temperature K R Ke 0 0000804 metric units 849 842 English units The total sampling time number of traverse points multiplied by minutes point as well as the final estimated gas sample volume Vmsta should be checked against any applicable environmental regulations for the industry to see if minimum sampling times and volumes will be acceptable The calculation may involve some iterations in selecting K factors and or nozzle size that will yield acceptable sampling volume and time Figure 2 22 Probe Nozzle Set Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 47 ISOKINETIC SOURCE SAMPLER MANUAL Method 5 Test Procedure A Pre Test Preparation Before Traveling to Site 1 Check filters visually against light for irregularities and 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
136. w Stopper Pitot Flow Checker to monitor leakage down to 0 02 liters Reinforced Polymer Diaphragm Figure 3 11 Positive Displacement Diaphragm Type Dry Gas Meter Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 79 ISOKINETIC SOURCE SAMPLER MANUAL Dual Column Inclined Manometer Manometer fluids are color coded for ease of reading in the field red is used for the pitot tube manometer and orange yellow for the Orifice Tube manometer 1 Inspection e Visuallv inspect the pitot and orifice manometer lines both on the front panel and inside back of unit Thev should be free of fluid Replace the red manometer fluid if it is faded e Check quick connect O rings for cuts or deterioration that mav cause leaks Make sure the plastic quick connects are engaged and sealed Check the sight and fluid level The manometer can be filled with fluid bv removing the screw on the left side When the manometer is zeroed the fluid level plunger should have about 3 to 6 mm 1 8 to 1 4 travel inward Replace the fluid level plunger or O rings if necessary 2 Cleaning e Wipe the manometer so that it is free from dirt smudges and grease use soap and warm water DO NOT USE hydrocarbon solvents 3 Leak Checking e Check for leaks especiallv around the fluid level plunger and drain screws Use leak check procedure given in Section 5 7 Repair leaks bv tighte
137. weight of water collected g K 0 001335 m g metric units 0 04715 ft g English units and B Viet ws Vaca Venda where B Proportion of water vapor by volume in the gas stream Next the average stack gas velocity is calculated The equation for average gas velocity in a stack or duct is IT slave V g KO Ap ll PM where V Average stack gas velocity m sec ft sec C Pitot tube coefficient dimensionless VAP we Average of the square roots of each stack gas velocity head T Absolute average stack gas temperature K R P Absolute stack gas pressure mmHg in Hg Pya P 13 6 Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com 57 ISOKINETIC SOURCE SAMPLER MANUAL Bis Baromettic pressure at measurement site mm Hg in Hg P Stack static pressure mm H2O in H2O M Molecular weight of stack on dry basis g g mole lb Ib mole M 1 B 18 0 B M Molecular weight of stack on dry basis g g mole lb Ib mole K Constant 34 97 for metric system 85 49 for English system The average percent isokinetic sampling rate is calculated as fe KTV et PV A 0 l B where A Cross sectional area of the nozzle m ft 0 Sampling time minutes K4 4 320 metric units 0 09450 English units At the conclusion of each sampling run it is prudent to calculate the stack gas moisture for the
138. with 2 inch Clamp 1 GA 109 12 Impinger Inlet Strain Relief with 2 inch Clamp 1 GA 100 Sample Case Umbilical Adapter 1 NS SET Stainless Steel Nozzle Set 1 GN DGS Deluxe M5 Glassware Set with Transport Case 1 GF 3GC 3 inch Glass Fiber Filters 100 box MFS GC50 82mm 1 PBX S Modular Probe Brush Set Nylon Brushes with Aluminum Extensions 1 NB SET Nozzle Brush Set sizes 3 5 amp 8 in Carrying Tube 1 MS5A 1M Slide Rule Nomograph Metric Units 2 P1000 9 9 foot Monorail 2 P2751 Monorail Trolley 1 TC 522 Console Transport Case MC 522 572 1 TC 0523 Pump Unit Transport Case 1 M5CO SET Calibration Critical Orifice Set It is also recommended to have additional Probe Assemblies to best suit vour 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 svstem Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com A 2 ISOKINETIC SOURCE SAMPLER MANUAL 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 Temp
139. y volume dry basis CO Percent Carbon Monoxide CO by volume dry basis CO Percent N2 100 02 CO2 CO N2 CALCULATIONS Ma Dry molecular weight g g mole or Ib Ib mole M 0 44 CO 0 32 0 0 28 N CO M 0 44 0 32 0 28 g g mole or Ib Ib mole M Wet molecular weight g g mole or Ib Ib mole M M 1 B 18 0 B M l 18 0 g g mole or Ib Ib mole Ss EA Excess Air oe O 0 5 CO tie 0 264 N O 0 5 CO 3 0 5 __ vr epee SOs S S Apex Instruments Inc Phone 919 557 7300 Fax 919 557 7110 Web www apexinst com e mail info apexinst com E 6 ISOKINETIC SOURCE SAMPLER MANUAL FEDERAL REFERENCE METHOD 4 Determination of Moisture Content of Stack Gases Plant Location INPUT PARAMETERS Volume of gas sampled through dry gas meter Dry gas meter DGM calibration factor Average DGM temperature K C 273 or R F 460 Average DGM orifice pressure differential mm H20 or in H20 Volume of water collected condensed V Vi ml Volume of water collected in silica gel W Wi g Barometric pressure mm Hg or in Hg CALCULATIONS Vmsta Volume of gas sampled at standard conditions dscm or dscf m std lm Pyar Z E ita P 13 6 std aft 3 Vaan JI ffe l ia std Date Test No Vwe sta Volume of water vapor condensed

Method 5 Manual - Apex Instruments, Inc.

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