Slide sequence

107-3

Key points

If free ammonia is present, alternate methods, subject
to the approval of the administrator, are required.

APPARATUS

The sampling train is the midget impinger sampling
train.

The tester has the option of substituting sampling
equipment described in Method 8 in place of the
midget impinger train. However, the Method 8 train
must be modified to include a heated filter between
the probe and the isopropanol impinger and the opera-
tion of the train and analysis must be as specified
in Method 8. The heated filter will help to elimi-
nate the possibility of the S02 reacting with the par-
ticulate matter.

The tester also has the option of determining SO2
simultaneously with particulate matter and moisture
by replacing the water in a Method 5 impinger system
with 3 percent hydrogen peroxide solution or by re-
placing the Method 5 water impinger system with a
Method 8 isopropanol-filter-peroxide system. The
analysis for SO2 must be consistent with Method 8
procedures.

The probe is constructed of borosilicate glass or
stainless steel, approximately 6-mm inside diameter,
with a heating system to prevent water condensation
and a filter (either in-stack or heated out of stack)
to remove particulate matter, including sulfuric acid
mist. A plug of glass wool is a satisfactory filter.

One midget bubbler, with medium-coarse glass frit and
borosilicate or quartz glass wool packed in the top
to prevent sulfuric acid mist carryover, and three
30-ml midget impingers. The bubbler and impingers
must be connected in series with leak-free glass con-
nectors. Silicon grease may be used to prevent leaks.
At the option of the tester, an impinger may be used
in the place of the bubbler.

1-63


Slide sequence

205-6

Key Points

The Pretest Agreement of Continuing Compliance Condi-
tions constitutes the next item of business. This
agreement covers process and control equipment opera-
tion after the test.

Process

1. Process parameters that must be recorded and sub-
mitted to the agency or kept on file for later inspec-
tion.

2. Percentage by which each process parameter can ex-
ceed the tested rate and on what time weighted average.

3. Future operating procedure.

Control Equipment

1. Control equipment parameters that must be recorded
and submitted to the agency or kept on file for later
inspections.

2. Normal operating procedures.
3. Normal maintenance schedule.
4. Frequency of inspections by agency.

Signature and approval by the agency and industry.

11-20


Slide sequence

103-35

Key points

8. After the traverse, check the differential pres-
sure gauge zero setting. If the zero has shifted,
reset and repeat the traverse.

9. If liquid droplets are present in the gas stream,
a liquid trap should. be inserted in the gauge line

“leading to the upstream pitot tube leg (impact open-

ing). In some cases a trap may be required for both
egs.

Static pressure measurement procedure

There are three acceptable means of measuring static
pressure. These are discussed in the order of
decreasing acceptability:

1. Install a tap perpendicular to the stack gas flow
or insert a \%" steel tube into the sample port while
maintaining a good seal. Connect one side of a U-tube
manometer to the tap and vent the other side of the
manometer to the atmosphere.

2. Use the static pressure tap of a standard pitot
tube connected to one side of a manometer. (If the
stack pressure is obviously negative, connect the
static pressure tap to the other side of the manome-
ter.) Vent the remaining side of the manometer to
the atmosphere. Point the pitot tube pressure open-
ing directly into the flow and seal the port around
the tube.

3. Use a type S pitot tube with the pitot tube open-
ings facing perpendicular to the gas stream. Con-
nect only one leg of the pitot tube to the manometer.
Vent the other side of the manometer to the atmosphere.
One static pressure reading is usually adequate for
all points within a stack, however, this must be con-
firmed by randomly moving the pressure probe over the
stack to see if there are any significant variations.

4. Record the static pressure (be sure to include
the proper sign) as read from the manometer on the
velocity data form.

1-26


Slide sequence

301-10

301-11

301-12

Key Points

Use of the closed-faced high volume sampler and
Method 5 as described in Method 5D have been used for
roof monitors. The nozzle or opening on the closed-
face high volume sampler should be sized to give as
close to isokinetic conditions as can be determined
from a pre-site visit and preliminary velocity
determinations.

Grain dryers usually have louvers or an open
screen as shown in the diagram. The openings are
extremely large, ranging from 15 to 30 feet wide
and 30 to 80 feet high.

To sample this type source, a cylindrical stack can
be affixed to the end of a standard Method 5 sampling
probe such that the nozzle is aligned along the axis
at the cylinder. The face of the dryer can be por-
tioned into equal areas and isokinetic sampling per-
formed at the centroids of these areas. Placement

of the open-ended cylinder directly against the
screen covering the face of the dryer will block out
the effects of ambient air motion. When such a device
is employed, it must be assumed that the flow rate is
not restricted by the cylinder, so that the sample is
representative.

ITI-6


Slide sequence Key points

254-15,16 These equations give a good estimate of the amount of
SO, generated in terms of Ib/h.
254-17 This equation gives a check on the orsat data for

bituminous coal.

II-51


EVALUATION OF STATIONARY
SOURCE PERFORMANCE TESTS

Lecture Objectives and Instructor's Notes

Prepared by

PEDCo Environmental, Inc.
505 South Duke Street, Suite 503
Durham, North Carolina 27701

Prepared for

U.S. ENVIRONMENTAL PROTECTION AGENCY

OFFICE OF AIR, NOISE AND RADIATION

STATIONARY SOURCE COMPLIANCE DIVISION
WASHINGTON, D.C. 20460

August 1982


Slide sequence

204-4

204-5

204-6

Key Points

The reporting requirements are as noted. Having a
standardized reporting format enhances data complete-
ness and provides a greater ease of review.

The observer should be aware of the requirements of
Confidential Business Data. Procedures must be
established to safeguard any data that is deemed
confidential. An agency employee can 1) lose his

job, 2) be fined, and/or 3) sent to jail for releasing
confidential data. It is also noted that EPA does

not consider any emissions data to be confidential.

The observer should be aware that data which is con-
sidered confidential by an industry can be deemed
unconfidential by EPA and then released to the indus-
try's competitors under the Freedom of Information

t.

II-16


Slide sequence

108-3

108-4

Key Points

A U-tube manometer, 36 in. with 0.1 in. divisions
or other gauge capable of measuring pressure to
within +0.1 in. Hg.

A pump capable of evacuating the collection flask
to a pressure equal to or Tess than 3 in. Hg
absolute.

A one-way squeeze bulb.

A high vacuum, high-temperature chlorofluorocarbon
grease is required.

A barometer as described in Method 2.

Sample recovery and analytical apparatus consist of
the typical instruments found in a well equipped
laboratory. The following are very important in the
analytical phase of this method.

Porcelain evaporating dishes, 175 to 250 ml capacity
with lip for pouring. One is needed for each sample
and each standard. The coors No. 45006 has been
found to be satisfactory. Alternatively, polymethyl]
pentene beakers, or glass beakers may be used. When
glass beakers are used, etching of the beakers may
cause solid matter to be present in the analytical
step. The solids should be removed by filtration.

Aspectrophotometer capable of measuring the absorb-
ance at 410 NM (or the maximum peak), a set of
neutral density filters, and a filter for wavelength
calibration also required.

REAGENTS

All reagents should conform to the specifications
established by the American Chemical Society when
such specifications are available; otherwise, use
the best available grade.

1-73


Slide sequence

301-0 (cartoon or
title)

301-1

301-2

301-3

301-4

301-5

Key points

Speaker should give objectives of lecture and point
out reference material.

These are three examples of sources with unconfined
flow: 1) pressurized baghouses, 2) roof monitors,
and 3) open-faced grain dryers.

This is a picture of a pressurized baghouse. The main
reason these do not have stack is the cost saving
from not building a stack or duct.

This is a picture of a roof monitor. Many sources
do not easily lend themselves to a method of duct-
ing emissions. Roof monitors are common of all
primary smelters (copper, lead, zinc and aluminum).
The heat from the process causes the emissions to
exit through the roof monitor.

This is a picture of a grain dryer. Grain dryers
usually only need a screen with a moving vacuum
system for air pollution control. Therefore, they
do not require a duct to transport the emissions to
a control device. :

Two basic approaches exist for sampling unconfined
emissions: 1) Approach 1 is to confine the source

and then measure the confined emissions and 2) Approach
2 actually consists of measuring the unconfined emis-
sions.

This slide relates to Approach 1 - confining the
source. This is done by obtaining an effective seal
with a stack extension at the interface between the
flue (stack extension) and the source. Prior to and
after the addition of a stack extension, a check
should be made to ensure that the modification does
not affect emissions from the source or source opera-
tion,

III-4



Slide sequence

109-7 4.

109-8

Key Points

Prepare and assemble the sampling train.

a. Place 100 ml of 80 percent isopropanol in
the first impinger, 100 ml of 3 percent
hydrogen peroxide in the second and third
impingers. Retain a portion of each reagent
for use as a blank. Place 200 g of silica
gel in the fourth impinger.

b. If moisture content is to be determined by
impinger analysis weigh each of the impingers
to the nearest 0.5 g.

c. Filters should be inspected but does not need
to be desicated, weighed, or identified.

Leak~check the sampling train using the procedure
discussed in Method 5. Instead of plugging the
inlet to the filter holder, plug the inlet to the
first impinger.

Perform the mechanics of running the train and col-
lecting the sample.

Periodically during the test, observe the con-
necting line between the probe and first impinger
for signs of condensation. If it does occur,
adjust the probe heater setting upward to the
minimum temperature required to prevent condensa-
tion.

At the end of the test conduct the mandatory posttest
leak-check.

Drain the ice bath and, with the probe disconnected,
purge the remaining part of the train by drawing
clean ambient air through the system for 15 minutes
at the average flow rate used for sampling.

SAMPLE RECOVERY

If a moisture content analysis is to be done weigh
the impingers to the nearest 0.5 g.

Transfer the contents of the first impinger to a
250 ml graduated cylinder. Rinse the probe, first
impinger, all connecting glassware before the fil-
ter, and the front half of the filter holder with
80 percent isopropanol. Add the rinse solution

1-85


Slide sequence

103-6

103-7

103-8

Key points

As an alternative to conditions 1 through 3 this
calculation may be used to determine the necessity
of using a more sensitive differential pressure
gauge.

If T is greater than 1.05, the velocity head data
are unacceptable and a more sensitive differential
pressure gauge must be used.

TEMPERATURE SENSOR

A temperature sensor capable of measuring stack temp-
erature to within 1.5 percent of the minimum absolute
stack temperature shall be used.

Thermocouples, bimetallic thermometers, mercury-in-
glass thermometers and liquid filled bulb thermometers
are typically used in stack test application.

The temperature gauge shall be attached to the pitot
tube such that the sensor tip does not touch any metal.

The gauge shall be in an interference-free arrange-
ment with respect to the pitot tube face openings.

Alternate positions may be used if the pitot tube-
temperature gauge system is calibrated.

If a difference of not more than 1% in the average
velocity measurement is introduced, the temperature
gauge need not be attached to the vitot tube (subject
to the approval of the administrator).

1-16


LECTURE 207
DETERMINING REPRESENTATIVE FACILITY OPERATION

OBJECTIVES

The objective of this lecture is to discuss how to determine, monitor,
record, and observe representative facility operations with the baseline con-
cept. Examples will be given for both process and air pollution control equip-
ment operational tricks used by the industry to produce an atypical reduction
in emissions for the short time period during the performance test.

At the conclusion of the lecture the student should be familiar with
procedures used to establish representative facility operation and to determine
the representativeness of the facility operation during the performance test.

11-25


Slide sequence

208-4

Key Points

Sampling and Analytical Procedures

1, Sampling port location and dimensional cross-
section

2. Sampling point description including labeling
system

3. Sample train description

4. Brief description of sampling procedures, with
discussion of deviations from standard methods

5. Brief description of analytical procedures, with
discussion of deviations from standard methods

Appendix
1. Complete results with example calculations
2. Raw field data (original, not computer printouts)
3. Laboratory report (with chain of custody)
. Raw production data (signed by plant official)
« Test log

4
5
6. Calibration procedures and results
7. Project participants and titles

8. Related correspondence
9. Standard procedures

REPORT REVIEW

The primary purpose of the emission test report review
is to evaluate the data and to determine if it can be
used in the decision making process.

Data requirements should be established before per-
forming the emission test review.

After establishing data requirements, a written report
review package should be used. This package along
with the observers summary report will be attached

to the emission test report for reference.

II-32


Slide sequence Key points

309-9 This is expected to be in the Federal Register in the
fall of 1982.

309-10 The options are ranked according to the purpose of
the test.
309-11 Conclusions and notes are as noted. When secondary

particulate formations occur in the stack, the sample
port location should be located within a diameter of
the stack exit or as close to that as feasible.

III-46


LECTURE 307
FLUCTUATING VELOCITY

OBJECTIVES

The objectives of this lecture are to categorize the type of fluctuating
velocity and to discuss the best means to handle the problems.

At the conclusion of this lecture the student should be familiar with
the apparatus and procedures to handle the problems created by fluctuating
velocities.

III-33


Slide sequence

108-14

10.

11.

Key Points

Pipette a 25-ml aliquot into the porcelain
evaporating dish. Return unused portion of
the sample to the polyethylene storage bottle.

Evaporate the 25-ml aliquot to dryness on a
steam bath and allow to cool.

Add 2 ml phenoldisulfonic acid solution to the
dried residue and tritrate thoroughly with a
polyethylene policeman. Make sure the solution
contacts all the residue.

Add 1 m1 deionized distilled water and four

drops of concentrated sulfuric acid. Heat the
solution on a steam bath for 3 min. with occasional
stirring.

Allow solution to cool, add 20 ml deionized, dis-
tilled water. Mix well by stirring and add con-
centrated ammonium hydroxide dropwise, with con-
stant stirring until the pH jis 10.

If sample contains solids, these must be removed
by filtration.

If solids are absent, transfer solution directly
to a 100-ml volumetric flask and dilute to the
mark with deionized distilled water.

Mix the contents of the flask thoroughly, and
measure the absorbance at the optimum wavelength
used for the standards, using the blank solution
as a zero reference.

Dilute the sample and the blank with equal volumes
of deionized, distilled water if the absorbance
ay A,. (the absorbance of the 400 ug stan-
dard).

1-79


Slide sequence

104-14

104-15

Key points

Calibrate using a wet test meter or volume meter which
has been recently calibrated against a primary stan-
dard.

Calibrate at 0.5, 0.75, and 1.0 2/min.

Construct a calibration curve of rate meter readings
versus flow rate for the meter using corrected wet
test meter stopwatch readings.

SAMPLING METHODS
Single-point grab sampling

1. Sampling point should be at the centroid of the
cross section or at a point >3.28 ft from the wall
of a large stack.

2. Place the probe securely in the stack and seal
the sampling port to prevent dilution of stack gas
by ambient air.

3. Purge the sample line several times by squeezing
the one-way squeeze bulb and then attach the analyzer.

4. Aspirate sample into analyzer.

Single-point integrated sampling

This procedure uses the same point location as the
single point grab sampling method. The integrated
sampling train is used to collect the samples. After
selecting the sample site and placing the probe, con-
duct the following:

1. leak-check the flexible bag

2. leak-check sampling train

3. connect the probe and purge the system

4. connect the evacuated flexible bag and
begin sampling; record time, flow rate,
and other appropriate data.

5. sample at a constant rate so that 30 to 90 2
of gas are collected simultaneously with the
pollutant emission rate test.

Multi-point integrated sampling

This procedure is similar to the single-point inte-
grated sampling procedures but it is used when the

stack cross section is traversed.
1-32



LECTURE 155
USE OF SIGNIFICANCE OF ERROR FOR SOURCE TEST OBSERVER'S DECISIONS

OBJECTIVES

The objectives of this lecture are to discuss the significance error
associated with each of the measured parameters in Methods 1 through 5. Also,
the most significant procedures and parameters will be pointed out in an ef-
fort to allow the observer to make the best of his efforts.

At the conclusion of this lecture the student should be able to deter-
mine the significance of any potential error related to EPA Methods 1 through
5. This knowledge will provide the basis to allow the observer to make on-
site and posttest decisions as to the acceptability of data and procedures
which are not explained by the reference methods' descriptions.

Note: Since the slide presentation is an exact representation of the reference
material, no instructors notes are provided.

1-113


Slide sequence

105-4

Key points

The wet bulb-dry bulb method is a popular alternative
to the approximation method described in Method 4.
This method is only applicable in low temperature
situations (moisture content less than 15% and dew
point less than 125°-F). In acid gas streams this
method cannot be used.

REFERENCE METHOD

The reference method consists of the procedure and
equipment described in Method 5.

Probe constructed of stainless steel or glass tubing
heated to prevent condensation, and equipped with a
filter either in-stack (plug of glass wool) or heated
out-of-stack (Method 5).

The condenser consists of four impingers connected
in series with ground glass, leak-free fittings or
any similar leak-free noncontaminating fittings.

The first, third, and fourth impingers shall be of
the Greenburg-Smith design, modified by replacing
the tip with s in. ID glass tube extending to about
4 in. from the bottom of the flask.

The second impinger shall be of the Greenburg-Smith
design with standard tip.

The first two impingers shall contain known volumes
of water; the third shall be empty; and the fourth
shall contain a known weight of 6- to 16-mesh indi-
cating type silica gel, or equivalent desiccant. If
the silica 9g! has been previously used, it can be
dried at 350°F for two hours.

A thermogeter capable of measuring temperature to
within 2-F shall be placed at the outlet of the
fourth impinger, for monitoring purposes.

Alternatively, any system may be used (subject to the
approval of the administrator) that cools the sample
gas stream and allows measurement of both the water
that has been condensed and the moisture leaving the
condenser, each to within 1 ml or 1 gram. Acceptable
means are to measure the condensed water, either
gravimetrically or volumetrically, and to measure the
moisture leaving the condenser by: 1) monitoring and
using Dalton's Law of partial pressures or 2) passing
the sample gas stream through a tared silica gel (or
equivalent desiccant) trap, with exit gas kept below
68 F, and determining the weight gain.

1-41


LECTURE 304
LOW VELOCITY FLOW

OBJECTIVES

The objective of this lecture is to discuss the methods used to measure
low velocity flows. The specific discussions include:

1.

3.

5.
6.

more sensitive velocity pressure devices for the pitot tube,
pressure drop measurement devices,

temperature differential measurement devices,

mechanical displacement devices,

source modification to increase velocity, and

computational methods.

At the conclusion of this lecture the student should be familiar with several

methods to measure low flow and be able to select the methodology best suited
for each specific site.

Il-17


Slide sequence Key points
5. Purge the train for 15 minutes. First remove the

probe and drain the ice bath. Then draw clean
ambient air through the system.

107-8 SAMPLE RECOVERY
1. Disconnect the impingers after purging.
2. Discard the contents of the midget bubbler.

3. Recover the contents of the midget impingers into
a leak-free polyethylene bottle.

4. Rinse the impingers and the connecting tubes with
deionized, distilled water, and add washings to
the sample bottle.

5. Mark liquid level, seal and identify the container.

107-9 SAMPLE ANALYSIS

1. Check liquid level to confirm whether any sample
was lost during shipment. If a noticeable amount
of leakage has occurred, void the sample or use
methods subject to the approval of the administra-
tor to correct the final results.

2. Transfer sample to a 100 ml volumetric flask and
dilute to exactly 100 ml with deionized distilled
water.

3. Pipette a 20 ml aliquot of this solution into a
250 ml Erlenmeyer flask.

4, Add 80 mi of 100 percent isopropanol and two to
four drops of thorin indicator.

5. Titrate to a pink endpoint using 0.0100 N barium
perchlorate.

I-68


Slide sequence

254-9

254-10

254-11

254-12,13

254-14

Key points

This figure can be used to estimate the thermal
efficiency of the unit. The temperature should repre-
sent the temperature after the last heat exchanger.

The stack temperature could be too low if a large
amount of air inleakage has occurred. The low tempera-
ture would give a greater than true thermal efficiency.

The flue gas flow rate can be calculated using any
of the heat input values from the last series of
slides with the exception of Equation 1, which uses
the flow rate to calculate the heat input. If the
observer desires to check his calculations, the value
from Equation 1 can be used and should produce the
same value. These calculated values should then be
compared with the measured value. In many cases, the
calculated value is more accurate than the measured
one. If the sample site is in a poor location, it is
common that the measured flue gas flow rate will be
about 20% higher than the calculated value. This is
because the pitot tube tends to give erroneous high
values in disturbed flow.

This equation gives a good estimate of the amount of
particulate to the inlet of the air pollution control
device in terms of 1b/10° Btu.

These equations give a good estimate of the amount of
particulate to the inlet of the air pollution control
device in terms of 1b/h.

This equation gives a good estimate of,the amount of
SO, generated in terms of 1b of S0,/10 Btu.

TI-50


Slide sequence

104-20

104-21

104-22

Key points
Calculation

My = 0.48(%C02) + 0.32(802) + 0.28(%N2 + %C0)

where
My = dry molecular weight

%CO2 = percent CO. by volume (dry basis)

%02 = percent 02 by volume {cry basis)

%N2 = percent No by volume (dry basis)

%CO = percent CO by volume (dry basis)

0.44 = molecular weight of C02 divided by 100

0.32 = molecular weight of 02 divided by 100

0.28 = molecular weight of No or CO divided by 100

EMISSION RATE CORRECTION OR EXCESS AIR DETERMINATION

Sample must be collected using the sampling method
specified in the applicable subpart of the standard.

A Fyrite type combustion gas analyzer -is unacceptable
for excess air or emission rate correction factor
determination unless approved by the administrator.

The sample must be analyzed within four hours after
collection for percent C02, 02, and CO.

Pretest and posttest leak-checks of the orsat analyzer
are mandatory.

To ensure complete absorption of C02, 02, and CO,
make repeated passes through each absorbing solution
until two consecutive readings are the same.

Several passes should be made between readings.

If constant readings cannot be obtained after three
consecutive readings, replace the absorbing solution.

Repeat the analysis until the following criteria
are met:

For C02
Repeat the analytical procedure until the results of

any three analyses differ by no more than
1-36


Slide sequence
108-0 (cartoon or
title slide)

108-1

108-2

Key Points

Speaker should give objectives of lecture and point
out reference materials.

A grab sample is collected in an evacuated flask
containing a dilute sulfuric acid-hydrogen peroxide
absorbing solution, and the nitrogen oxides (NO)
except nitrous oxide, are measured colorimetrically
using the Phenoldisulfonic acid (PDS) Procedure.

This method is applicable for the measurement of
NO, emissions from stationary sources.

The range of the method has been determined to be 2
to 400 milligrams NO, (as NO2) per dry standard
cubic meter, without having to dilute the sample.

APPARATUS

The probe is constucted of borosilicate glass tubing,
sufficiently heated to prevent water condensation
and equipped with an in-stack or out-stack filter to
remove particulate matter (a plug of glass wool will
serve this purpose).

Stainless steel or teflon tubing may also be used
for the probe. Heating is not necessary if the
probe remains dry during the purging period.

The collection flask consist of a two-liter borosili-
cate, round bottom flask, with short neck and 24/40
standard taper opening, protected against implosion
or breakage.

The flask valve is a T-bore stopcock connected toa
24/40 standard taper joint.

Temperature gauge consists of a dial type thermomgter
or other temperatyre gaugg capable of measuring 2°F
intervals from 25° to 125°F.

Vacuum line capable of withstanding a vacuum of 3

in. Hg absolute pressure with T connection and
T-bore stopcock.

1-72


LECTURE 310
INTERMITTENT PROCESS OPERATION

OBJECTIVES

The objective of this lecture is to discuss procedures to establish an
intermittent process operation testing protocol. The discussion will include
consideration of both legal and technical aspects.

At the conclusion of this lecture, the student should be familiar with
the steps necessary to establish a testing protocol for an intermittent process
operation.

III-47


LECTURE 156
STACK SAMPLING NOMOGRAPHS FOR FIELD ESTIMATIONS

OBJECTIVES

The objectives of this lecture are to explain how to use the nomographs
provided and to discuss how the nomographs are used for field estimations.

At the conclusion the student will be able to use the nomographs provided
as a data validation check on emission test data.

1-115


Slide sequence

304-14
304-15
304-16

304-17

304-18
304-19

Key Points

2. At zero line velocity the bridge is balanced so
that no flow occurs through the transducer and
purge gas exits equally through both openings
of the pitot tube.

3. As flow across the tip occurs, a differential
pressure is developed, unbalancing the bridge
and causing a small amount of purge gas to flow
through the transducer.

4. The transducer measures the flow which is related
to the main gas flow at the tip of the pitot tube.

5. Purge gas still exhausts through both openings,
but at slightly unequal rates.

Temperature Differential Measuring Devices

Hot wire anemometer - determines gas velocity by
Measuring temperature change in a resistance
wire, or by the amount the passing gases are heated.
These are accurate down to 100 ppm.

Thermister anemometers - identical to hot wire anemo-
Meters but thermisters are used instead of resist-
ance wire as heating and sensing elements. These
are sensitive to velocities of less than 20 ppm.

Hot-film anemometers - these are hot wire anemometers
that have a sheilding on the resistance wire. These
return to calibration when particulate is removed
from the element.

MEASUREMENT BY MECHANICAL DISPLACEMENT

Operate on the principle that mechanical displace-
ment due to impact pressure of a moving gas if pro-
portional to the gas velocity. Among these are ro-
tating vane and swinging vane anemometers and drag
body meters.

These are all subject to damage and/or loss of
accuracy in wet or dirty gas streams. Also, they
are not suitable for elevated temperature.

III-20


Slide sequence

206-4

206-5

Key Points

Critical orifice to audit sample train metering
system

Audit samples for Methods 6 and 7 which are
used to check the analytical phase of these
methods

B. Systems Audit

The systems audit is an on-site qualitative inspection
of the total measurement system. The auditor should
observe the field team's overall performance of the

test.

Specific operations to observe should include,

but not be limited to:

1.
2.
3.
4.

Setting up and leak testing the sampling train
Isokinetic sampling check of the sampling train
Final leak check of train

Sample recovery.

3. Use standardized data sheets to observe facility
operations

a.

Assist the observer in recording key process
and control equipment operating parameters.

Provides data that is easily summarized for
the observer's summary report.

4. Record visible emissions

a.

Visible emissions should be recorded during
each test for a period of time sufficient
to provide documentation of opacity for the
operating parameters during the test

Use standardized data sheets from EPA Method 9
or other forms approved by the agency

Use procedures outlined in EPA Method 9 or
other procedures approved by the agency

II-23


Slide sequence

106-0 (cartoon or
title)

106-1

106-2

106-3

Key points

Speaker should give objectives of lecture and point
out reference materials.

Particulate matter is withdrawn isokinetically from
the source and collected on a glass fiber filter °
maintained at a temperature in the range of 248 +25 F
or such other temperature as specified by an applic-
able standard or approved by the administrator. The
particulate mass, which includes any material that
condenses at or above the filtration temperature, is
determined gravimetrically after removal of uncombined
water.

This method is applicable for the determination of
particulate emissions from stationary sources.

Apparatus
Probe nozzle is constructed of 316 stainless steel

- or glass, of the button-hook or elbow design, with

a sharp tapered leading edge.

The angle of taper shall be <30 and the taper shall
be on the outside to preserve a constant internal
diameter.

Probe liner is constructed of borosilicate or quartz
glass tubing with a heating system capable of main-
taiping a gas temperature at the exit end of 248

+25 F or such other temperature as specified by an
applicable standard or approved by the administrator.

Note: the tester may opt to operate at a lower temp-
erature than specified.

Borosilicate or quartz linerg may be used for stack
temperatures up to about 900 F.

Quartz liners shall be used for temperatures between
900 and 1650°F.

Both type liners may be used at higher temperatures
than specified for short periods of time.

1-48


Slide sequence

151-8

151-9

Key points

EPA Method 5

Sample gas volume - Vin(std) (DSCF)

AH
y -y_ _( 'sta)\|Pbar * 13-6
m(std) myY\ T. P

m std

+ (AH/13.6)

Vin(std) = dry gas volume measured by the dry

gas meter corrected to standard condi-
tions, dscm (DSCF)

Y = dry gas meter calibration factor
= barometric pressure

Ky = 0, 3858,°K/mm Hg for metric units and
17.64 ~R/in. Hg for English units

V_ = dry gas volume measured by dry gas
meter temperature, dem (DCF)

AH = average pressure differential across
the orifice meter, mm H20 (in. H20)

13.6 = conversion factor from in. H20 to in.

mercury
T_ = absolute temperature at meter, °K (°R)

Leak rate correction

Case No. 1:

No component changes made during run

(1, - t,) @]

p

leakage rate observed during the posttest leak
check, m°/min (CFM)

maximum acceptable leakage rate, 0.0057 m°/min
(0.02 CFM) or 4 percent of average sampling rate
whichever is less

total sampling time, min
1-95


Slide sequence

102-4

102-5

102-6

102-7 - 102-8

Key points

Demonstrate how to determine the number of traverse
points using slide 102-4.

Discuss four curves appearing in figure on slide
102-4 (dotted curves used for nonparticulate traverses)

Circular stacks

Demonstrate how to determine the location of traverse
points on circular stacks using slide 102-5.

Discuss calculating distance along traverse for each
point and schematic showing 12 point layout in circular
stack.

Discuss criteria for sample point location in circular
stacks.

One particulate traverse must be in the plane contain-
ing the greatest expected concentration variation.

No traverse point shall be located within 2.5 cm
(1.0 in.) of the stack walls for stacks greater than
0.62 M (24 in.) in diameter. Relocate these points
to a distance of 2.5 cm (1.0 in.) or a distance equal
to nozzle ID, whichever is larger.

No traverse point shall be located within 1.3 cm

(0.5 in.) of the stack wall for stacks with diameters
equal to or less than 0.61 M (24 in.). Relocate these
points to a distance of 1.3 cm (0.5 in.) or a distance
equal to nozzle ID, whichever is larger.

1-9


CONTENTS (continued)

Page
PART II. (continued)
Section C--Lecture 203. Role, Responsibilities and Behavior
of the Observer . 11-9
Section D--Lecture 204. Establishing Testing Protocol’ II-13
Section E--Lecture 205. Plant Entry and Pretest Meeting II-17
Section F--Lecture 206. Observing the Test II-21
Section G--Lecture 207. Determining Representative Facility
Operations Tt-25
Section. H--Lecture 208. Source Test Report Requirements and
Review II-29
Section I--Lecture 250. NSPS Determination of Applicability 11-35
Section J--Lecture 251. Agency Approval of Equivalent and
Alternative Test Methods II-37
Section K--Lecture 252. Enforceability Criteria for Develop-
ment of Compliance Test Methods T1-41
Section L--Lecture 253. Safety in Stack Testing 11-43
Section M--Lecture 254. Data Validation Techniques 11-47
PART IIT. VOLUME III - SERIES 1-300-7/82: SPECIAL PROBLEMS AND
CONCEPTS IlI-1
Section A--Lecture 301. Unconfined Flow 111-3
Section B--Lecture 302. High Temperature Sources III-7
Section C--Lecture 303. High Moisture Content III-13
Section D--Lecture 304. Low Velocity Flow III-17
. Section E--Lecture 305. Cyclonic Flow TII-23
Section F--Lecture 306. Condensibles III-29
Section G--Lecture 307. Fluctuating Velocity III-33
Section H--Lecture 308. Soot Blowing III-37
Section I--Lecture 309. Sampling Port Location III-43
Section J--Lecture 310. Intermittent Process Operation I11-47

vi


VOLUME III. SERIES 1-300-7/82
SPECIAL PROBLEMS AND CONCEPTS

IlI-1


Slide sequence

105-8

105-9

105-10

Key points

PARTIAL PRESSURE METHOD

The reference method may yield questionable results
when applied to saturated gas stream or to streams
which contain water droplets. When these conditions
exist or are suspected, determine the moisture con-
tent using partial pressures.

1. Assume that the gas stream is saturated.

2. Agtach a temperature sensor capable of measuring
to +2°F to the reference method probe.

3. Measure the stack gas temperature at each traverse
point during the reference method traverse.

4. Calculate the average stack gas temperature.

5. Determine the moisture fraction using saturation
vapor pressure tables and the following equation:

Bp = S:V-P
ws Pp
where
Bus = proportion (by volume) of water vapor in
a gas-mixture for saturated conditions.
S.V.p = saturated vapor pressure of water at
average stack temperature.
p = absolute pressure of the stack.
Example
Average stack temperature 140°F
Barometric pressure 29.2 in. Hg
Static pressure +0.5 in. Hg
Saturated vapor pressure 5.88 in. Hg
- 5.88
Bus ~ 29.7
By, = 0.1980

This value should then be compared with the reference
method and the lower value used.

1-44


Slide sequence

303-0 (cartoon or
title)

303-1

303-2

303-3

303-4

303-5

303-6

Key points

The speaker should give the objectives of the lecture
and point out the reference material.

These are several common sources with high moisture
content. A high moisture content source is any
source that is approaching 50 percent by volume or
any source that the moisture content may vary by
more than 10 percent during the sample run.

As can be seen by this picture of a wet process cement
plant, high moisture content stack generally produce
an obvious water vapor plume.

In stacks with a low moisture content the percent
moisture may be estimated or determined by Method 4
or obtained from plant data. The effect of an error
in determining moisture at low moisture levels is
relatively small.

However, as the moisture content increases, the
effects of error increase. A point may be reached
where a 2 percent error (or 2% change in the moisture
content from the initial value) will result in a
non-isokinetic sampling rate. This is due to the
non-linearing of the correction factor for water
removal found in the nomograph equation.

The resulting sampling problems are as noted.

The solution to the sampling problems is to place
the orifice meter before the impingers.

The resulting solution gives the equation noted

which is independent of moisture content. The equa-
tion is still dependent on the orifice meter tempera-
ture and pressure.

III-14


Slide sequence

108-12

108-13

2.
3.

Key Points

Inject oxygen into flask after sampling.

Terminate sampling with a minimum 2 in. Hg
vacuum remaining in the flask; record this
final pressure, and then vent the flask to the
atmosphere until flask pressure is almost equal
to atmospheric pressure.

SAMPLE RECOVERY

Let the flask set for a minimum of 16 hours and
then. shake the contents for 2 minutes.

Connect the flask to a mercury filled U-tube mano-
meter. Open the valve from the flask to the
manometer and record the difference between the
mercury levels in the manometer. The absolute
internal pressure in the flask (Pf) is the baro-
metric pressure less the manometer reading.

Record the flask temperature and barometric pres-
sure.

Transfer the contents of the flask to a leak-free
polyethylene bottle. Rinse the flask twice with
5 ml portions of deionized, distilled water and
add the rinse water to the bottle.

Adjust the PH to between 9 and 12 by adding sodium
hydroxide (IN) dropwise.

Mark liquid level, seal and identify container.

ANALYSIS

1. Confirm whether or not any sample was lost
during shipment by checking the liquid level
of the sample container.

2. Transfer the contents of the sample container
to a 50-ml volumetric flask, rinse the con-
tainer with 5-ml portions of deionized distil-
led water. Add the rinse water to the flask
and dilute to the mark with deionized, distil-
led water; mix thoroughly.

1-78


LECTURE 150
HIGHLIGHTS OF EPA METHODS 1 THROUGH 5

OBJECTIVES

The objectives of this lecture are to update experienced attendees with
recent changes in procedures and to quickly summarize key points of EPA
Methods 1 through 5.

At the conclusion the experienced student will be updated to the recent
changes of EPA methods 1 through 5. This update is designed to provide a
refresher and provide a better understanding for the following lectures.

Note: This lecture will be prepared at a later date and will be included in
this manual at that time.

1-89


Stationary Source Compliance Series

August 1982

Series 1 - 002 - 8/82

EVALUATION OF STATIONARY
SOURCE PERFORMANCE TESTS

Lecture Objectives and
Instructor’s Notes

Ss
US ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR, NOISE AND RADIATION

STATIONARY SOURCE COMPLIANCE DIVISION
WASHINGTON DC 20460


LECTURE 201
PERFORMANCE TEST - AN INTEGRAL PART OF THE ENFORCEMENT CYCLE

OBJECTIVES

The objectives of this lecture are to explore the enforcement cycle and
to illustrate the relationship of the performance test as an integral part of
this cycle. An enforcement cycle has been created and will be presented using
a script to enhance the professionalism of the presentation.

The preceding slide sequence illustrates the enforcement cycle concept
and the relationship of the performance test to the overall enforcement pro-
gram.

At the conclusion of this lecture, the student should be familiar with
the enforcement cycle and the role the performance test play in completing the

_cycle.

Note: Due to the large number of slides, no copies of slides will be
presented here. Also, since the script explains the slides, no instructor's
notes have been prepared for this tecture.


Slide sequence

308-0 (cartoon or
title)

308-1

308-2

308-3

Key points

Speaker should give the objective of the lecture
and point out the reference material.

Generally intermittent soot blowing is handled by
the regulation in one of three ways:

1. The soot blowing is measured and the time
weighted average is mathematically combined
with the normal emission rate.

2. Testing is performed during soot blowing
and the emissions are averaged as is.

3. Soot blowing is defined as nontypical
operation and is not included in any
emissions determination.

EPA guideline intends that intermittent soot blowing
be handled by the first procedure. The last two pro-
cedures only require the testing to be performed at a
certain part of the operation and the sample runs
averaged.

The following discussion is designed to follow the
EPA guidelines and include the emissions from the
intermittent soot blowing on a daily averaging basis.
To establish a soot blowing test protocol the agency
must determine the items noted.

After the normal intermittent soot blowing cycle has
been determined then a soot blowing test protocol
should be developed as noted.

IIT-38


LECTURE 208
SOURCE TEST REPORT REQUIREMENTS AND REVIEW

OBJECTIVES

The objectives of this lecture are to familiarize the student. with an
acceptable source test report format and to review techniques for reviewing
source test reports. Specific items to be discussed include the following:

1. minimum acceptable criteria for report,
2. report format, and
3. report review techniques

At the conclusion of this lecture, the student should be familiar with
the necessary items that should be in a complete report and techniques for
reviewing reports.

II-29


Slide sequence Key points

302-14 Certain other problems inherent to high-temperature
sampling must be dealt with regardless of the type
probe selected. Two of the more common are:
ts) sagging of the stainless steel pitot tube.

0 heat radiation from the process affecting
temperature measurement.

It is especially important that problems such as

these be anticipated and advance preparations be
made to lessen their effects.

IlI-11


CONTENTS

Page
PART I. VOLUME I - SERIES 1-100-7/82: EMISSION TESTING CONCEPTS
AND SPECIAL TOPICS I-1
Section A--Lecture 101. Introduction to Source Sampling 1-3
Section B--Lecture 102. Method 1--Sample and Velocity Tra-
verses for Stationary Sources 1-7
Section C--Lecture 103. Method 2--Determination of Stack
Gas Velocity and Volumetric Flow Rate I-13
Section D--Lecture 104. Method 3--Gas Analysis for Carbon
Dioxide, Oxygen, Excess Air, and Dry Molecular Weight 1-27
Section E--Lecture 105. Method 4--Determination of Moisture
Content in Stack Gases 1-39
Section F--Lecture 106. Method 5--Determination of Particulate
Emissions from Stationary Sources 1-47
Section G--Lecture 107. Method 6--Determination of Sulfur
Dioxide Emissions from Stationary Sources 1-61
Section H--Lecture 108. Method 7--Determination of Nitrogen
Dioxide Emissions from Stationary Sources I-71
Section I--Lecture 109. Method 8--Determination of Sulfuric
Acid Mist and Sulfur Dioxide Emissions from Stationary
Sources 1-81
Section J--Lecture 150. Highlights of Methods 1-5 1-89
Section K--Lecture 151. Summary of Equations 1-91
Section L--Lecture 152. Misalignment of Pitot Tube 1-99
Section M--Lecture 153. Isokinetic Sampling and Biases from
Nonisokinetic Sampling T-103

Section N-~Lecture 154. Precision and Accuracy of Test Methods 1-109
Section O--Lecture 155. Significance or Error for Source Test

Observers 1-113
Section P--Lecture 156. Stack Sampling Nomographs 1-115
PART II. VOLUME II - SERIES 1-200-7/82: OBSERVATION AND EVALUATION
OF PERFORMANCE TESTS II-1
Section A--Lecture 201. Performance Test--An Integral Part of
the Enforcement Cycle TI-3
Section B--Lecture 202. Overview of Observation of Performance
Test 11-5

Vv


Slide sequence

310-0 (cartoon or
title)

310-1

310-2

310-3

310-4

310-5

Key points

Speaker should give objectives of the lecture. No
reference material was available.

This is a picture of a steel mill. Probably the most
common examples of intermittent process operation is

for the different metallurgical cycles. Now there are
numerous processes that work on batch type operations.

The steps for establishing the protocol are noted.
The most important step is number 1.

These are some general guidelines that should be
followed.

If intermittent operations are common or significant
to the agency, standardized procedures should be
written into law.

If the legal decision is that the entire cycle must
be sampled, the two procedures noted should be used.
The facility should not, however, be allowed to ab-
normally extend the period of the cycle to reduce
emission. The facility should be told that the cycle
should be normal or the run will be invalidated and
another run required.

ILI-48


LECTURE 202
OVERVIEW OF OBSERVATION OF PERFORMANCE TEST

OBJECTIVES

The objective of this lecture is to present an overview of the performance
test series. Important items will be discussed for each phase in the order
that they should be performed.

At the conclusion of the lecture the student should have an understanding

of the phases and key points for observing and evaluating the performance
test.


Slide sequence ~

104-8

104-9

104-10

Key points
For lower C02 values or 02 values >15%, an analyzer

equipped with a burette have 0.1-ml divisions with
spacings of >0.04 in. should be used.

Orsat analyzer reagents

Four reagents are required for an orsat analyzer.

The gas-confining solution - due to the solubil-
ity of C02 in water, a colored aqueous acidic
salt solution is used as the confining solution;
it contains sodium sulfate, sulfuric acid, and
methyl] orange;

The CO. absorbent is a solution of potassium
or sodium hydroxide;

The 02 absorbent is a solution of alkaline
pyrogallic acid or chromous chloride;

The CO absorbent is usually cuprous chloride or
a sulfate solution.

Fyrite analyzer

These devices are simpler and easier to use than an
orsat and they are more rugged.

However, they provide less precision and can thus be
used only for molecular weight determinations.

There is one gas absorber for C02 and an absorber
for 02.


Slide sequence Key points

151-13 Isokinetic variation - I (from raw data)
_ Ty [ks Vio t (VaTn) Phar + AH/13.6)]
60 6 Vy P. A,
where:

= 0.003454 mm Hg - m?/m1 - °K for metrig.
units and 0.002669 in. Hg - ft? /ml
for English units

151-14 From intermediate values

Ts Vin(std) Potd
"td Vy 8 AA P. 601-8.)

_
q

100

2K Ts. Vin(std)
“ “4 PVR, 6 (I-BY
4 PS Vy A, 6 (1 Bus

where:

K, = 4.320 for metric units and 0.09450 for
English units

151-15 Concentration of particulate in sample - c.
Grains per SCF
M
C. = 0,154 ~—
m(std)

lbs per hour

C. = 2.2x10 ~— x Q x 60

s Vin std) s(std)

where

M = total amount of particulate matter

collected, mg

1-97


Slide sequence

151-0 (cartoon or
title)

151-1

151-2

Key points

Speaker should give objectives of lecture and point
out reference materials.

EPA Method 2
Absolute stack p

Ps = Phar *
where:

Py = abs

Phar =

Potat = sta

13.6 = con

Stack velocity -

Ve -avg = 85

where:

Ve-avg
85.49 =

Cc. =

(YP) avg =

avg

TSayg =
Py =

M, =

1-92

ressure (P,)

stat
13.6

olute pressure of the stack

barometric pressure

tic pressure
version factor, in. H,0 to in. Hg

Ve (ft/sec)

Sav
-49(C,)( AP )ayg eT

average stack gas velocity
pitot tube constant
pitot tube coefficient

average of the square roots of the velo-
city head

average absolute temperature of the stack
absolute pressure of the stack
molecular weight of stack gas, wet basis


LECTURE 103

EPA METHOD 2 - DETERMINATION OF STACK GAS VELOCITY
AND VOLUMETRIC FLOW RATE

OBJECTIVES

The objectives of this lecture are to familiarize the student with the
equipment, calibration techniques and procedure for measuring stack gas
velocity. Specific items to be discussed include:

1. The type S (stausscheibe or reverse type) pitot tube and

differential pressure gauge;

2. procedures for conducting the velocity traverse;

3. temperature sensing devices; and

4. calibration techniques for the type S pitot tube, temperature

sensing devices and differential pressure gauges.
At the conclusion of this lecture the student should be familiar with the
procedures for measuring stack gas velocity, calibration techniques and the
dimensional specification check for the type S pitot tube. The student should
be able to observe experienced test teams conduct velocity traverses in the
field, perform the pitot tube dimensional specification check and review data
and calculations used to determine velocity and gas flow rate.


Slide sequence

106-20

Key points

Add ice as required to the condenser to maintain the
silica gel exit temperature at or below 68°F.

The manometer level and zero should also be checked
periodically during each test. Vibrations and temp-
erature fluctuations can cause the manometer zero to
shift.

7. At the end of the test conduct the mandatory post-
test leack check. This leak check is conducted
using the procedures outlined for the pretest
leak check. Also, leak check the pitot lines,
the lines must pass this leak check to validate
the velocity pressure data.

SAMPLE RECOVERY

Sample must be recovered from the probe, nozzle, all
glassware preceding the filter and from the front
half of the filter holder. The filter is also re-
covered.

Recovery should take place in an area sheltered from
wind and dust to prevent contamination of the sample.

The impinger box and probe should be capped off prior
to being transported to the clean up area.

FILTER

The filter should be recovered using a pair of
tweezers and/or clean disposable surgical gloves.

Carefully remove the filter from the filter holder
and place it in its designated petri dish. Any
filter fibers or particulate which adhere to the fil-
ter gasket should be removed and placed in the con-
tainer. Close, seal and label container.

Filter blanks should be collected and analyzed along
with the sample filters.

PROBE AND CONNECTING GLASSWARE

Clean the outside of the probe, pitot tube and nozzle
to prevent particulate from being brushed into the
sample bottle.

Remove the nozzle and rinse and brush the inside sur-
face of the probe and nozzle until the acetone rinse
is clear. A minimum of three rinses are required
for a.glass-lined probe and a minimum of six rinses
are required for a metal-lined probe.

1-57


Slide sequence

305-7

305-8

305-9

305-10

305-11

305-12

Key points

The blind man's approach simply means that the
cyclonic flow is ignored and the test is performed
in the normal manner. The results are noted. The
mass flow rate cannot be determined but would most
likely be slightly biased high. If during testing
by any of the following approaches a negative veloc-
ity point is sensed in the stack, record the veloc-
ity pressure and place the negative sign on it-for
flow rate calculation purposes, then move the sam-
ple train to the next point and continue testing.

In the alignment approach, the nozzle is pointed into
the direction of the flow and then the sample time
at each point is corrected by the cosine of the mis-
alignment angle. In the final calculations of veloc-
ity the velocity pressure at each point is corrected
by the cosine of the misalignment angle.

This equation shows how the sample time at each point
is corrected by the cosine of the misalignment angle.

The results are as noted. The point that the mis-
alignment angle is only compensated for in the one
plane should be stressed. To compensate for the
misalignment in the other plane, it takes a special
pitot tube with three inclined manometers and then
the probe would have to be tilted up and down to be
corrected in both planes and would not then be at
the same point in the stack.

In the compensation approach testing is performed
in the normal manner as if there were no cyclonic
flow, with the exception that the nozzle diameter is
increased to compensate for the misalignment angle.
The results are noted.

The nozzle diameter must be corrected for two errors:
1. the apparent reduction in the nozzle area, and
2, the higher than true velocity pressure readings.

III-25


Slide sequence

153-0

153-1

153-2

153-3

153-4

Key Points

Speaker should give the objectives of the lecture
and point out reference material.

Note: This is probably the most complex lecture to
present. The speaker must go through the example
very slow and ask at several points in the lecture

if everyone is keeping up. Give the attendees time

between statements to comprehend what has been said.
It may be necessary to repeat many teaching points
before the attendee understands.

Both points are required before the sample is obtained
in an isokinetic manner. If testing is performed in a
disturbed flow pattern the particulate will not approach
the nozzle correctly and will bias the pollutant concen-
tration level.

Two particle sizes are used only as'a teaching example.

Yn = “s - means that the velocity at the face of

the nozzle is the same as the velocity at that point
in the stack.

The equation is concentration equals the mass collected
divided by the volume sampled. It is also assumed

(as a teaching point) that 1ft? of gas sampled is the
correct isokinetic rate.

‘Yn = Zs - means to be equal; the velocity at the

face of the nozzle is double the velocity in the stack

at that point. Therefore, double the amount of sample
volume is collected.

1-104


Slide sequence

308-12

308-13

308-14

308-15

Key points

Each of the calculated -and recorded values can now
be put into the summation equation shown.

These are the actual numbers for each run. All flue
gas flow rates have been divided by 1,000,000 to make
it easier to put the data on one slide. The equation
also had to be split to put on one slide. This is
the mathematically correct method of calculating the
emission results to compensate for soot blowing on a
daily or continuous basis.

When the flue gas flow rate and 05 values are fairly
constant, the equations shown canbe used to approxi-
mate the results.

The conclusions are as noted.

ITI-41


Slide sequence Key points

305-0 (cartoon or The speaker should give objectives of lecture and
title) point out the reference materials.
305-1 The definition of cyclonic or nonparallel flow is
as noted.
305-2 This is a picture of an asphalt plant where a cyclonic

separator is commonly used after the wet scrubbers.

305-3 The agency must establish and agree upon a written
testing protocol prior to the actual test. This
is done because most of the sampling approaches are
either more costly than the standard methods or causes
a bias on the data results. The key points are noted.

305-4 The tester and agency can only be certain about two
facts if the standard Method 5 test procedures are
used in cyclonic or nonparallel flow. These facts
are noted.

305-5 If the velocity was plotted vs. its position in the
stack, the resulting profile would look like the
diagram for cyclonic flow. Some cyclonic flows are
so severe that the flow in the middle of the stack
is actually negative, meaning that the flow is
traveling down the stack in the middle.

305-6 The four approaches are noted.

III-24


LECTURE 109

EPA METHOD 8 - DETERMINATION OF SULFURIC ACID MIST AND
SULFUR DIOXIDE EMISSIONS FROM STATIONARY SOURCES

OBJECTIVE

The objectives of this lecture are to familiarize the student with the
equipment and procedures of Method 8 and to highlight important parameters
to ensure good data quality.

At the conclusion of this lecture the student should be familiar with
the Method 8 sampling system and the sample recovery and analytical proce-
dures. The student should be able to observe Method 8 testing and review
reports of tests conducted using Method 8.

1-81


Slide sequence

104-23

Key points

a) 0.3% by volume when C02 is greater than 4.0%
b) 0.2% by volume when C02 is less than or equal
to 4.

For 02

Repeat the analytical procedure until the results of
any three analyses differ by no more than
a) 0.2% by volume when 0, is greater than 15.0%
b) 0.3% by volume when 0, is less than 15.0%
For CO

Repeat the analytical procedure until the results of
any three analyses differ by no more than 0.3%

Average the three acceptable values for each component
and report the results to the nearest 0.1%.

Calculation
405 - 0.52%C0
BEA = (OER, = (80, = 0.5800)! 100
where
ZEA = percent excess air
%02 = percent O02 by volume (dry basis)
%CO = percent CO by volume (dry basis)
%N2 = percent No by volume (dry basis)
0.264 = ratio of 02 to Nz in air, v/v

This equation assumes that ambient air is used as
the source of 02 and that the fuel does not contain
appreciable amounts of No. If these cases exist an
alternate method subject to the administrator's
approval is required.

1-37


LECTURE 308
INTERMEDIATE SOOT BLOWING

OBJECTIVES

The objective of this lecture is to discuss testing procedures and
calculations used to compensate for intermediate soot blowing emissions in
the average emission rate. The procedures used will be in support of the
agency regulation's intent of how to compensate for intermediate soot blowing.

At the conclusion of this lecture the student will be familiar with the

testing methodology and corresponding calculations used to compensate for
intermediate soot blowing.

IlI-37


Slide sequence Key points

106-11 Initial calibration

1. Before its initial use, leak-check the metering
system. Leaks must be eliminated before proceeding.

2. Assemble the apparatus with the outlet of the
wet test meter connected to a needle valve that is
connected to the inlet of the meter box.

3. Run pump for 15 min at a AH of 0.5 in. H,0 to
allow the pump to warm up and the interior surfaces
of the wet test meter to be wetted.

4. Adjust the needle valve so that a vacuum of 2 to 4
in. Hg is on the meter box during calibration.

5.- Run calibration at the recommended orifice set-
tings between 0.5 and 4 in. H20.

6. The dry gas meter is acceptable if no value falls
outside the interval y +0.02 y.

7. The orifice meter is acceptable if no AH@ varies
by more than 0.15 in. H20.

106-12 Posttest check

1. Three calibration runs at a single, intermediate
orifice setting (based on field test data), with the
vacuum set at the maximum value reached during the
test.

2. If the posttest calibration factor y deviates
by less than 5% from the initial calibration factor
y, the dry gas meter volumes obtained during the
test are acceptable.

3. If y deviates by greater than 5%, perform a full
calibration of the metering system and use which-
ever meter coefficient that yields the lowest gas
volume.

106-13 TEMPERATURE GAUGES

Impinger_ thermometer

The impinger thermometer should initially be compared
with a mercury-in-glass thermometer which meets

ASTM E-1 No. 63C or 63F specifications. Using the
following procedure:

I-51


Slide sequence

204-0

204-1

204-2

204-3

Key Points

Speaker should give objectives of lecture and point
out reference materials.

A written test protocol is important for the purpose
of ensuring and expediting necessary information
exchange, and providing the agency with the maximum
requirable information in a standardized format.

The protocol also provides written documentation of
each phase of the performance test that can be reviewed
and changes or alterations made during the preparation
and planning phase of the test.

The Performance Test Guidelines package provides the
foundation upon which a written protocol can be based.

The initial section of the guidelines package contains
a discussion which includes the regulations which gives
the agency authority to require performance tests.

The source test procedures section discusses the required
agency notification period and reviews the administrative
procedures for reviewing the test protocol, requesting
additional data and the agency's policy on data handling
and confidentiality.

The protocol section requests pertinent information
from the source and testing agency that is necessary
to plan and review the test program.

The specific information requested (data form) includes:

1. Source Information - name, address, key person to
contact and telephone number

2. Testing Firm Information - again the name, address,
and key person to contact and telephone number

3. Gas Stream Information - identification of pollutants
to be sampled, number of sampling points for each pollu-
tant, total time per test, number of tests (a minimum of
3 are required for each pollutant) and the test method
to be used for each pollutant.

All this information is contained in a prepared form.
II-14


Slide sequence

Key points

c. if an asbestos string is used for the probe
gasket, leak-check the train by plugging the
’ inlet of the filter holder and pulling 15 in.
Hg vacuum. Then attach the probe and leak-
check at 1 in. Hg vacuum. Alternatively,
the probe may be leak-checked at 15 in. Hg
vacuum with the rest of the tain

Leakage rates greater than 0.02 ft?/min or 4% of the
average sampling rate are unacceptable.

During sampling if a component change is necessary

a leak check should be conducted before the change.
The leak check is conducted according to procedures
described for the pretest leak check, except it should
be conducted at a vacuum equal to or greater than
maximum value recorded up to that point in the test.
Leakage rates less than 0.02 ft?/min or 4% of the
average sampling rate are acceptable and no correc-
tion need be applied to the total volume of gas
metered.

If a higher leakage rate is obtained the sample vol-
ume should be corrected or the sample run voided.

Note: be sure to record the dry gas meter reading
before and after each leak check performed during
and after each test so that the sample volume can
be corrected.

6. Perform the mechanics of running the train and
collecting the sample

It should be noted that if the nomograph is standard
(designed as shown in APTD-0576), it can be used only
with a type S pitot tube which has a cp of 0.85 +0.02
and when the stack gas dry molecular weight is 2 +4.
If cp and Ms are outside of these ranges do not use
nomograph without compensating for the differences.

Recalculate isokinetic rate or reset nomograph if
the absolute stack temperature changes by more than
10%.

The sampling rate must be adjusted at any sampling
point if a 20% variation in velocity pressure occurs.

Periodically during the test, observer the connecting
glassware from the probe, through the filter, to the
first impinger for water condensation. If any is
evident adjust the probe and/or filter heater until
the condensation is eliminated.

1-56


Slide sequence

251-0

251-1

251-2

251-3

Key Points

Speaker should give objectives of lecture and point
out reference material.

The responsibilities of executing the Federal Regula-
tions have been delegated to most states and their
representatives (some local agencies). However, the
authority to make decisions that could have regional
or national impact should always be made by the proper
agency.

40 CFR 60.8(a) give four options with regard to using
the reference method for proof of compliance with the
applicable regulation. Option 1 is to approve minor
changes to the reference method. If the minor
changes are site specific and would apply only to

the source in question, the approval can usually be
made by the agency responsible for the evaluation of
the emission test. If the minor modification will
affect the testing at other similar sites, the
decision should be made at the EPA regional office
level in consultation with the EPA headquarters
group. Option 2--equivalent method--can only be
granted by the EPA headquarters group. Option 3--
alternative method--is usually made at the EPA
regional office level with consultation to the EPA
headquarters group. Option 4--waiver of the per-
formance tests--is not usually granted. Any such
request should be relayed to the EPA regional office.

There are two types of minor modifications. One type
(as described by the reference method) must have prior
approval from the administrator. The second type is
allowed in the reference method at the testers’
disgression. Most of the options which may be used

by the tester will produce measured values of equal

or greater value. Therefore, many of these options

are not advisable for a performance test used to certify
continuous emission monitors. When the tester decides

11-38


Slide sequence

Key points

Negative leak check

This procedure checks the vacuum system to and in-
cluding the pump.

1. Plug the inlet to the control box. If a leak-
free quick disconnect is on the meter box the inlet
will not have to be plugged.

2. Turn on pump; pull a vacuum to within 3 in. Hg
of absolute zero and observer the dry gas meter.

3. Leakage must not exceed 0.005 ft?/min.
Positive leak check

This procedure checks the dry gas meter, orifice
meter, orifice-inclined manometer and all the plumb-
ing.

1. Disconnect and plug the downstream orifice pres-
sure tap.

2. Vent the negative side of the manometer to the
atmosphere.

3. Place a rubber stopper, with a rubber or plastic
tube attached, in the exit of the orifice.

4. Open the positive side of the orifice manometer.

5. Plug the inlet to the pump if quick disconnect
is not installed.

6. Open the main valve and the bypass valve.

7. Blow into the tube connected to the end of the
orifice until a pressure of 5 to 7 in. H20 is built
up in the system.

8. Plug the tube and observe pressure reading for
1 min. No noticeable movement in the manometer fluid
levels should occur.

Leakage for systems with diaphragm pumps

The leak check procedure described above will not
detect leaks within the pump. For these cases, the
following leak check procedure is suggested:

Make a 10-min calibration run at 0.02 ft/min. At
the end of the run, take the difference between the
measured wet test meter and the dry gas meter vol-
umes; divide the difference by 10 to get the leak
rate. The leak rate should not exceed 0.02 ft?/min.

1-52


Slide sequence

109-4

109-5

109-6

Key Points

CALIBRATION

Calibration of equipment is exactly the same as for
Method 5.

ON SITE SAMPLING

Procedures for on site operations follow those out-
lined in Method 5.

1. Preliminary measurement and set up.

2. Collect stack parameters for setting isokinetic
sampling rate.

3. Set up the nomograph and select the proper nozzle
size based on the range of velocity heads. The
nozzle size cannot be changed during a sample run.

The sampling rate is not to exceed 1.0 cfm during the
test. Calculate the maximum AH which will not exceed
1.0 cfm using the following equation:

1.09 PM AH @
Maximum AH <|§ ———->————
m

where:

maximum AH = pressure differential across the orifice,
in. H20, that will produce a flow of
1.0 ft3/min.

Pin = pressure of the dry gas meter, in. Hg

M = molecular weight of stack-gas

AH@ = pressure differential across the orifice
that will produce a flow of 0.75 scfm,
(in. H20)

Th = temperature of the meter, OR,

1-84


Slide sequence Key points

151-10 Case No. 2: One or more component changes made
during the sampling run

n
[Yq 7 (Ly - by) % “2 (Ly - L) 82 - (Ly - by) 6]

Zz

151-11 Total flow of stack gas. - Q (CFM)

Qa = As x Vy x 60

where:
Qa = stack gas flow rate at stack conditions
Ay = area of stack
Ve = average stack gas velocity
60 = convert seconds to minutes
151-12 Total flow of stack gas at standard conditions -

Qs(stay (SCFM)

Pp. OT. :
s__std
Q =Q. po = (1 - 8B)
s(std) Ss Pia 's WS

where:

(sta) = stack gas flow rate at std conditions

1- Bus

mole fraction of dry gas

1-96


Slide sequence Key points

105-11 WET BULB-DRY BULB METHOD

As mentioned earlier, this method is ngrmally used
for moisture contents of less than 125°F. The method
cannot be used in acid gas streams.

1. Measure the wet bulb temperature by wetting the
wick on the thermometer, inserting the thermometer
into the stack and recording the temperature when it
stabilizes.

2. Measure the dry bulb temperature using the
thermometer without the wick.

3. An estimate of moisture can be obtained from a
psychrometric chart.

Note: psychrometric charts are based on standard
pressure and is not accurate if the pressure differs
greatly from 29.92 in. Hg.

105-12 You can also calculate the moisture content using
: the wet bulb-dry bulb temperatures, a saturated vapor
pressure table and the equation

= VP
Bus =p
where
= Tw - 32
V.p = S.v.p - [(0.000367)(p) (Ty - TQ + “pT!

s.v.p = saturated water vapor pressure at the wet
bulb temperature
absolute pressure in the stack

bo]
on

Ty dry bulb temperature
wet bulb temperature

4
"

water vapor pressure

<
3
"

1-45


Slide sequence

207-0

207-1
207-2
207-3

207-4
207-5

207-6

207-7

207-8

207-9

207-10

207-11

Key Points

Speaker should give objective of lecture and point
out reference material.

The purposes are as noted.
The definition of the baseline concept is as noted.

The four steps noted should help the agency establish
representative facility operations. The agency should
try to take the maximum advantage of the facility's
knowledge of its own process and control equipment by
having the facility write the preliminary test proto-
col. If the facility is advised that it must maintain
the source at or near the required conditions as estab-
lished during the performance test, its testing proto-
col will likely be more reliable and realistic.

The final testing protocol should contain all items
noted.

During the pretest survey the observer may want to
validate or check certain operating parameters. The
inspection equipment that is usually needed to per-
form a complete inspection of the facility is as

noted. :

The four major categories of concern for process
operation are as noted.

The specific items for each process condition are
noted.

As noted.

The specific items for the different types of control
equipment are noted.

As noted.
11-26


LECTURE 203
ROLE, RESPONSIBILITIES AND BEHAVIOR OF THE OBSERVER

OBJECTIVES

The objective of this lecture is to explore the role of the observer in
the performance test program. Specific responsibilities of the observer will
be discussed to illustrate the importance of the observer to a successful
test program.

At the conclusion of this lecture, the student should have a broad pre-
spective of the role the observer plays in a performance test program.


Slide sequence

205-4

205-5

Key Points

Sampling Methodology to be Used - Any changes or addi-
tions to the testing methodology should be noted here
and resolved.

During this time confidentiality of data can be dis-
cussed. The agency can outline its procedures for
handling any data that is labeled confidential. The
industry can also specify any special handling of pro-
cess and other data that is supplied for the test report.

The Pretest Agreement on facility operations is the
next item to be discussed. This will cover process
and control equipment operation during the test.

Process

1. Maximum process rate/capacity (as established by
the manufacturer and/or operating history)

2. Method of process weight or rate determination:
a. calibration of scales

b. variability of computer program to tabulate
short time periods.

3. Process parameters to be monitored and recorded
and their acceptable limits to document process opera-
tion

4. Raw material feed and/or fuel acceptable analyzed
values

5. Normal operating cycle or procedures.

6. The portion of the operating cycle that will be
represented by each run.

Control Equipment

1. Control equipment and effluent parameters to be
monitored and recorded and their acceptable limits to
document control equipment operation.

2. yormal operating cycle (cleaning, dust removal,
etc. ).

3. Normal maintenance schedule.
4, Manner in which control equipment will be operated.

Signature by all parties to the agreement.

II-19


Slide sequence Key points

206-6 5. Exit interview

a. The observer should conduct an exit
interview with the plant contact person
and test team leader

b. Request any additional information neces-
sary to document test program

c. Verbally critique test program

I-24


LECTURE 301
UNCONFINED FLOW

OBJECTIVES

The objectives of this lecture are. to discuss several examples of uncon-
fined flow and methods best suited to measure flow rate and emissions. Some
specific sources are:

1. pressurized baghouse,
2. roof monitors, and
3. open-faced grain dryers.

Some methods to be discussed are:

1. confining the source,
2. designing a movable duct, and
3. sampling open areas in the unconfined flow.

At the conclusion of this lecture the student should be familiar with EPA
Method 5D and other methodology and be able to choose the most practical
means of measuring unconfined flow.

III-3


LECTURE 302
HIGH TEMPERATURE SOURCES

OBJECTIVES

The objectives of this lecture are to provide the student with the best
approach for sampling emissions from high temperature sources. The discussion
will survey various materials suitable for constructing high temperature probes
and review the advantages and disadvantages of each material.

At the conclusion of this lecture the student should be able to select
the best sample probe material or method for use at each high temperature
source.

III-7


INTENDED PURPOSE

This is not an official policy and standards document. The opinions,
findings, and conclusions are those of the authors and not necessarily those
of the Environmental Protection Agency. Every attempt has been made to repre-
sent the present state of the art as well as subject areas still under eval-
uation. Any mention of products or organizations does not constitute endorse-
ment by the United States Environmental Protection Agency.

This document is issued by the Stationary Source Compliance Division,
Office of Air Quality Planning and Standards, USEPA. It is for use in work-
shops presented by Agency staff and others receiving contractual or grant
support from the USEPA. It is part of a series of instructional manuals
addressing compliance testing procedures.

Governmental air pollution control agencies establishing training pro-
grams may receive single copies of this document, free of charge, from the
Stationary Source Compliance Division Workshop Coordinator, USEPA, MD-7,
Research Triangle Park, NC 27711. Since the document is specially designed
to be used in conjunction with other training materials and will be updated
and revised as needed periodically, it is not issued as an EPA publication
nor copies maintained for public distribution.

Wi


LECTURE 254
DATA VALIDATION TECHNIQUES

OBJECTIVES

The objectives of this lecture are to discuss the general use of data
validation techniques and to provide and discuss specific data validation
techniques for coal-fired boilers.

At the conclusion of the lecture the student should be familiar with
the need and some general techniques for data validation and be able to
validate the emission data from a coal-fired boiler including the use of the
F-factor.

II-47


Slide sequence Key points

Example
P_ = 30 jn. Hg
1 = joo
V7 = 100 mi,H,0
Vv = 100 ft
m
156-3 This nomograph (chart 8) is used for estimating

dry molecular weight of flue gas.

To use this nomograph:

° Simply align percent excess air with the
type fuel being burned and read flue gas
composition and molecular weight from
scales.

Example

50% excess air
Burning No. 6 oi]

1-117


LECTURE 108

EPA METHOD 7 - DETERMINATION OF NITROGEN OXIDE EMISSIONS
FROM STATIONARY SOURCES

OBJECTIVES

The objectives of this lecture are to familiarize the student with the
sampling train, sample collection technique and analytical procedure for de-
termining nitrogen oxide (NO,) emissions.

At the conclusion of this-lecture the student should be familiar enough
with the methodology to observe on site testing for NO, emissions and to review
test reports containing data and calculations for accuracy.

1-71


Slide sequence

106-19

Key points

ON SITE SAMPLING

Preliminary measurement and setup
a. select sampling site according to Method 1
criteria

Collect stack parameters for setting the isokinetic
sampling rate
a. determine stack pressure, temperature and
the range of velocity heads encountered
b. determine the moisture content using the
approximation method or its alternatives
c. determine the dry molecular weight using ©
the applicable procedure from Method 3

Set up the nomograph and select the proper nozzle
size based on the range of velocity heads. The

nozzle size cannot be changed during a sampling
run

Prepare and assemble the sampling train

a. prepare the condenser as per Method 4
using a very light coat of silicone grease
on the outside of all ground-glass joints

b. use a tweezer or clean disposable surgical
gloves to install a filter in the filter.
holder. Be sure the filter is properly
centered and that the gasket is properly
placed to prevent the sample gas stream
from circumventing the filter. Check filter
for tears after the assembly is complete.

Leak-check the sampling train

Leak checks are necessary to assure that the
sample has not been biased low by dilution air.

The pretest leak check is recommended, but not
required. If the tester opts to conduct the
pretest leak check, the following procedure should
be used:

a. turn on filter heating system and allow temp-
erature to stabilize at the operating temp-
erature

b. if a viton O-ring or other leak-free gasket
is used in connecting the nozzle to the
probe, leak-check the train by plugging the
nozzle and pulling 15 in. Hg vacuum

Note: a lower vacuum may be used if it is not ex-
ceeded during the test.


Slide sequence

305-20

305-21

305-22

305-23

305-24

Key points

This is a diagram of two examples of flow straighteners.
One is for circular ducts and the other is for rec-
tangular ducts.

The second method of source modification is to add

a device that will remove the flow in a parallel
manner. The results are noted. An involute system
will not cause a back pressure and will not increase
the source's emissions.

This is a diagram of how an involute system is
installed on a cyclone.

This slide ranks the approaches for facility tested
sources.

This slide ranks the approaches for agency tested
sources.

II-27


Slide sequence

154-0

154-1

154-2

154-3

154-4

154-5
154-6

Key Points

Speaker should give the objectives of the lecture and
point out the reference material.

The precision and accuracy of the test methods are
obtained by three methods as noted. The methods are
described in the following slides.

The average result for all the laboratory results
is assumed to be the true value since there is not
a better method for determining true value.

Traceable pollutant concentrations are fed to a
common manifold for testing. The known value of
the pollutant is used as the true value. The pollu-
tant concentration is varied to determine the effect
of different concentrations on measurement error.

A "methods evaluation" sample train is used; this train
pulls a minimum of four complete samples from approxi-
mately the same point in the stack. As a result, any
sampling parameter can be varied on one pair of the
sample trains to determine its effect on test results.
The average value of the standard reference method train
is used as the true value.

Diagrams of one of the methods evaluations used for
sampling in Method 5, 5B and 17.

I-110


LECTURE 104

EPA METHOD 3 - GAS ANALYSIS FOR CARBON DIOXIDE, OXYGEN,
EXCESS AIR, AND DRY MOLECULAR WEIGHT

OBJECTIVES

The objectives of this lecture are to familiarize the students with the
three sampling methods and the two analytical methods for determining the
molecular weight of dry stack gas and the excess air correction factor.
Specific items to be discussed include the:

grab sampling train,

integrated sampling train,

orsat analyzer,

fyrite analyzer, and

+ emission rate correction or excess air determination.

OP w ne

At the conclusion of this lecture the student should be familiar with the gas
sampling methods, use of the orsat and fyrite analyzers, and the emission
rate correction or excess air determination. The student should be able to
observe and review molecular weight and excess air determinations.

1-27


Slide sequence

103-26

103-27

103-28

Key points

If, at each point the Ap read by the differential pres-
sure gaugé and gauge-oil manometer agree within 5%,
the differential pressure gauge is acceptable.

Temperature sensor

Temperature sensors should be calibrated initially
and after each field use.

After each field test calibrate sensor at a tempera-
ture within 10% of the average absolute stack temp-
erature.

The calibration reference for temperatures up to
761 F consist of an ASTM mercury-in-glass refer-
ence thermometer or equivalent.

Alternatively a reference thermocouple and potentio-
meter (calibrated by NBS) or thermometric fixed
points, such as ice bath and boiling water (corrected
for barometric pressure) may be used.

For temperatures above 761°F, use an NBS-calibrated
reference thermocouple potentiometer system or an
alternate reference subject to the approcal of the
administrator.

Thermocouple calibration - perform a three point
calibration. The three points can consist of:

1. Ice point - form a slurry from crushed ice and
water (deionized, distilled)

2. Boiling water

3. A ljquid that has a boiling point in the
300-800 F range.

1-23


Slide sequence

156-0

156-1

156-2

LECTURE 156

STACK SAMPLING NOMOGRAPHS

Key points

Nomographs have been found to be very useful in
estimating or checking data used in stack
sampling.

Nomographs are to be used as guides and are not
to be assumed accurate to the third significant
figure.

The first nomograph (chart 2) is simply a psy-
chrometric chart which is used with the wet
bulb/dry bulb method. It does not have any
pressure correction and is only good at 29.92
inches of mercury.

To use this nomograph:

to) Draw a line from the dry bulb temperature
through the wet bulb temperature and read
results on the % water scale

Example

wet bulb - 1609F
dry bulb - 230°F
Answer: 30% 0

This nomograph (chart 6) can be used to check
your moisture calculations.

To use this nomograph:

fe) Draw line from Pa to Th to obtain point A
on ref. 1.

° Draw line from point A to Vis read B on
ref. 2.

° Draw line from point B to V. and read

answer, 4.9% H50 in stack gis.

1-116


Slide sequence
303-7

303-8

303-9

303-10

303-11

303-12

303-13

Key points

Three sample trains have been designed to eliminate
moisture content from the sampling equation. These
trains are noted. .

This is a diagram of the JACA train. Note the orifice
erer is tocated in the heated sample box behind the
Iter.

The advantages and disadvantages are noted. The
orifice meter pressure changes with the particulate
buildup on the filter.

This is a sketch of the EPA Train. Note that the
orifice meter is located in the stack. This train
is not designed for sources with significant
particulate content.

This train works well for light particulate or
smal] aerosols and gases. It was designed to test
ammonium nitrate plants. The impinger contents are
analyzed for nitrates.

Since the temperature and pressure of the orifice
meter and stack are the same, the isokinetic sampling
equation is further simplified as noted.

This is a sketch of the Entropy sample train. By
placing the orifice meter in front of the filter

the orifice meter pressure will remain constant.
However, the particulate is collected in the orifice
and must be recovered from it. One of the biggest
problems is that water tends to get in the orifice
meter lines. This system is designed to periodically
blow the water out. The added volume of air blow
back is not taken into account; however, it is
extremely small compared to the entire sample volume.

IIT-15


Slide sequence

304-0 (cartoon or
title)

304-1

304-2

304-3

304-6

304-7

Key Points

Speakers should give objectives of lecture and point
out reference materials.

The velocity measurement is used to determine proper
nozzle size and to obtain the K-factor for setting
isokinetic sampling rates. The final velocity deter-
mination for each run is used to calculate isokinetics
for the test and, in areas where regulations are based
on mass emissions, the volumetric flow rate is used

in the emission calculation.

The problems encountered at flow rates consists of
the following:

Typical gauge oi] manometers and magnetic gauges, used
in testing, are insensitive at velocities below 1000
feet per minute. These instruments cannot meet the

10 percent accuracy requirement for reading AP below
400 ft/min the pitot tube accuracy is questionable.

More sensitive pressure differential devices are
available to allow accurate use of the pitot tube
system down to 400 ft/min.

This is a 0 to 0.25 in. inclined manometer manufactured
by Dwyer Instruments, Inc.

The manometer has scale divisions of 0.005 in. H,0.

This is a micromanometer manufactured by Thermo-Systems,
Inc. The full-scale range of the micromanometer is
0 to 1.2 in. water volume.

The scale divisions are 0.01 in. H,0, but the instru-
ment has a micrometer dial, making’ it possible to read
velocity head to the nearest 0.001 in. Hy0.

This is a micro-tector hook gauge manufactured by Dwyer
Instruments, Inc.

A differential pressure signal from the sensing element
causes a slight displacement of gauge fluid.

III-18


LECTURE 305
CYCLONIC OR NONPARALLEL FLOW

OBJECTIVES

The objective of this lecture is to familiarize the student with the
errors associated with cyclonic or nonparallel flow. Four approaches to test-
ing the flow will be discussed along with the errors associated with each of
the four methods as shown:

1. blind man's approach,

2. alignment approach,

3. compensation approach, and
4. source modification.

At the conclusion of this lecture the student should be able to select the
proper approach, taking into account the source and applicable regulation. The
student should also be able to establish written protocols to be used by the
facility and test team.

ILI-23


Slide sequence

104-18

104-19

Key points

ANALYSIS
Leak-check procedure for orsat analyzers

Moving an orsat analyzer frequently causes it to
leak. Therefore the analyzer should be thoroughly
leak-checked on site before analysis.

1. Bring the liquid level in each pipette up to
the reference mark on the capillary tubing and close
the pipette stopcock.

2. Raise the leveling bulb sufficiently to bring the
confining liquid meniscus on to the graduated portion
of the burette, then close the manifold stopcock.

3. Record the meniscus position.

4. Observe the meniscus in the burette and the liquid
level in the pipette for four minutes.

Two conditions must be met for the orsat to pass the
leak-check.

1. The liquid level in each pipette must not fall
below the bottom of the capillary tubing.

2. The meniscus in the burette must not change by
more than 0.2 ml. “

Dry molecular weight determination

Sample may be collected using any one of the three
sampling methods.

Sample must be analyzed within eight hours after
collection.

Analysis may be conducted using an orsat analyzer
or a fyrite combustion gas analyzer.

Repeat the analysis and calculation procedures until
the individual dry molecular weights for any three
analyses differ from their mean by no more than 0.3
1b/1b-mole.

Average these three molecular weights and report
the results to the nearest 0.1 1b/1b-mole.



Slide sequence Key points

306-0 (cartoon or The speaker should give objectives of the lecture and
title) point out reference materials.

306-1 As noted.

306-2 One example of a positive bias is the condensation

of sulfuric acid on the filter of the Method 5 sample
train. The original intent of subpart D was not
to include condensibles.

One example of a negative bias is if Method 5 is used
to test on an asphalt roofing plant. Much of the
organic material will pass through the heated filter.

306-3 This slide gives the magnitude of material that is
collected in the impingers compared to the amount
collected on the filter and in the impingers (total

catch).

306-4 The first generation sample train designed in Los
Angeles only measured what could be filtered at stack
temperature.

_ 306-5 It was obvious that the first generation train allowed

a lot of matter to penetrate the filter at stack tempera-
ture, so the second generation sample train was designed
to collect the material in the impingers and was backed
up with a filter. This train proved to be good for

many sources but allows the particulate to come into
contact with the large intersurface of the impingers.

The same recovery of material like fly ash and soot

was extremely difficult to remove.

III-30


Slide sequence

203-3

203-4

203-5

Key Points

BEHAVIOR OF THE OBSERVER
The overall objective of the performance test program
is to achieve accurate and reliable data.

The observer should do all within his power to see
that testing is completed successfully.

He must work cooperatively with the source and the
consultant.

The observer must be specific and forthright in his
requests.

The observer must be respectful of the positions of
the other parties involved.

While observing onsite testing the observer should
adhere to the following:

Observing Facility Operations

1. Don't write on process charts and graphs.
2. Don't turn knobs and dials.

3. Don't collect unnecessary data or data that was
not agreed upon in the pretest meeting without
obtaining approval.

Observing Testing Methodology

1. Don't touch or adjust test equipment.

Don't question tester or interfere during
critical times of the test.

3. Don't conceal unacceptable acts or procedures
to later use as justification to reject tests.

II-11


LECTURE 250
NSPS DETERMINATIONS OF APPLICABILITY

OBJECTIVES

The objectives of this lecture are to point out the listings of the
"NSPS Determinations of Applicability" and to discuss some of the more impor-
tant decisions.

_At the conclusion of this lecture the student will be familiar with the
Procedures used by EPA to determine NSPS applicability and will be familiar
with several of the more important determinations.

Note: No slides have been prepared due to the large number of determina-
tions. The instructor should select a few examples that are the most applicable
to that region of the county and agency. :

11-35


Slide sequence Key points

can be designed or redesigned to match the intent of
the regulations.

306-12 EPA contends that sulfuric acid was not intended to
be included in the measured emissions for power
plants--subpart D and Da. They have, therefore,
allowed Method 17 to be an alternative method for
subpart Da and are further considering adding pro-
cedures to remove the sulfate emissions from the
Method 5 sample. This is Method 5B. Four procedures
were considered during the development of EPA Method 5B.
These four procedures are noted.

306-13 Some sources like primary smelters have a very high
sulfate content. As a result, some states have
legally defined the sulfate to be included as part
of the particulate emissions. The sulfate is in-
cluded by the. two options noted.

306-14 If inorganic condensibles are not to be included as
part of the particulate emissions, three sampling
options can be used. These options are noted.

306-15, 16 Many sources have a high content of inorganic and
organic condensible matter. Several states regulate
the condensible matter as part of the particulate
emissions. In general, they are collected by use of
impingers. Both the problems and elimination of the
problems are noted.

306-17 Exclusion or inclusion of condensible matter can be
tricky. Three cautions are noted. If the agency
is unsure of the sample train design they should
seek technical help from the EPA headquarter group.

ITI-32


Slide sequence

107-0 (cartoon or
title)

107-1

107-2

107-2

Key points

Speaker should give objectives of lecture and point
out reference materials.

A gas sample is extracted from the sampling point in
the stack. Sulfuric acid mist (including sulfur tri-
oxide) and sulfur dioxide are separated. Sulfur di-
oxide is measured using the barium-thorin titration
method.

This method is applicable for the determination of
sulfur dioxide emissions from stationary sources.

The minimum detectable limit of the method has been
determined to be 3.4 mg of S02/m?. Although no upper
limit has been established, tests have shown that con-
centrations as high as 80,000 mg/m? of SQ, can be col-
lected efficiently in two midget impingers, each con-
taining 15 ml of 3 percent hydrogen peroxide, at a
rate of 1.0 2pm for 20 minutes.

Based on theoretical calculations, the upper concen-
tration limit in a 20-liter sample is about 93,300
mg/m?,

Interferences are possible from free ammonia, water-
soluble cations, and fluorides.

Cations and fluorides are removed by glass wool filter
and an isopropanol bubbler, and do not affect the SO2
analysis.

When samples are collected from a gas stream with high
concentrations of very fine metallic fumes (such as
inlets to control devices) a high-efficiency glass
fiber filter must be used in place of the glass wool
plug in the probe.

1-62


Slide sequence

202-8A (cartoon slide)
202-8

202-9A (cartoon slide)
202-9

202-10 (cartoon slide)
202-10 :

Key Points

The observer should compare the relative amount of
particulate collected with the visible emissions
reading during the test. The color and texture of
the particulate collected should also be noted.
(This is discussed in “The Role of the Observer"
paper.)

The observer should be satisfied that the sample will
maintain its integrity during sample transport.

Since the agency generally does not observe the sample
analysis, some control may be necessary. This can be
in the form of control sample analysis, audit sample
analysis or having the test team check off steps on

an analytical procedures form provided to them.

Such forms are included in the QA manual.

As noted.


Slide sequence

109-0 (cartoon or
title slide)

109-1

109-2

Key Points

Speaker should give objectives of lecture and point
out reference materials.

A gas sample is extracted isokinetically from the
stack. The sulfuric acid mist (including sulfur
trioxide) and the sulfur dioxide are separated and
both fractions are measured separately by the barium-
thorin titration method.

This method is applicable for the determination of
sulfuric acid mist (including sulfur trioxide) emis-
sions from stationary sources.

Collaborative tests have shown that the minimum
detectable limits of the method are:

0.05 mg SO3/m?
1.2 mg SO2/m?

No upper limits have been established. Based on
theoretical calculations for 200 ml of 3 percent
hydrogen peroxide solution, the upper concentration
Limit in a 1.0 m? gas sample is about 12,500 mg
S02/m?.

The upper limit can be extended by increasing the
quantity of peroxide solution in the impingers.

Possible interferences with this method are fluorides,
free ammonia, and dimelthy] aniline. If any of the
interferents are present (as determined by knowledge
of the process) alternative methods, subject to the
approval of the administrator, are required.

Filterable particulate matter may also be determined
along with SO3 and SOQ2 (subject to the approval of
the administrator), however, the procedures for
particulate matter must be consistent with the speci-
fications and procedures given in Method 5.

APPARATUS

The sampling train is the same as used in Method 5,
except the filter position is different and the filter

1-82


Slide sequence
104-2

104-3

104-4

104-5

Key points

APPARATUS

Grab sampling train

The grab sampling train consists of a probe, one-way
squeeze bulb, and flexible tubing.

The probe should be constructed of stainless steel
or borosilicate glass tubing and equipped with an

in-stack or out-stack filter to remove particulate
matter (a plug of glass wool is satisfactory).

Other materials inert to 02, C02, CO, and N2 and
resistant to elevated temperature may be used for the
Probe. Examples: aluminum, copper, quartz, glass,
and teflon.

Integrated sampling train

The probe is the same as described for the grab samp-
ling train.

Condenser - an air or water cooled condenser, or other
condenser that will not remove 02, C02, CO or Nz may
be used to remove excess moisture.

Valve - a needle valve to control sample gas flow rate.

Pump - a leak-free, diaphragm-type pump, or equivalent
is used to transport sample gas to the flexible bag.

A surge tank should be installed between the pump

and rate meter to eliminate the pulsation effect of
the diaphragm pump on the rotometer.

Rate meter - the rotameter used should be capable of
measuring flow rate to within +2% of the selected
flow rate. A flow rate range of 500 to 1000 cm?/min
is suggested.

1-29


Slide sequence

152-9

Key Points

This curve illustrates the error which results when
“he pitot tube is properly oriented with respect to
she stack wall but the gas stream is traveling at a
‘itch angle (Type B misalignment).

‘he error represents the error from Type B misalign-

lent and the cosine of the angle between the flow
ind the pitot tube.

‘ort X in the diagram with a bend or elbow in the

luct will give errors corresponding to the left half
f this figure.

‘ort Z in the same diagram gives errors corresponding
1o the right half of this figure. The most important
‘onclusion to draw from these two curves is that if
she pitot tube is aligned properly with respect to
she stack, regardless of the direction of flow, the
‘esultant velocity reading will be either close to
correct or too high. There will never be a large
‘rror on the low side.

1-102


Slide sequence

102-9

102-10

Key points

Relocated traverse points shall be the “adjusted”
traverse points. When two points are combined to
form an adjusted traverse point, treat adjusted point
as 2 in sampling, velocity determination, and date
recording.

Rectangular stacks

Rectangular stacks are divided into equal areas by
the use of a "balanced matrix" scheme. This scheme
results from research conducted by Fluidyne Corp.!
and Entropy Environmentalists? which revealed the
following:

1. The mean error for using 12 to 24 traverse points,
when 48 would normally be required, was generally less
than 2%, and the error did not decrease proportion-
ately when more points were chosen.

2. In optimizing the arrangement of a given number
of points on a rectangular cross section, the minimum
error is realized for a given total number of points,
when the number of points is the same in both direc-
tions. Therefore, for 36 points, a 6 x 6 matrix would
be preferable to a 2 x 18, 3 x 12, or 9 x 4 matrix.

3. For stacks with larger straight runs, it was
found that the number of points could be reduced by
half or more without any significant difference in
the average velocity.

Discuss example for rectangular stacks

Calculate equivalent diameter (De)

p LW. 736 x 36

De = Ww * 236 + 36

1sampling Strategies for Large Power Plants Including Nonuniform Flow,
EPA-600/2-76-170, June 1976.

2Determination of the Optimum Number of Traverse Points: An Analysis of

Method 1 Criteria.

1-10


Slide sequence

Key’ Points

holder does not have to be heated. Therefore, the
discussion will include only the apparatus and items
which are different from Method 5.

Probe liner is constructed only of borosilicate or
quartz glass with a heating system to prevent visible
condensation. Metal probe liners cannot be used.

The filter holder is the same as for Method 5, but is
Placed between the first and second impingers.

The first and third impingers are of the Greenburg
Smith design with standard tips.

REAGENTS

The reagents are the same as specified for Method 6.

Experience has shown that only A.C.S grade isopropanol
is satisfactory. Tests have shown that isopropanol
obtained from commerical sources occasionally have
peroxide impurities that will cause erroneously high
sulfuric acid mist measurement. Check each lot of
isopropanol for peroxide using the following proce-
dure:

1. Shake 10 ml of the isopropanol with 10 ml of
freshly prepared 10 percent potassium iodide
solution.

2. Prepare a blank by similarly treating 10 ml of
distilled water.

3. After 1 minute, read the absorbance on a spectro-
photometer at 352 manometers. If the absorbance
exceeds 0.1, the isopropanol shall not be used.

Peroxides may be removed from isopropanol by redistil-
ling, or by passage through a column of activated
alumina. However, reagent-grade isopropanol with suit-
ably low peroxide levels is readily available from
commercial sources, therefore, rejection of contaminated
lots may be more efficient.

1-83


LECTURE 151
SUMMARY OF EQUATIONS - METHODS 1 - 5

OBJECTIVE

The objective of this lecture is to review the calculations for methods
one through five. Equations will be reviewed by method and emphasis will be
placed on familiarizing the student with nomenclature.

At the end of this lecture the student should be familiar with the equa-
tions and nomenclature used in Methods 1 through 5.

1-91


Slide sequence

101-4

101-5

Key points

These three terms are related to each other by the
equation:

Por. = ¢, Qa,

where

Pmr. = average pollutant mass emission rate

°|
"

average stack concentration

a

R=)
a
"

average volumetric flow rate from the stack

The objective is to determine Pmr > so the general

approach is to determine cand Q- cy is deter-

mined through sampling train design. Q, is given
by the equation:

Q, = Vy Ay
where:
Vy = average stack gas velocity
AS = cross sectional area of the stack

1-5


Slide sequence

202-4A (cartoon slide)
202-4

202-5A (cartoon slide)
202-5

202-6A (cartoon slide)
202-6

202-7A (cartoon slide)
202-7

Key Points

The final test protocol should then be discussed and
agreed upon with the facility (and test team if re-
quired). This does not have to be performed in a
separate presurvey meeting but is advisable if the
source does not agree to all conditions, or if the
test is complicated. The agency should always review
the final test protocol with the facility and test
team prior to the start of the test to ensure that all
parties are in agreement.

A representative from the facility, the test team,

and the agency, should be designated as the key
contact. These individuals should be available at

all times during the testing and all official communi-
cations should be made through them. No changes,
modifications or problems should be discussed between
groups with anyone other than the designated contact
person. . :

The agency contact person should make it clear if there
are times when his approval or presence is necessary
for any phase of the testing.

The agency is responsible for observing both the faci-
lity operations and source testing and for taking the
visible emission readings. It is recommended that the
agency use the field investigator responsible for the
facility tested to observe the facility operations and
make the visible emissions readings. This will
strengthen their position and investigations in the
future.

The sample recovery phase is usually the most critical
for making or detecting errors made during the
testing. Since there is a very small amount of
pollutant collected during a normal source test, any
errors during this phase are critical.

II-7


Slide sequence Key Points

109-11 Container No. 2. Sulfur Dioxide

1. Thoroughly mix the solution in the container
holding the contents of the second and third
impingers.

2. Pipette a 10 ml aliquot of the sample into a
250 ml Erlenmeyer flask.

3. Add 40 m1 of isopropanol and two to four drops
thorin indicator.

4. Titrate to a pink end point using 0.0100 N barium
perchlorate. Repeat the titration with a second
aliquot from the same sample. Replicate titrant
volumes should be within 1 percent or 0.2 ml,
whichever is greater.

Blanks

Prepare blanks by adding two to four drops of thorin
indicator to 100 ml of 80 percent isopropanol. Titrate
the blanks in the same manner as the samples.

1-87


Slide sequence

309-5

309-7

309-8

Key points

We would have to sample 48 points for Location A and
12 points at Location B. But what would the results
be based on our known facts? Location A results com-
pared to Location B would be that the measured pol-
lutant concentration would likely be low and the
measured flow rate would tikely be too high.

Therefore, what is really the results of increasing
the number of sampling points? The data will be more
precise but not more accurate. The pitot tube and
sample train will be biased in nonparallel flow even
if every square inch of the stack is sampled. The
last result of increasing the number of points is that
it also fatigues the tester and observer.

Note: This lecture is not saying do less than the
minimum number of sampling points. If less than the
minimum number of sampling points are done, then the
test wil] not be legally acceptable.

Based on the discussion, when the sample location does
not meet the requirement of Method 1 or two sample
points are available, use the options in the order
shown. Make sure the option is feasible. Do not
require a source to move the sampling ports a few
feet at the cost of tens of thousands of dollars if
any other option can be used. If moving the sample
port location only requires the use of a blow torch
and scaffolding to be erected, then it should be
considered.

As noted, this option was discussed in the cyclonic
flow lecture.

TII-45


VOLUME II. SERIES 1-200-7/82
OBSERVATION AND EVALUATION OF PERFORMANCE TESTS


Slide sequence

152-0 (cartoon or
title slide)

152-1

152-2

152-3

152-4

152-5

Key Points

Speaker should give objectives of lecture and point
out reference materials.

Pitot Tube Misalignment

This is the proper orientation of the Type S pitot
tube in a gas stream.

There are two basic types of pitot tube misalignment.
1. Type A or yaw angle misalignment.

From the plot of velocity error vs. angle of misalign-
ment it can be seen that the alignment which gives
the highest reading does not indicate the direction
of flow. :

Also important is the fact that Type A misalignment
of up to 50° will result in a relatively small error
in velocity.

2. Type B or pitch angle misalignment

The error for Type B mi salignment is not symmetrical
on either side of the correct alignment.

When the pitot tube is pointed into the flow (+ 6),
the velocities measured are generally too high and
when the pitot tube is pointed away from the flow
(- 6), the velocities measured are too low.

T-100


Slide sequence
307-6

307-7

Key points

When the fluctuating is minor and over a longer
period of time, the tester should make the corre-
sponding isokinetic rate change as the velocity
Changes. Then at the conclusion of each sample point
the average time weight AP and AH should be recorded.

When the fluctuating is more significant such as the
change in flow normally associated with a cyclonic
flow pattern, the tester should make changes to the
point possible. When the isokinetic rate cannot be
obtained due to the large variation in flow, the
tester should be allowed to proceed with the testing
at the maximum rate the sample train will pull. The
result will be a low percent isokinetic rate which
will bias the data high. Under no circumstances
should the nozzle size be changed during the sample
run. The use of two nozzle sizes for one run will
be an invalid test.

III-35


Slide sequence
308-4

308-5

308-6

308-7

Key points

If the regulations are.on a 1b/h basis the emission
will be averaged using the equation shown. Although
it may not be obvious, all the other equations shown
use the same averaging technique of the mass emission
rate average on their time weighted basis.

1b/10° Btu is a concentration standard and not a mass
emission rate standard. If the agency so desires
they can convert 1b/10® Btu to a 1b/h basis using the
equation shown.

After converting the 1b/10° Btu to 1b/h for both the
normal and soot blowing runs they can be averaged on
a mass emission rate basis using the first equation
(slide 308-4). The only problem with this is that
the averaged value will be in terms of 1b/h and not
1b/10® Btu.

To obtain the final results in terms of 1b/10° Btu,
the values must in effect be multiplied by the flue
gas flow rate to convert to 1b/h and then divided by
the flue gas flow rate to obtain 1b/10° Btu. The
equation shown is the equation used in the reference
paper. This equation uses the measured pollutant
concentration to average the results. Since the
agency generally receives the results in terms of
1b/10° Btu, this equation will not be explained but
should be clear on how to use it after the discussion
of the next equation.

III-39


Slide sequence

107-4

Key points

A dial thermometer or equivalent to measure the
temperature of gas leaving impingers to within 2°F.

A drying tube packed with 6 to 16 mesh indicating
type silica gel, or equivalent, to dry the gas sample
and to protect the meter and pump. Alternately,
other types of desiccants (equivalent or better.) may
be used subject to approval of the administrator.

Needle valve to regulate sample gas flow rate.

Leak-free diaphragm pump or equivalent, to pull gas
through the train. Install a small tank between the
pump and rate meter to eliminate the pulsation effect
of the diaphragm pump on the rotameter.

Rotameter, or equivalent, capable of measuring flow
rate to within 2 percent of the selected flow rate
of about 1000 cc/min.

Dry gas meter, sufficiently accurate to measure the
sample volume within 2 percent accuracy, equipped with

a temperature gauge capable of measuring temperature
to within 5.4°F.

A 30 in. Hg vacuum gauge to be used for leak check
of the sampling train.

Barometer which meets the specifications reviewed in
Method 2.

Sample recovery apparatus as outlined in the method.

Reagents, unless. otherwise indicated, must conform
to the specifications established by the American
Chemical Society. Where such specifications are not
available, use the best available grade.

Certain reagents should be checked as follows:

Check each lot of isopropanol for peroxide impurities.
To check: Shake 10 ml of isopropanol with 10 mi of
freshly prepared 10 percent potassium iodide solution.
Prepare a blank of similarly treating 10 ml of de-
jonized distilled water. After 1 min. read the
absorbance of the alcohol sample against the water

1-64


Slide sequence

106-25

Key points

Alternatively, the sample filter may be oven-dried
at 220 F for 2 to 3 hours, allowed to cool ina
desiccator and then weighed to a constant weight.

Treat the blank filter in the same manner as the sam-
ple filter. The average final weight of the blank
filter should be within +5 mg of the initial tare
weight or 2% of the sample weight whichever is great-
er. If the above limit is not met, complete the
analysis and calculations using standard procedures
and make a note in the test report of the nonagree-
ment.

Acetone rinse

Confirm that no leakage has occurred during trans-
portation of the sample. If a noticeable amount of
leakage has occurred, either void the sample or use
methods approved by the administrator to correct the
final results.

Measure the contents in the container volumetrically
to the nearest 1 ml or gravimetrically to the near-
est 0.5 g.

Transfer the contents to a tared 250-ml beaker, evap-
orate and then desiccate for a minimum of 24 hours.

Weight to a constant weight and record the data to
the nearest 0.1 mg.

Alternatively, the acetone rinse may be evaporated
at elevated temperature. If this is the case, the
temperature must be below the boiling point of ace-
tone, approximately 1330F. The acetone solution
must be swirled occasionally to maintain an even
temperature.

Treat the acetone blank in the same manner as the
sample.

1-59


Slide sequence

103-15

103-16

103-17

103-18

Key points

Place the pitot tube in the angle aluminum and level
the assembly as indicated by the bull's eye level.
A vice may be used to hold the angle aluminum and
Pitot tube in the lab. In the field a "C" clamp
can be used to hold the assembly.

When checking a permanently mounted pitot tube and
probe assembly, a shorter section of angle aluminum
may be required to allow proper mounting on the
assembly.

Evaluate the construction specifications by placing
the degree indicating level at the following posi-
tions:

measure the face opening plane misalignment,
angles o, and a2

measure the parallel misalignment of the face
opening planes from the longitudinal tube axis,
angle Bi and B2

measure the misalignment of the length of the
pi tot tube legs, angle y (gamma for calculating
Zz

1-19


Slide sequence

106-6

106-7

106-8

106-9

106-10

Key points

leak-free pump .

two thermometers capable of measuring
temperature to within 5.4°F

dry gas meter capable of measuring volume

to within 22.

The barometer and gas density determination equipment
are the same as described in Methods 2 and 3.

Reagents and apparatus used for sample recovery
and analysis are outlined in the method. Special
care should be taken to use only the specified items.

Calibration

Probe nozzles--probe nozzles should be calibrated
Tnitially and prior to each field use.

1. Make three separate measurements using a dif-
ferent diameter each time.

2. Calculate the average of the measurements.

3. The difference between the high and low numbers
shall not exceed 0.004 in.

When nozzles become nicked, dented, or corroded, they
shall be reshaped, sharpened and recalibrated before

use. Each nozzle shall be permanently and uniquely
identified.

Metering system

The metering system (orifice and dry gas meters) must
be calibrated prior to its initial use against a wet
test meter. At the end of the test program a cali-
bration check of the metering system is required.

Leak-check procedure

Before calibrating the metering system it is suggested
that both positive and negative leak checks be con-
ducted.

1-50


Slide sequence

106-16

106-17

106-18

Key points

Probe blockage

In smal] ducts (~ 12 to 36 inches in diameter), a re-
duction in CP (pitot tube coefficient) of up to 4
percent can occur, resulting from reduction of the
effective cross-sectional area of the duct by the
probe sheath. Therefore, in certain instances it may
be necessary, prior to sampling, to make adjustments
in the coefficient values obtained by pitot tube cali-
bration. To determine whether adjustments are
necessary, proceed as follows:

1. Make a projected-area model of the pitobe assembly,
with ‘the type S pitot tube impact openings positioned
at the center of the duct. This model represents the
approximate “average blockage" of the duct cross-
section which will occur during a sample traverse.

2. Calculate the theoretical average blockage by
taking the ratio of the projected area of the probe
sheath (in.?) to the cross-sectional area of the duct
(in.?). If the theoretical blockage is either 2 per-
cent or less for an assembly without external sheath,
or 3 percent or less for an assembly with an external
sheath, the decrease in Cp will be less than 1 percent
and no adjustment in the pitot tube coefficients will
be necessary.

3. If the theoretical blockage exceeds these limits,
apply corrections to the pitot tube coefficient as
shown.

Effect of prabe sheath

If a pitobe assembly is constructed in such a way
that the distance from the center of the pitot tube
impact openings to the leading edge of the probe
sheath is less than 3 inches, a slight reduction
(up to 3%) in Cp can occur.

The spacing between the nozzle and the pitot tube
must be a minimum of 3/4 inch when a 1/2 inch nozzle
is installed.

The impact pressure opening plane of the pitot tube
shall be even with or above the nozzle entry plane.

1-54


Slide sequence

109-9

109-10

Key Points

to the cylinder. Dilute to 250 ml with 80 percent
isopropanol. Add the filter to the solution, mix
and transfer to storage container No. 1. Protect

_the solution against evaporation. Mark the liquid

level and identify the container.

Transfer the solutions from the second and third
impingers to a 1000 ml graduated cylinder. Rinse
all connecting glassware (including back half fil-
ter holder) between the filter and silica gel im-
pinger with deionized, distilled water, and add
the rinse water to the cylinder. Dilute to a
volume of 1000 ml with deionized, distilled water.
Transfer the solution to storage container No. 2.
Mark the liquid level, seal and identify the con-
tainer.

ANALYSIS

Confirm that no leakage occurred during the trans-
portation of the samples. If a noticeable amount of
Jeakage has occurred, either void the sample or use
methods approved by the administrator to correct the
final results.

Container No. 1. Sulfuric Acid Mist

1.

Shake the container holding the isopropanol solu-
tion and the filter. If the filter breaks up,
allow the fragments to settle for a few minutes
before removing a sample.

Pipette a 100 ml aliquot of this solution into
a 250 ml Erlenmeyer flask.

Add two to four drops of thorin indicator, and
titrate to a pink end point using 0.0100 N barium
perchlorate.

Repeat the titration with a second aliquot from
the same sample. Replicate titrant volumes should
be within 1 percent or 0.2 ml, whichever is
greater.

1-86


LECTURE 253
SAFETY IN STACK SAMPLING

OBJECTIVES

The objective of this lecture is to discuss safety with respects to
construction of the sampling platforms, exposure to source pollutants, testing
and analytical reagents, and performance of the test.

At the conclusion of the lecture the student should be familiar with the
legal requirements of sampling platform safety, methods to check hazards of
pollutants, hazards of testing and analytical reagents, safety procedures for
conducting the performance test and his responsibility with respect to all of
the above.

II-43


Slide sequence Key Points

208-5 This package was developed to review test reports
that may be used to set standards by the U.S.
Environmental Protection Agency.

The package consist of three parts:

Part 1 - Review summary: Identifies report and con-
tains the observer's summary.

Part 2 - Report review: Consists of four subsections

A. Introduction

B. Source Operation

C. Test Procedures and Results
D. Documentation

Part 3 - Summary data sheet

208-6 The two most important items of the data requirements
are data completeness and accuracy. The data forms
will help evaluate data completeness. Data accuracy
will have to be checked through independent calcula-
tions using the raw data and comparison with observer's
field notes and other data validation procedures.

208-7 The agency should also submit a compliance notifica-
tion status letter to the source of the status that
has been determined.

I-33


Slide sequence

103-0 (cartoon or
title)

103-1 - 103-2

103-3

Key points

Speaker should give objectives of lecture and point
out reference materials.

The average velocity is determined for the stack
cross section since we would expect some cross-
sectional variation.

Velocity is determined using:

A type S (stausscheibe or reverse type) pitot
tube and a differential pressure gauge to
measure velocity pressure (AP)

A temperature sensor to measure gas temperature
A sensor to determine static pressure
A method to determine stack gas density

During this lecture, our major concentration will be
on AP measurement, temperature measurement and static
pressure measurement.

Method 2 is only applicable at sites which meet the
criteria of method 1, and does not contain cyclonic
or swirling flow.

When unacceptable conditions exist, alternative pro-
cedures subject to the approval of the administrator
Must be used to make accurate flow rate determina-
tions.

Examples of alternatives procedures include 1) install
straightening vanes, 2) calculate the total volume-
tric flow rate stoichiometrically, or 3) move to
another measurement site at which the flow is accept-
able.


LECTURE 251
AGENCY APPROVAL OF EQUIVALENT AND ALTERNATIVE TEST METHODS

OBJECTIVES

The objectives of this lecture are to discuss the definitions and the
responsible agency and procedures used to approve equivalent and alternative

methods and procedures. The approval must be made by the correct agency and
must conform to the intent of the test.

At the conclusion of the lecture the student should be familiar with
options that are approved at his level, procedures to request approval for
those above his level, and procedures used to request and approve all changes.

II-37


Slide sequence

106-21
106-22

106- 23

106- 24

Key points

Wipe all connecting joints clean of silicone grease
and clean the inside of the front half of the filter
holder by rubbing the surface with a nylon bristle
brush and rinsing with acetone. Repeat at least
three times or until no particles are evident in the
rinse.

Clean any connecting glassware which precedes the
filter holder using the above procedure.

After the rinsings are complete make sure the sample
bottle is securely sealed and the liquid level marked
on the bottle.

Collect an acetone blank to be analyzed for residue
along with the samples.

Determine the liquid quantity in the impingers either
by measuring the volume to the nearest 1 ml with a
graduated cylinder or by weighing it to the nearest
0.5 g with a balance. Make a notation on the sample
recovery form of any color or film in the impinger
water.

Note the color of the indicating silica gel to deter-
mine whether it has been completely spent and make a
notation of its condition.

Determine the final weight gain to the nearest 0.5 g.

ANALYSIS

The analytical procedures consist of evaporations and
weighings. Although both procedures are relatively
simple, it is essential that sample handling be mini-

- mized and be done carefully to avoid loss and con-

tamination.

For these procedures, the term "constant weight" means
either a difference between two consecutive weighings
of <0.5 mg or 1% in the total weight less tare weight
(whichever is greater) with a minimum of 6 hours of
desiccation between weighings.

Filter

Leave the filter in the petri dish or transfer the
filter and any loose particulate matter to a tared
weighing dish and desiccate for a minimum of 24 hours.
Weigh the filter to a constant weight and record

the results to the nearest 0.1 mg.

1-58


VOLUME I. SERIES 1-100-7/82
EMISSION TESTING CONCEPTS AND SPECIAL TOPICS

I-1


LECTURE 306
CONDENSIBLES

OBJECTIVES

The objective of this lecture is to discuss the positive and negative
biases resulting from condensible matter on measurement of particulate emis-
sions. The discussion will focus on the definition of particulate and method-
ology to include or exclude condensible matter present in the effluent.

At the conclusion of this lecture the student should be able to apply
methodology to selectively include or exclude condensible matter for the
sources discussed, based on the requirements of the applicable regulations.

I1I-29


Slide sequence

303-14

303-15

303-16

303-17

303-18

303-19

Key points

The Entropy system is also not designed for sources
with high particulate loading. It is for use as
noted and the advantages are also noted.

For very high moisture content sources, the sample
control valves on the meter console are not suffi-
cient to adjust the flow. A valve should be located
after the orifice meter but before the moisture is
condensed.

In addition to the relocation of the orifice meter,
three other problems are common:

1) entrained water droplets that wet the filter and
make sampling very difficult;

2) water condenses and plugs up the orifice meter
and pitot tube lines; and

3) the collection of the water droplets gives an
improper calculated stack gas moisture content
when based on the condensation in the impingers.

Placing the cyclone and flask back in the method 5
train will greatly reduce the chance of wetting
the filter.

Placing water knock jars at the end of the pitot tube
will remove the condensed water droplets.

An accurate stack gas temperature (+2°F) must be
made and the moisture content calculated by the
partial pressure equation. Saturated vapor pres-
sure divided by absolute stack pressure.

III-16


Slide sequence

108-10

108-11

10.

Key Points

Record the volume of the flask and valve (Vf),
the flask temperature (Ti) and the barometric
pressure.

Turn the flask valve counter clockwise to its
“purge" position and do the same with the pump
valve. Purge the probe and vacuum tube using
the squeeze bulb. If condensation occurs in the
probe and flask valve area, heat the probe and
purge until condensation disappears.

Turn the pump valve to its "vent" position; turn
the flask valve clockwise to its "evacuate" posi-
tion and record the difference in the mercury
levels in the manometer. The absolute internal
pressure in the flask (Pi) is equal to the baro-
metric pressure less the manometer reading.

Turn the flask valve to the "sample" position
and permit the gas to enter the flask until
pressure in the flask and sample lines are
equal. This will usually require about 15
seconds; a longer period indicates a plug in
the probe, which must be corrected before sam-
pling is continued.

Turn the flask valve to its "purge" position
and disconnect flask from sampling train.

Shake the flask for at least 5 minutes.

If the gas being sampled contains insufficient oxy-
gen for the conversion of NO to NOz, then oxygen
shall be introduced into the flask to permit this
conversion. Oxygen may be introduced into the flask
by one of three methods:

1.

Before evacuating the sampling flask, flush with
pure cylinder oxygen then evacuate flask to 3
in. Hg absolute pressure or less.

1-77


Slide sequence Key points

104-0 (cartoon or Speaker should give objectives of lecture and point
title) out reference materials.
104-1 A gas sample is extracted from a stack by:

single-point grab sampling
single-point integrated sampling
multi-point integrated sampling

The gas sample ts analyzed for percent carbon dioxide
(C02), percent oxygen (02), and if necessary, percent
carbon monoxide (C0).

If a dry molecular weight determination is to be
made either an orsat analyzer or a fyrite analyzer
may be used for analysis.

For excess air or emission rate correction factor
determination an orsat analyzer must be used.

This method is applicable for determining C02 and 02
concentrations, excess air and dry molecular weight
of a sample from a fossil-fuel combustion source.

The method may also be applicable to other sources
where it has been determined that compounds other

than C02, 02, CO and nitrogen (N2) are not present
in concentrations sufficient to affect the results.

1-28


Slide sequence

108-6

108-7

108-8

Key Points

Spectrophotometer. The spectrophotometer calibration
consists of two parts:

1) optimum wavelength determination

2) for fixed and variable wavelength spectrophoto-
meters calibrate against a standard with a certi-
fied wavelength of 410 NM every 6 months.

Alternatively, for variable wavelength spectrophoto-
meters, scan the spectrum between 400 and 415 NM
using a 200 mg NO2 standard solution. If a peak does
not occur, the spectrophotometer is probably malfunc-
tioning and should be repaired.

When a peak is obtained within the 400 to 415 NM
range, the wavelength at which this peak occurs
shall be the optimum wavelength for the measurement
for both the standards and samples.

CALIBRATION FACTOR DETERMINATION

Add 0, 1.0, 2.0, 3.0 and 4.0 ml of the KNO3 working
standard solution (1 ml = 100 yg N02) to five porce-
lain evaporation dishes. Add to each 25 ml of absorb-
ing solution, 10 ml deionized distilled water, and
sodium hydroxide (IN) dropwise until the PH is between
9 and 12. Then handle using same procedure used with
unknown sample beginning with the evaporation step.

Measure the absorbance of each solution at the optimum
wavelength, as determined in the first part of the
calibration procedure.

The calibration factor must be determined each day
that samples are analyzed.

Calculate the spectrophotometer calibration factor
as follows:

= 199 At 2 Ar + 3 As +4 As
Ko = 100 RF Ae + Age FA?

1-75


Slide sequence

254-0

254-1

254-2

254-3

254-4

Key points

Speaker should give objectives of lecture and point
out reference materials.

The data as noted should be collected when possible.

The equation calculates the exact F-factor for any
fossil fuel. The F-factor is the volume of dry
gases generated per 10° Btu of heat released.

This F-factor equation is used to calculate the emis-
sions rate. The pollutant concentration is at stan-
dard conditions and the oxygen correction factor is

to correct the pollutant concentration to 0% excess
air or theoretical air. Because of the excess air
correction, it does not matter if there is air inleak-
age in the stack after combustion. The air inleakage
will be corrected by this equation.

This is the standard equation used to calculate the
mass emissions rate. One point of interest is that
the allowable particulate emissions rate in subpart

D is 0.1 1b/10° Btu for particulates. This calculates
very closely to 1 pound per megawatt. So a 200 mega-
watt plant would be allowed approximately 200 pounds
per hour.

11-48


Slide sequence Key points
BAROMETER

The Barometer should be calibrated according to the
Procedures discussed in Method 2.

107-7 ONSITE SAMPLING

1. Prepare collection train. Measure 15 ml of 80
percent isopropanol into the midget bubbler.
Using a different pipette or graduated cylinder,
place 15 ml of 3 percent hydrogen peroxide into
the first two midget impingers. Leave the final
impinger dry. Adjust probe heater to operating
temperature. Place crushed ice and water around
the impingers.

2. Conduct leak check (optional). With probe dis-
connected, place a vacuum gauge at the inlet to
bubbler and pull a vacuum of 10 in. Hg. Plug or
pinch off the outlet of the flow meter and turn
off the pump. The vacuum must remain stable for
at least 30 seconds.

Carefully release the vacuum gauge before re-
leasing the flow meter’ end to prevent backflow
of the impinger fluid.

3. Perform the mechanics of running the sampling
train.

If the stack is under a negative pressure greater
than 2 in. H20. Position the probe at the sampling
point, turn on the sample pump, and then the

Probe connected to the train to prevent the im-
Pinger solution from being siphoned backwards and
contaminating the isopropanol.

Sample at a constant rate of approximately 1.0
&/min and maintain this constant rate within 10
percent during the entire sampling run.

4, At the conclusion’of the run, conduct a posttest
Jeak check using the procedures outlined for the
pretest leak check. This leak check is mandatory.
If a leak is found, void the test run.

1-67


Slide sequence

103-23

Key points
6. a8 the external tube diameter, between 3/16 and
3/8 i .

If the pitot tube meets the dimensional specifications
and the diameter of the tubing is between 3/16 and 3/8
in., the pitot tube may be calibrated or a baseline
coefficient of 0.84 may be assigned.

If the pitot tube meets all dimensional specifica-
tions but the diameter of the tubing and/or P, and
P, are outside of the specified limits, the pttot
thbe must be calibrated.

Wind tunnel calibration

A test setup for calibrating the type S pitot tube
can be constructed from a straight section of duct 10
to 12 duct diameters long.

The diameter of a circular duct must be at least 12
in. and the width (shorter side) of a rectangular
duct must be at least 10 in.

The flow system should generate a test section veloc-
ity around 3000 ft/min. The velocity must be constant
with time to guarantee steady flow during calibration.

Coefficients obtained by single-velocity calibration
at 3000 ft/min will generally be valid to within +32
for measurement of velocities above 1000 ft/min and
to within +6% for the measurement of velocities be-
tween 600 and 1000 ft/min.

A more precise correlation between Cp and velocity can
be obtained if at least four distinct velocities
covering the velocity range from 600 to 5000 ft/min
are used.

Two entry ports, one each for the standard and type S
pitot tubes, shall be cut in the test section. The
standard pitot entry port shall be located slightly
downstream of the type S port, so that the standard
and Type S impact openings will lie in the same
cross-section plane during calibration.

To facilitate alignment of the pitot tubes during
calibration, the test section should be constructed
of plastic or some transparent material.

I-21


LECTURE 105
EPA METHOD 4 - DETERMINATION OF MOISTURE CONTENT IN STACK GASES

OBJECTIVES

The objective of this lecture is to familiarize the student with methods
for determining stack gas moisture content. Specific topics to be discussed
include:

1. reference method for determination of moisture,
2. approximation method for determination of moisture,

3. moisture determination using partial pressure for
saturated stacks, and

4. moisture determination using wet bulb-dry bulb method

At the conclusion of this lecture the student should be familiar with the four
methods for determining moisture content listed above. The student should be
able to determine which method to be used in a given situation, observe mois-
ture determinations in the field, and review moisture data submitted in a
test report.

1-39


Slide sequence

302-5

302-6

302-7

302-8

Key points

Another common problem is that the test team will use
probes that are heated. Organic material in the glue
on heat tape, used to secure the heating wire will
burn and contaminate the sample. The probe should
be free of tape and heating wires since there is no
need to heat the probe.

As the stack temperature nears the softening tempera-
ture of borosilicate glass, one alternative is to
switch to a metal probe liner. Two items must be
checked with the use of metal probe liners:

1. at high temperature many reactive substances may
be present and will react with the exposed surfaces
of the metal liner.

2. high-temperature effluent can cause softening of
the nozzle and pitot tube even if the probe liner

is a special alloy that will withstand the tempera-
ture.

As shown in the picture, one advantage of the metal
probe liner is that stainless ferrels can be used
to provide a leak-free seal and also they will not
break.

The most common means of handling high-temperature
is constructing a high temperature probe. These
probes are of two approaches: 1) coolant probe or
2) special alloy or materials probe.

When a cooling system is devised it allows the use
of standard stainless steel liner. Coolants used are
ambient air, water, or steam.

Probe may also be made of special alloys or materials.

There are advantages and disadvantages to both type
probes. This is a picture of a water cooled probe.
You can note that one disadvantage is its size and

weight.

IlI-9


LECTURE 107

EPA METHOD 6 - DETERMINATION OF SULFUR DIOXIDE EMISSIONS
FROM STATIONARY SOURCES

OBJECTIVES

The objectives of this lecture are to familiarize the student with the
equipment and procedures of Method 6 and to highlight the important parameters
to ensure good data quality. Specific topics to be discussed include:

1. sample train components,
calibration of components,

3. leak check procedures,

4. sampling procedures, and

5. sample recovery and analysis.

At the conclusion of this lecture, the student should be familiar with the
Method 6 sampling system and the sample recovery and analytical procedures.
The student should also be able to observe Method 6 testing and review test
reports of tests conducted using Method 6.

I-61


Slide sequence

103-29

103-30, 31, & 32

Key points

If the absolute temperature values agree within +1.5%
at each point , plot the data on linear graph paper
and draw the best fit line between the points or
calculate the linear equation using the least-squares
method. The data may be extrapolated above and be-
low the calibration points and cover the entire man-
ufacturer's suggested range for the thermocouple.

Thermometer calibration - use the same tmperatures
as for thermocouple or other temperatures that

encompass the expected range of temperatures to be
encountered.

If the absolute temperature values agree within +1.5%
at each point, the thermometer may be used over the
range of calibration points without applying any
correction factor.

If a correction factor is needed it must be affixed
to the thermometer.

Barometer

The field barometer should be adjusted initially and
before each test series to agree within 0.1 in. Hg
of the mercury-in-glass barometer or the station
pressure value reported by a nearby national weather
service station corrected for elevation.

1-24


Slide sequence

253-4

Key points

5. Exposure to pollutant - A list of chemical
compounds and the effect on humans is contained
in the back of the safety paper in this lecture.
The observer should be aware of the possible
health effects.

6. Exposure to process materials - The raw materials,
products and by-products can cause serious health
effects if a malfunction or upset occurs. The
observer should be briefed on any possible dangers
prior to testing and carry the proper protective
equipment.

7. Exposure to sampling chemicals - Many of the
chemicals used for reference method sampling and
analysis can be a health hazard. For this reason,
the observer should avoid contact with any solu-
tions he is unsure of. Diluted acid is used in
many sample trains so the observer should wear
safety glasses when in close proximity of sample
recovery.

The safety precautions are noted. The best detection
device is common sense in noting unsafe conditions.
The observer has the best vantage point since he is
the least physically involved.

11-45


Slide sequence Key points

151-16 Acetone blank concentration - c.
Cc “¥ "a
a‘a
where:
Cc. = acetone blank residue concentration, mg/g
V, = volume of acetone blank, ml

density of acetone, mg/ml

151-17 Acetone wash blank

Wa = Ca Vay Sa

=z
w

weight of residue in acetone wash, mg
Vv... = volume of acetone used in wash, ml.

1-98


Slide sequence

305-13

305-14

305-15

305-16

305-17

305-18

305-19

Key points

This diagram shows the true area of the nozzle when
the flow is parallel with the. stack walls.

This diagram shows the effect of the apparent nozzle
area or how the nozzle area is reduced from misaligned
flow.

This diagram shows the theoretical error on velocity
measurement in cyclonic flow. The actual error can
be even greater due to the additional interference of
the nozzle on the pitot tube readings.

To compensate for the two misalignment errors, the
procedures as noted should be followed. The pro-
cedures use the average angle of misalignment. Some
agencies prefer to use the maximum angle of misalign-
ment. This can be done but the agency should be con-
sistent and the use of the maximum angle should only
be used when the source has the responsibility of
proving compliance. Never use only the maximum error
if the agency is trying to prove a violation. The
step-by-step procedures are noted.

Equation 1 increases the nozzle diameter to compen-
sate for the two errors.

Equation 2 gives the appropriate nozzle size that is
used to set the nomograph and determine the isokinetic
sample rate.

The last method mentioned is the best method when it
can be reasonably applied. This method is to modify
the source to remove the cyclonic flow. Make sure
the students are aware that source modification is
many times not practical and may greatly increase the
source's emissions by removing the cyclonic flow
which is used as an inertial separator for particulate
removal. The results are noted.

III-26


LECTURE 106

EPA METHOD 5 - DETERMINATION OF PARTICULATE EMISSIONS
FROM STATIONARY SOURCES

OBJECTIVES

The objectives of this lecture are to familiarize the student with the
equipment and procedures of Method 5 and to highlight the important parameters
to ensure good data quality. Specific topics to be discussed include:

sample train components,
2. calibration of components,
3. leak-check procedures,
the probe blockage model,
sample train operation, and
6. sample recovery and analysis.

At the conclusion of this lecture the student should be familiar with the
Method 5 sampling system and the sample recovery and analytical procedures.
The student should be able to observe Method 5 testing and review test reports
conducted using this method.

1-47


Slide sequence / Key points

151-3 EPA Method 3
Dry gas molecular weight (MQ)

Ma = 0. 44(% CO) + 0.32(% 0,) + 0.28(% No +% co)

where:
Mg = dry molecular weight
0.44 = molecular weight of C05 divided by 100
0.32 = molecular weight of 055 divided by 100
0.28 = molecular weight of NJ or CO, divided by 100
% COy = percent CO, by volume (dry basis)
% 0) = percent 0, by volume (dry basis)
% CO = percent CO by volume (dry basis)
% No = percent No by volume (dry basis)
0.264 = ratio of 0, to No in air, V/V
% EA = percent excess air

151-4 Molecular weight of stack gas (M,)
My = Mg(1-B,.) + 18(B,.)

where:

molecular weight of stack gas
Bus = proportion of water vapor, by volume in the

gas stream
151-5 Percent excess air (EA)
% 0, - 0.5 % CO
% EA = 2
0.264 % No - % 0, - 0.5 % CO)

1-93


Slide sequence
306-6

306-7

306-8

306-9

306-10

306-11

Key points

The third generation L.A. train was then designed to
move the filterable matter up front and collect the
condensible matter in the impinger.

The proposed EPA Method 5 was designed to be the same
as the third generation L.A. sample train. However,
there was so much outcry about the creation of “pseudo-
particulates" or artifacts in the impingers that when
EPA promulgated the Method 5 they did not include the
portion collected in the impinger.

Subsequent sample trains were designed to collect
condensibles or particulate and gaseous pollutant
simultaneously. EPA Method 13 is the same as the
second generation L.A. sample train.

EPA method 13 train also allows for the addition of
a filter in front and back of the impingers.

After many years of work and research, EPA then
designed the first generation L.A. sample train and
called it EPA Method 17. Sample trains are like
old clothes--if you wait long enough, they will come
back in style.

Industry has been requesting the use of Method 17 as
an alternative method to Method 5. This is under-
standable since for apy source with a stack tempera-
ture greater than 250°F Method 17 will likely give
a smaller measured value than Method 5.

EPA has in some cases allowed the use of Method 17
as an alternative since they said the regulation did
not intend to regulate some of the material that is
collected by Method 5.

To properly handle the question of condensibles, the
agency staff must have a clear understanding of what
emissions their regulations were intended for. After
the determination as to whether condensible matter is
to be regulated or not, then the proper sample train

ITI-31


Slide sequence

107-6

Key points

4. Calculate the calibration factor y for each run
and average the results.

5. If any y value deviates by more than 2 percent
from the average, the metering system is unaccept-
able. Otherwise, use the average as the calibra-
tion factor for subsequent test runs.

POSTTEST CALIBRATION
CHECK

After each field test series, conduct a calibration
check using the following parameters:

1. The leak check is not to be conducted,

2. Three or more revolutions of the dry gas meter
may be used.

3. Only two independent runs need be made.

4. If the calibration factor does not deviate by
more than 5 percent from the initial calibration
factor, then the meter volumes obtained during
testing are acceptable.

5. If the calibration factor deviated by more than
5 percent, recalibrate the metering system using
the full calibration procedure and for the cal-
culations use the calibration factor that yields
the lower gas volume.

THERMOMETER

The thermometer used to measure temperature of gas

leaving the impinger train should be calibrated using
the procedures reviewed gn Method 5. The thermometer
should agree to within 2 F at both calibration points.

The dry gas meter thermometer should also be cali-
brated using the procedures reviewed in Method 5.
The thermometer should agree to within 5.4°F at both
points.

ROTAMETER
The rotameter does not need to be calibrated but

should be cleaned and maintained according to the
manufacturer's instructions.

1-66


Slide sequence

151-6

151-7,

Key Points
EPA Method 4
Volume of water vapor condensed - W(std) ({DSCF)
(Vv Vv.) e. RT
Vw(sta) = f 5 i a std
std ow
Ky (Ve - v;)
where

Ww(std) = volume of water vapor condensed corrected
to standard conditions

Kk, = 0.001333 m3/ml for metric units and
0.0471 ft?/ml for English units

Ve = final volume of condensed water, ml/g

vy = initial volume, m1/g

Py «= density of water, 0.9982 g/ml (0.002202
1b/m1)

R = ideal gas consfant: 0.06236 (mm Hg)

(m?)/(g-mole)(°K) for metric ugits and
21.83 Gn. Hg) (ft?) (1b- mote) ( R) for
English units

Teta = tease) absolute temperature, 293°K

Potd = standard absolute pressure, 760 mm Hg
(29.92 in. Hg)

My = molecular weight of water, 18. -0 g/g-mole
(18.0 1b/1b-mole)

Moisture content (B,,.)

= Ywe(std)

8
ws Ywe(std) * Vin(std)

where:

Bus = proportion of water vapor, by volume, in
the gas stream

1-94


Slide sequence

205-0

205-1

205-2

205-3

Key Points

Speaker should give objectives of lecture and point
out reference materials.

The pretest meeting should be attended by all three
parties involved in the performance test.

1, The Regulatory Agency
2. The Industry
3. The Test Consultant

The first item of business is to establish official
lines of communication.

The pretest meeting checklist can be used in designat-
ing the-responsible person to be contacted from each
of the three organizations involved.

The next items to be discussed are plant entry and
safety requirements, acceptability of sampling sites,
and changes or modifications to the testing methodo-
logy.

The Pretest Plant Requirements and Testing Methodo-
logy Data Sheet provide a worksheet for these dis-
cussions.

Plant Requirements

Safety - Any required safety equipment needed by visi-
tors in the plant should be specified at this time
along with who will provide the equipment. Any manda-
tory safety briefings should also be mentioned and
scheduled if possible.

Entrance - Which gate should be used for entry and
exit? How will the passes be handled? Will new
passes be required each day?

Other - Any special conditions etc. that everyone
should be aware of.

Sample Site - Information regarding the sample site
and number of points required.

II-18


LECTURE 206
OBSERVING THE TESTS

OBJECTIVES

The objectives of this lecture are to familiarize the student with techniques
for observing on-site testing and to review a prepared checklist to illustrate its
value to the observer. Specific items to be discussed include:

1. use of prepared checklists,
2. systems audits, and
3. performance audits

At the conclusion of this lecture, the student should be familiar with the use
of prepared checklists as an aid to the observer in the field and some techniques
for observing tests.

II-21


Slide sequence

104-11

104-12

104-13

Key points

These devices operate similarly to the orsat by
absorbing the gas in a colored solution; then the
volume absorbed is read directly on a scale as per-
centage by volume.

CALIBRATION

Analyzers
Calibration is recommended:

Initially and before any field test in which
the analyzer has not been checked during the
previous three months.

Frequently used analyzers should be calibrated
prior to every third field test.

To check the 02 absorbing reagent and operator tech-
nique, determine the percentage of 02 in air. The
average of three replicates should be 20.8 +0.7% when
using the standard orsat.

A measured average value >21.5% generally indicates
poor operator technique while a value <20.1% generally

- indicates leaking valves, spend absorbing reagent

(for 02 only), and/or poor operator technique.

The three replicates and their averages should be
reported on an x and R chart.

A more thorough check would be to analyze a calibra-
tion gas containing a known mixture of CO2 and 02.

The average of the three replicates should be +0.5%
of the known concentration of each gas.

Again, high measured values indicate poor operator
technique, while low values indicate leaking valves,

“spent absorbing reagent, and/or poor ‘operator tech-

nique.

Rate meter

Clean and calibrate the rate meter in the integrated
sampling train every six months and at any sign of
erratic behavior.

1-32


Slide sequence

302-0 (cartoon or
title)

302-1

302-2

302-3

302-4

Key points

Speaker should give objectives of lecture and point
out reference materials.

There are many high temperature sources. Three of
the more common sources are 1) incinerators, 2) gas
turbines, and 3) glass furnaces.

This is a picture of a tester trying to test a pack-
age incinerator that is used to burn cardboard boxes
at a grocery store. Note: the testing team had to
add a sheet metal stack extension since there were

no ports in the refractory lined port. The team also
had to use a bucket truck to get access to the duct.

Several problems occur with the probe at temperatures
that cannot be handled by the standard glass-lined
probes.

1. Achieving air tight seal between the nozzle and
probe liner. The Teflon ferrels or Viton 0-ring-
will reach their softening point before the glass-
liner does. These must be replaced with asbestos
string to achieve the seal.

2. Breakage of the glass-liner is very common since
there is a difference in the coefficients of thermal
expansion between the glass probe liner and metal
sheath.

Some test teams have solved this problem by having
a spring loaded liner. The tension of the spring
keeps the seal tight and also allows for the differ-
ence in the thermal expansion.

This is a picture of how the Teflon ferrel or Viton
O-ring is removed and asbestos string added to main-
tain the seal. The asbestos string does not provide
the same tightness as the other method so the final

leak check procedures are different with the use of
asbestos string.

III-8


Slide sequence

307-0 (cartoon or
title)

307-1

307-2

307-3

307-4

307-5

Key points

The speaker should give the objectives of the lecture.
(No reference material was available on this topic.)

The fluctuating velocity is broken down into four
categories for discussion’/purposes. The four cate-

gories are noted.

If the fluctuating velocities are minor and occur

in short time intervals, two procedures are noted to
dampen the variations and give a more stable reading.
The two procedures are noted.

This picture shows how an additional pitot tube line
is used to dampen fluctuations. There is no adverse
effect from this procedure. The additional line in

effect integrates the fluctuations.

The addition of a capillary tube will have the same
effect. The picture of a capillary tube is shown.
This method is less desirable to the pitot tube line
because if the capillary tube is too small, there
will be too much lag time in obtaining the proper
readings.

When major variations occur in a short time interval,
the additional pitot tube line should again be added.
The isokinetic flow can be set to be readjusted

every two minutes. When the fluctuating is too major
to make the corresponding isokinetic rate adjustment,
the impact of the fluctuation can be calculated and
the isokinetic rate modified accordingly to compensate
for the wild variations.

III-34


Slide sequence

102-0 (cartoon
or title)

102-1

102-2

102-3

Key points

Speaker should give objectives of lecture and point
out reference materials.

Importance of site selection to obtaining an accurate,
representative sample.

Ideal site location requirements of two diameters
upstream and eight diameters downstream from flow
disturbance.

Minimum location requirements of two diameters down-
stream and a half diameter upstream from any flow
disturbance.

Typical flow disturbances include bends, expansions
or contractions in the stack, and visible flame.

DISCUSS DISTANCES A AND B
Example for circular stacks

Procedure for determining distance B: (measure from
last disturbance to the sample site)

Procedure for determining distance A: (measure from
sample site to outlet of stack or disturbance)

Measure inside diameter of stack

Determine duct diameters from distance B: (divide
inside diameter of stack into distance B)

Determine duct diameters from distance A: (divide
inside diameter of stack into distance A)

Discuss example

I-8


Slide sequence

251-4

251-5

251-6

251-7

Key Points

to use the options that do not require administrator
approval, it should always be noted in the source
test report. Likewise, options that are approved by
the administrator should also be noted in the source
test report.

Potentially acceptable options are those that must
receive agency approval. If the option could have
national or regional impact, it should be sent to
the proper level for approval. If the option is site
specific, then the State agency can approve the
option which should include the points noted.

The decision must always be made at least at the
minimum level which can effect enforcement decisions
in the future.

An alternative method can be approved at the EPA
regional office level if the method has the proper
supporting evidence to show that it will be adequate
for the demonstration of compliance.

No criteria has yet been developed for equivalent
methods. An equivalent method would be evaluated at
the EPA headquarters level and would likely be pub-
lished as such in the Federal Register.

II-39


Slide sequence

254-5

254-6

254-7

254-8

Key points

In an effort to validate the data, four equations are
given to calculate the heat input rate. If the agency
can use at least three of these methods, a good data
validation can be made on the measured flow rate and
resulting reported percent isokinetic. Using the
F-factor, equation 1 uses the measured flow rate to
calculate the heat input rate. The F-factor calcula-
tion counts only the fuel actually combusted. (If
80% of the fuel is combusted, the other 20% is not
counted by the F-factor since it does not require
air for combustion. )

This equation uses the fuel firing rate. Most facili-
ties do not have very good calibration on their fuel
feed monitoring device, but this method should be
used as a check.

This equation uses the power and heat rate. Most
facilities try to keep good records on the quality
of fuel combustion. A good average value is about
10 million Btu's per megawatt or 10,000 Btu's per
kilowatt.

The last equation is usually used for small boilers
that do not generate electricity. The equation cal-
culates the heat input based on the amount of steam
generated and the thermal efficiency required to
generate the steam. If the thermal efficiency is un-
known, an estimate can be obtained from the next slide.

11-49


Slide sequence
301-6

301-7

301-8

301-9

Key points

This is a diagram of a stack extension installed on
a squirrel cage blower.

Sheet metal is a good material for the extension due
to its resistance to high temperatures, its rigidity
and its relatively light weight. Plywood is often
used when high temperature is not a factor.

This is a diagram of a stack extension installed on
a vane axial fan.

Note: a flow straightener has been added to remove
the cyclonic flow.

An extension which will not bias test results is
desired, however, one which introduces a high bias
will be acceptable for the purpose of determining
compliance.

This is a picture of the addition of a plywood stack
extension.

In order to conform to EPA's Method 1 guidelines,
the extension would have a length equal to ten

times its diameter. In no case should the length

be less than 2 1/2 diameters. Of course, the smal-
ler the diameter, the more manageable the apparatus
becomes. A lower limit of about 24 inches in dia-
meter should be observed, so that probe blockage will
not become a factor during sampling.

Exit velocity of the effluent must also be considered.
S-type pitot tubes are unreliable at flow signifi-
cantly below 600 feet per minute.

Approach II is used when confining the emissions are
impractical. The equipment and procedures for this
condition should be agreed upon prior to the actual
test. Both the source and agency should agree on a
written test protocol. EPA Method 5D was designed
to help develop a protocol for sampling pressurized
baghouses that do not have a duct. This requires
the use of a Method 5 sample train. Open-faced high
volume samplers have also been used but some prelimi-
nary data tends to indicate that the use of open-faced
high volume samplers give lower results than the EPA
Method 5 sample train.

III-5


Slide sequence

106-4

106-5

Key points

Alternatively, metal liners (316 stainless steel or
other corrosion resistant metals) made of seamless
tubing may be used, subject to approval of the
administrator.

A type S pitot tube as described in Method 2 shall
be attached to the probe to allow constant monitor-
ing of stack gas velocity.

Two differential pressure gauges as described in
Method 2. One gauge shall be used for velocity head
(AP) readings, and the other for orifice differen-
tial pressure readings.

A filter holder constructed of borosilicate glass
with a glass frit filter support and a silicone
rubber gasket.

Other materials of construction such as stainless
steel, teflon or viton may be used, subject to
approval of the administrator. The holder design
shall provide a positive seal against leakage from
outside or around the filter. The holder shall be
attached immediately at the outlet of the probe or
cyclone, if used.

Any filter heating system capable of maintaining a
temperaturg around the filter holder during sampling
of 248 +25°F, or such other temperature as specified
by the standard or approved by the administrator.

Alternatively, the tester may opt to operate the
equipment at a temperature lower than that specified.

A temperature gauge capable of measuring temperature
to within 5.4°F shall be installed for monitoring
and regulating the temperature around the filter
holder during sampling.

The condenser consists of the same impinger train
described in reference method 4.

The metering system consists of:
vacuum gauge

1-49


LECTURE 102
EPA METHOD 1 - SAMPLE AND VELOCITY TRAVERSES FOR
STATIONARY SOURCES
OBJECTIVES

The objectives of this lecture are to familiarize the student with the
following sample site selection and preparation techniques:

1. selecting the proper measurement site for circular and
rectangular stacks,

2. determining the correct number of traverse points and
dividing the stack into the appropriate number of equal
areas, and

3. performing the test to verify the absence of cyclonic flow.

At the conclusion of this lecture the student should be proficient in perform-
ing the tasks listed above and be familiar enough with the methodology to
observe and review sample site selection, sample point layout, and the per-
formance of the test to verify the absence of cyclonic flow.

1-7


Slide sequence Key points

If means other than silica gel are used to determine
the amount of moisture leaving the condenser, it is
recommended that silica gel (or equivalent) stil]

be used between the condenser system and pump to pre-
vent moisture damage to the pump and meter and to
avoid the need to make corrections for moisture in
the metered volume.

The cooling system is comprised of an ice bath con-
tainer and crushed ice to aid in condensing moisture.

The metering system is the same as used in Method 5
and will be discussed in more detail in that method.

Barometer is the same as described in Method 2.

Graduated cylinder and/or balance to measure condensed
water and moisture in silica gel to within 1 ml or
0.5 9. Graduated cylinders shall have subdivisions

no greater than 2 ml.

105-5 Procedure

Traverse points as determined by Method 1 shall be
used.

Select a total sampling time such that a minimum _
total gas volume of 21 scf will be collected, at a
rate no greater than 0.75 cfm.

When both moisture content and pollutant emission
rate are to be determined, the moisture determination
shall be simultaneous with and for the same total
length of time as the pollutant emission rate run.

Set up sampling train and leak-check without probe
(pretest leak check optional).

During the sampling run, maintain a sampling rate
within 10% of constant rate.

After sampling, disconnect the probe and conduct

a leak-check (mandatory). If leak rate exceeds
allowable, the results may be rejected or the sample
volume may be corrected as illustrated in method 5.

Verify the constant sampling rate. Determine the
AVm for each time increment. Calculate the average.
If the value for any time increment differs from
the average by more than 10%, reject the results and
repeat the run.

1-42


LECTURE 205
PRETEST MEETING

OBJECTIVES

The objectives of this lecture are to familiarize the student with the
pretest meeting, the items that are discussed, and the forms used in finalizing
the test plan. Specific items to be discussed include the following:

1. establishing official lines of communication,
2. plant safety and entrance requirements,

3. pretest agreement on facility operations, and
4. pretest agreement of continuing compliance

At the conclusion of this lecture, the student should be familiar with
the pretest meeting format and the importance of planning to a successful
test program.

II-17


Slide sequence

103-19

103-20

103-21

103-22

Key points

Measure the misalignment of the centerlines,
angle 6 (theta for calculating w)

measure the distance from the base of each leg
of the pitot tube to its face opening plane,
dimensions Pa and Pa using a dial calliper

Measure the diameter of the tube, Dee using
a dial calliper

Record data on pitot tube inspection data sheet and
determine if measured values are within the published
criteria.

1. ai and a2 must be Tess than 10 degrees
2. 6B, and B2 must be less than 5 degrees

3. calculate z, the distance by which the legs are
unequal using the equation z = Asin y. z should
be less than 1/8 in.

4. calculate w, the distance by which the legs are
unequal using the equation w = A sin 6. “w should
be less than 1/32 in.

5. P, and P,, the base-to-opening plane distances,
should be eqtial and P between 1.05 and 1.50 times the
tube diameter; calculate A the distance between the
tips, A= Pa + Pe

I-29


Slide sequence Key points

103-4 PITOT TUBE

The type S pitot tube is made of metal tubing
(stainless steel) that is between 3/16 and 3/8 in.

A properly constructed pitot tube will have:

face opening planes perpendicular to traverse
axis

face opening planes parallel to longitudinal
axis

both legs of equal length and center lines
coincident when viewed from both sides

A pitot tube constructed to these specifications will
have a baseline coefficient of 0.84.

103-5 Differential pressure gauge

An inclined manometer or other suitable differential
pressure measuring device is used to read the velocity
pressure (AP).

Most sampling trains are equipped with a 10" (water
column) inclined-vertical manometer, having 0.01 in.
H,0 dividions on the 0 to 1 in. inclined scale, and
O71 in. H,0 divisions on the 1 to 10 in. vertical
scale. 2

This type manometer (or other gauge of equivalent
sensitivity) is satisfactory for the measurement
of AP values as low as 0.05 in. H,0.

A differential pressure gauge of greater sensitivity
shall be used if any of the following conditions
exist:

1. The arithmetic average of all AP readings
at the traverse points in the stack is less
than 0.05 in. H,0.

2. For traverses of 12 or more points, more
than 10% of the individual AP readings are
below 0.05 in. H,0.

3. For traverses of fewer than 12 points, more
than one AP reading is below 0.05 in. H,0.


LECTURE 101
INTRODUCTION TO SOURCE SAMPLING

OBJECTIVE
The objective of this lecture is to familiarize the student with the fol-

lowing concepts:

1. the purpose of source sampling,
2. basic terminology and nomenclature, and
3. the stack sampling flow diagram.

At the conclusion of this lecture the student should be familiar with the
basic concepts of particulate and gaseous sampling have an understanding of
the basic terminology used in the source sampling field.

1-3


Slide sequence

208-0

208-1

208-2

Key Points

Speaker should give objectives of lecture and point
out reference materials.

The observer should always make an effort to make
some type of a summary report soon after returning
from the field. The observations to be recorded
are as noted.

Results of the performance test shall be submitted
to the agency by the facility representative in the
form of a test report. The report should include as
a minimum the following:

1. Certification by the test team leader that sampling
and analytical procedures and data presented in the
report are authentic and accurate.

2. Certification by a responsible representative of
the testing firm (preferably by a professional engi-
neer) that all the testing details and conclusions
are accurate and valid.

3. Certification by the facility representative that
process data appearing in the report are accurate.

4, Legible data sheets with all applicable blanks
filled in.

5. All calculations made using applicable equations
from the Federal Register. Example calculations should
be included for at least one run.

6. Final results must be presented in English and
metric units and contain two significant digits for
each run. All rounding off of numbers will be per-
formed in accordance with the ASTM 380-76 Procedures.

I-30


Slide sequence Key Points

202-0 (title or ;
cartoon slide) Speaker should give objectives of lecture and point
out reference materials.

202-1A (cartoon slide)

202-1 The first step of determining the applicable regula-
tion can many times be the most important one. Since
many sources differ in construction and operation
it may be difficult to determine the intended appli-
cation from the regulations. The three items noted
must be determined and, if necessary, receive the

proper approval of both the legal and technical
staff.

202-2A (cartoon slide)

202-2 The EPA and its designated representatives have the
right of entry under Section 114 of the Clean Air
Act. The agency should establish contact with the
source early enough to allow sufficient time to
resolve any problems. The agency should require
the industry to submit a written testing protocol
that describes the proposed facility operations and
testing procedures for the performance test.

202-3A (cartoon slide)

202-3 After receiving the written testing protocol from the
facility, the agency should review all existing infor-
Mation on the source and establish a testing protocol
(design the experiment) that would be acceptable to
the agency and would baseline the facility.

4Note: The cartoon slides are optional. The instructor may use 1) the
cartoon slidé followed by the word slide, 2) only the cartoon slide since

the word slide is included in the manual, or 3) only the word slide if
the cartoon slides are not desired.

11-6


Slide sequence Key Points

The absorbing solution consists of concentrated
H2S0,, deionized distilled water, and 3 percent
hydrogen peroxide. ‘the absorbing solution must be
used within 1 week of its preparation and if
possible within 24 hours. Store in a dark-colored
bottle and do not expose to extreme heat or direct
sunlight.

Standard KNO; solution is prepared by dissolving
2.198 g of dried potassium nitrate (KNO3) in
deionized distilled watér and diluting to 1 liter
with deionized distilled water.

The working standard KNO; solution is prepared by
diluting 10 ml. of the standard solution to 100 mi.
with deionized distilled water. One milliliter

of the working solution is equivalent to 100 mg.
nitrogen dioxide (NO2).

Other reagents are prepared according to the method
or purchased ready to use.

108-5 CALIBRATION

Collection Flask. Assemble the clean flasks and
valves and fill with water at room temperature to
the stopcock.

Measure the volume to +10 ml by transferring the
water to a 500-ml glass (class A) graduated cylinder,
perform duplicate volume determinations, and use the
mean value.

Number each flask and record the volume mean value
on the flask or foam encasement.

This volume measurement is required only on the initial
calibration if the flask valves are not switched.

1-74


Slide sequence
103-33

103-34

Key points

Velocity measurement procedure

1. Leak-check the pitot tube and differential
pressure gauge assembly.

This is accomplished by blowing through the impact
opening until a reading of at teast 3 in. H,0 regis-
ters on the gauge. Seal the pressure openifia and
observe the gauge reading for 15 seconds. If the
reading does not drop, the impact side is leak-proof.
Repeat the procedure on the suction side of the pitot
assembly by applying suction to the other pitot tube
leg.

2. For circular stacks less than 10 ft in diameter,
two ports along diameters at right angles to each
other and in the same plane are sufficient. How-
ever, when the stack diameter is greater than 10 ft,
the use of four ports, one at each end of the two
diameters, is desirable to avoid the use of extra
long pitot tubes.

3. If it is necessary to use a type S pitot tube
longer than 10 ft, it should be structurally rein-
forced to prevent bending of the tube and misalign-
ment errors.

4. Each sampling port and traverse point should be
identified by a number or letter and designated on
a sketch of the site.

5. Measure the velocity head and temperature twice
at each traverse point accessible from a given port
by measuring each point once as the pitot tube is
inserted into the stack and moved across the stack's
diameter and repeating the measurement as the pitot
tube is withdrawn from the port.

6. Care should be taken to prevent touching the
pitot tube tip to the side of the stack.

7. All unused sampling ports must be plugged and the
port being used should be sealed as tightly as pos-
sible to minimize any disturbance to the gas flow
pattern when making a velocity measurement. The port
being used can be sealed with asbestos material, pre-
cut sponge, or duct tape depending on the temperature
of the stack gas.

1-25


Slide sequence

253-0

253-1

253-2

253-3

Key points

Speaker should give objective of lecture and point
out reference materials.

The legal requirements placed on the facility as
stated in Section 60.8(e) are noted.

Since the test team has been paid by the facility to
perform a test, they are usually reluctant to refuse
to test when unsafe conditions exist. However,
Federal regulations require that the facility pro-
vide safe access; otherwise, the observer should dis-
allow testing under unsafe conditions. Testing data
will likely be questionable if gathered when unsafe
conditions exist.

Safety problems are described in detail in this
lecture. The instructor should advise all attendees
to read the paper for their own benefit. Some defi-
nitions are listed below.

1. Physical injury - The causes of physical injuries
are too numerous to list; however, they can be
minimized if all the OSHA requirements are met.

2. Electrical shock - The greatest danger of electri-
cal shock is that of high voltage lines near the
sampling site.

3. Fire - Many pollutants are combustible. The
agency should be aware if there are restrictions
on open flames or nonintrinsically safe electri-
cal systems.

4. Exposure to heat and cold - Common sense should
be exercised when working in extreme weather con-
ditions. The testing equipment is subjected to
the same conditions and generally works as poorly
as the personnel under these conditions.

11-44


Slide sequence

102-11

102-12

102-13

Key points

For rectangular stacks with 12 points, the grid con-
figuration is a 4 x 3 matrix. Each point is placed
as illustrated. The situation of traverse points
being too close to the stack wall is not expected to
arise with rectangular stacks.

Slide 102-12 illustrates the exact location of the
traverse points in a 4 x 3 matrix layout for a 36 in.
duct.

Nonparallel flow determination

In most stationary sources the direction of stack
gas flow is essentially parallel to the stack walls.

Cyclonic flow may exist after cyclones and inertial
demisters following venturi scrubbers or in stacks
having tangential inlets or other configurations
which tend to induce swirling. In these cases, the
presence or absence of cyclonic flow at the sampling
location must be determined.

I-11


LECTURE 252
ENFORCEABILITY CRITERIA FOR DEVELOPMENT OF COMPLIANCE TEST METHODS

OBJECTIVES

The objective of this lecture is to discuss the criteria that should be
applied to all existing and the development of any new compliance test methods.
The criteria have items that are mandatory, necessary, and for the enhancement
of compliance test methods.

At the conclusion of the lecture the student should be able to evaluate
any compliance test method with the criteria discussed, and where necessary,
request that modifications be undertaken to further enhance existing test
methods for compliance testing purposes.

Note: Since the points on the slides are from the reference paper and
are self-explanatory, no instructor's notes are provided.

TI-41


Slide sequence

308-8

308-9

308-10

308-11

Key points

Since the final data results are on a 1b/10° Btu
basis, this equation is designed to average the re-
sults on that basis and give the final results on
the same basis. The 1b/10° Btu is multiplied and
divided by the theoretical or stoichiometric flue
gas volume. The summation equation is just a simple
addition of all of the sample runs.

To provide the required understanding, an example is
used as shown. This example assumes that the fourth
sample run is the soot blowing run. The run would
have been conducted during one of the 45 minute soot
blowing cycles. The run would have been conducted
for exactly 45 minutes. The minimum sample volume
and number of sample points does not have to be met
during the soot blowing run.

The first item to be calculated is the percent of time
that each sample run would account for each day or on
a continuing basis. The soot blowing accounts for

45 minutes 3 times a day. This is 9.375 percent of
the day. Each of the other three runs would account
for one third of the remaining time during the day
that soot blowing does not occur.

Next the theoretical or stoichiometric flue gas volume
must be calculated. This is done because 1b/10° Btu
has been corrected to this volume. The correction
uses the same oxygen value that was used to correct
the results to 1b/10° Btu in the F factor equation.
This must be done for all runs.

III-40


Slide sequence

104-6

104-7

Key points

Flexible bag - a leak-free plastic (Tedlar, Mylar,
Teflon) or plastic-coated aluminum bag may be used.
The bag should have a capacity consistent with the
selected flow rate and length of test. A capacity
of 55 to 90 liters is suggested.

Orsat analyzer - the orsat analyzer is used to deter-
mine the C02, 02, and CO stack gas concentrations.

A sample is analyzed by successfully passing it
through absorbents that remove specific gaseous com-
ponents.

The difference in gas volume before and after the
absorption represents the amount of the constituent
gas in the sampie.

Constant pressure and temperature must be maintained
throughout the analysis.

Results are reported as dry volume percentages.

The analyzer consists of:

A glass burette to accurately measure gas
volume;

A water jacket to maintain constant tempera-
ture;

A manifold to control gas flow;
Three absorption pipettes (CO, 02, and C02); °
Rubber expansion bags;

A liquid-filled leveling bottle to move the
gases.

The apparatus is usually assembled inside a case with
front and rear doors and a carrying handle.

For expected COz readings >4.0%, a standard orsat
analyzer containing a burette with 0.2-ml divisions
and spacing between divisions of about 0.04 in. is
satisfactory.

1-30


Slide sequence

304-8

304-9

304-10

304-11

304-12

304-13
Schematic

Key Points

A metal "hook," mounted in a micrometer barrel, is
carefully lowered until its point just contacts the
gauge fluid.

The instant of contact with the fluid is detected
by completion of a low power AC circuit.

On indication of contact, the operator stops lowering
the hook, and reads the micrometer to determine AP.

The full-scale range is 0 to 2 inches water column.
The micrometer scale is readable to the nearest
0.00025 in. H,0.

There are four alternative approaches for measuring
velocity at low flow conditions:

1. The use of techniques other than pitot tubes.

2. Modification of the source to effect a suffici-
ently high velocity for using the pitot tube.

3. Measure velocity at a different location and-use
data to calculate velocity at sampling site:

4. Compute the flow and velocity using process
parameters.

TECHNIQUES OTHER THAN PITOT TUBES

Pressure Drop Measurement Devices

Venturi meters - highly resistant to abrasion,
improdical for large ducts

Orifice meters - readily adaptable to large ducts,
extremely sensitive to abrasion and corrosion

Mass flow meters

Teledyne Hasting Mass flow meter - work well in
dirty gas streams, high moisture and low flow

Hasting Principle of Operation

1. Purge gas is injected into a pneumatic bridge

arrangement formed by the velocity transducer,
manifold and pitot tube.

IYI-19


LECTURE 309
SAMPLING PORT AND POINT LOCATION

OBJECTIVES

The objective of this lecture is to discuss the rationale of sampling
port location versus the number of sample points. Additional options will be
discussed and ranked according to the purpose of the test.

At the conclusion of this lecture, the student should be familiar with
the rationale of port and point selection and be able to choose the best feasi-
ble option when the sampling location does not meet the criteria of Method 1.

IIt-43


Slide sequence

153-11

153-12

153-13

153-14

153-15

153-16

Key Points

Again, the values must be obtained from prior
examples.

Both values are plotted for small and large particles.
No stack will contain al] small or all large particles
so the true biases will be in the colored area.

Only the mass is counted as a variable for the pollu-
tant mass rate on the ratio os areas basis. The mass
is obtained from the previous examples.

Pulling twice the volume results in twice the mass
of small particles. Pulling half the volume results
in half the mass. Mass is the only parameter.

You always get the same amount of large particles no
matter what rate is sampled. Therefore, you always
get the true value.

Again both the. small and large particles are plotted.
Since no stack has all large or all small particles
the actual bias will be somewhere in the colored area.

1-106


Slide sequence Key Points

251-8 The agency should use the criteria noted to deter-
mine if it can make the decision or if the request
should be relayed to the next level.

251-9 ‘Usually the bias concept is used when evaluating the
request for alternative procedures. The alternative
procedure must produce a measured pollutant of
equal or greater value.

251-10 The bias concept was used for allowing procedures
subject to the tester's disgression in the EPA reference
method. However, the agency should be aware that the
EPA reference methods are to be used by the industry
to demonstrate compliance with the Federal Regulations.
When the agency is performing the test, the procedures
that cause a high bias may not accomplish its pur-
pose. When the agency is trying to prove a violation,
these procedures should be avoided and, in some cases,
may have to be reversed to have the data results equal
to or lower than the true value. The use of the bias
concept depends on who is performing the test and
whether the source is trying to prove compliance or
the agency is trying to prove a violation.

251-11 This is the bias concept rule put in simpler terms.
251-12
251-13 The bias concept is not recommended in the four condi-

tions noted.

II-40


LECTURE 152
MISALIGNMENT OF THE PITOT TUBE

OBJECTIVE

The objectives of this lecture are to discuss the two types of pitot tube
misalignment and to review the magnitude of error caused by each type of mis-
alignment along with errors caused by nonstreamlined flow.

At the conclusion of this lecture the student should be familiar with
the two types of pitot tube misalignment and their effects on velocity.

1-99


Slide sequence

(The instructor will
demonstrate this pro-
cedure or illustrated
slides may be used)

102-14

Key points

To conduct the check for nonparallel flow:

1. Connect a type S pitot tube to a leveled and
zeroed manometer.

2. Attach an angle indicating device to the pitot
tube assembly or to the sampling port.

3. Insert the pitot tube so that the planes of the
face openings are perpendicular to the stack area
cross-sectional planes, i.e., parallel to the ex-
pected gas flow. The pitot tube is thus 90° from
its usual position.

4. When the gas flow is exactly parallel to the
stack walls and therefore parallel to the pitot tube
face openings, no reading will be obtained on the
manometer. If a reading is obtained, rotate the
pitot tube around its longitudinal axis until a zero
reading is indicated on the manometer.

5. Record the angle of rotation, a (starting with 0°
in the pitot tube's initial position), required to
obtain a zero manometer reading.

6. Traverse the stack area by measuring the angle
réquired to obtain a zero manometer reading at each
point. Keep the sampling port opening sealed with
a rag or sponge while traversing.

7. After the technique has been applied at each
traverse point, calculate the average of the absolute
values of a; assign a value of 0 to those points re-
quiring no rotation and include these in the average.

8. If the average value of a is greater than 10°,
the overall flow condition in the stack is unaccept-
able and alternative methodology, subject to the ap-
proval of the administrator, must be used.


Slide sequence Key Points

153-5 “Yn = Zs - means that the velocity at the face of
the nozzle is one half the velocity in the stack.
Therefore, half the required sample volume was collected.

153-6 The results show that when testing over-isokinetic,
the concentration is biased low even though a greater
mass will be collected on the filter. When testing
under isokinetic, the concentration will be biased
high even though less sample is collected on the filter.

153-7 There are two methods of calculating a pollutant mass
rate. EPA has chosen the first method. However, the
agency should be aware of both methods because there
is no proof that the other method is incorrect. It
may be advantageous for a source to use this method
for calculation.

153-8 When all the parameters that remain constant for this
example are removed the equations can be simplified.
(This will also simplify the teaching points. )

153-9 To obtain the number (gr) of small particles and the
sample volume, refer back to the examples with the
nozzle at varying isokinetic rates.

153-10 Since PMRc always gives the true value, it is plotted
on the true value line. (This is like taking a gaseous
sample which always gives the correct concentration no
matter what the sampling rate(s).

1-105


Slide sequence

309-0 (cartoon or
title)

309-1

309-2

309-3

309-4

Key points

Speaker should give objectives of the lecture and
point out reference material.

Method 1 criteria varies the number of sampling points
based on the sample port location. The criteria is
noted.

The rationale for increasing the number of points is
because the variation in velocity is probably greater
the further you get away from an ideal sampling loca-
tion (8 and 2 diameters). A teaching example is if you
want to get the average height of 50 men at a banquet
within +10. percent, you could likely pick any three
at random and measure the three, and average the re-
sults. However, if the banquet was for jockies and
NBA basketball players, you would have to select at
least 7 or the average results may not be within +10
percent. Therefore, the greater the variation, the
more points are required to obtain the desired ac-
curacy.

As discussed in the cyclonic or nonparallel flow
lecture, we have 4 known facts about nonparallel flow.
These facts are noted.

This is an example stack used to discuss the options
and biases of sample port location versus number of
sample points required. Location A requires the maxi-
mum number of sampling points. Location B requires
the minimum number of sampling points.

III-44


Slide sequence

154-7

154-8

154-9

Key Points

Picture of Methods Evaluation Train

Within laboratory is defined as the use of two test
teams from the same company. Between laboratory

is defined as comparing one company to another company.
The between laboratory precision is less because most
companies train their testers to use the same proce-
dures.

The average result for all test teams was assumed to
be the true value for all of these methods. The results
are as noted.

I-111


Slide sequence Key points

310-6 Conclusions are as noted.

IT1-49


Slide sequence

Key Points

The following information is requested as an attach-
ment:

1. Sampling Train Information - a detailed descrip-
tion of any sampling or sample recovery and transport
procedures which do not comply with procedures and
justification for deviation

2. Laboratory Analysis - a detailed description of
any analytical procedure and/or equipment which does
not comply with the specified procedures and justifi-
cation for deviation

3. Data Sheets - a sample of all field data sheets to
be used

4. Description of Process Operation - a description of
process operations to include as a minimum, the follow-
‘ing:

a. process flow sheet

b. maximum rated capacity

c. data normally monitored to ensure proper
operation

d. data to be monitored and recorded during
testing to ensure representative operations

@. normal process operation in a 24-hour period
(ies soot blowing, shut down, load shifts,
etc.

f. feedstock composition that tend to cause
greatest emissions and percentage of annual
production using this material

g. normal maintenance schedule

5. Description of emission control operation - a
description of emission control system to include as
a minimum, the following:

a. type and manufacturer of control equipment

b. all means of primary and secondary control
and their operation during testing

c. data to be monitored and recorded to ensure
representative operation during testing

d. minimum acceptable values of all control device
parameters, i.e., flow and pressure of liquids,
voltage and amperage of electrical input, normal
cleaning cycle, etc.

e. preconditioning of gases prior to control device
f. normal maintenance schedule on control equipment
TI-15


Slide sequence Key points
6. Repeat and average the titration volumes.
Replicate titrations must agree within 1 percent -
or 0.2 ml - whichever is larger.

7. Run a blank with each series of samples.

1-69


Slide sequence

108-9

Key Points

where: Ke = calibration factor

A, = absorbance of the 100-ug NO».
standard :

Az = absorbance of the 200-ug NO2
standard

A; = absorbance of the 300-ug N02
standard

A, = absorbance of the 400-ug NO»
standard

Calibrate mechanical vacuum gauges if used against
a mercury manometer.

Calibrate the barometer temperature gauge and analy-
tic balance using the procedures reviewed in the
other methods.

ON SITE SAMPLING

Pipette 25 ml of absorbing solution into a
sample flask. Insert the flask valve stopper
into the flask with the valve in the "purge"
position.

Place probe at the sampling point. Check and
make sure that all fittings are tight and leak-
free, and that all ground glass joints have been
properly greased with a high vacuum grease.

Turn the flask valve and the pump valve to their
evacuate positions. Evacuate the flask to 3 in.
Hg absolute pressure, or less. Evacuation to a

pressure approaching the vapor pressure of water
at the existing temperature is desirable.

Turn the pump valve to its “vent" position and
turn off the pump. Check for leakage by observ-
ing the manometer for any pressure fluctuation.
Any variation greater than 0.4 in. Hg over a
period of 1 minute is not acceptable and the
flask is corrected. Pressure in the flask
should be < 3 in. Hg absolute when sampling
commences.

1-76


Slide sequence
103-9

103-10

103-11

Key points

Static pressure

Static pressure must be measured accurately to within
0.1 in. Hg using one of the following sensors:

1. A piezometer tube and mercury or water filled
U-tube manometer.

2. The static tap of a standard pitot tube.
3. One leg of a type S pitot tube.

Barometric pressure

Barometric pressure must be measured accurately to
within 0.1 in. Hg.

A mercury, aneroid, or other barometer may be used
that meets accuracy requirements.

In many cases the barometric pressure may be obtained
from a nearby national weather station in which case
the station pressure (absolute barometric pressure)
is requested and an adjustment for elevation differ-
ences between the sampling site and weather station
is made.

The adjustment is applied at a rate of -0.1 in. Hg
per 100 ft elevation increase or vice-versa for ele-
vation decrease.

Gas density equipment will be covered in method 3.

Calibration techniques for pitot tubes

Calibration of the type S pitot tube consist of two
major parts:

the dimensional specification test, and if
required, wind tunnel calibration against a
standard pitot tube with an NBS-traceable
coefficient.

1-17


LECTURE 303
HIGH MOISTURE CONTENT

OBJECTIVES

The objectives of this lecture are to define the problems associated with
sampling in high moisture content stacks and to provide solutions. Several
likely sources of high moisture content will be provided and three sampling
trains designed for high moisture content will be discussed:

1. JACA train,
2. EPA train, and
3. Entropy train.

At the conclusion of this lecture, the student should be able to select a
suitable sampling method for high moisture content sources and specify addi-
tional procedures to help safe-guard from the common sampling problems that
result from the water condensation.

III-13


Slide sequence

153-17

153-18

153-19

Key Points

Both PMRc and PMRa are plotted. You can see that
each equation has the opposite bias for over- and
under-isokinetic sampling.

Since the biases are opposite for each equation, the
proposed EPA method, as noted, required the pollutant
mass rate to be calculated by both methods and
averaged. The promulgated method only used PMRc.

The agency should be aware of the different methods
and can determine PMRa by multiplying PMRc by the
percent isokinetic divided by 100.

1-107


Slide sequence

103-24

103-25

Key points

-The procedure consists of:

Label one leg of the Type S pitot tube A and the
other B

Adjust the fan speed or intake area to give a desired
velocity head as measured by the std pitot tube and
record AP sta

Check alignment of type S pitot tube, read and
record the velocity head AP(s)

Repeat until three sets of velocity head measurements
are obtained for each side of the pitot tube

Calculate Cp(s) according to example on slide
Calculate the deviation according to example on slide

Calculate the differences between the average C. pth)
and c,(8) according to example on slide

Use the type S pitot tube only if the deviation from
both sides are equal to or less than 0.01 and the
absolute value of the differences between C pA) and
C (8) is less than or equal to 0.01.

Differential pressure gauge

Differential pressure gauges other than manometers
must be calibrated prior to use and their calibra-
tion checked each test series using the following
procedure:

1. Connect the differential pressure gauge to a
gauge-oi] manometer.

2. Vent vacuum side to the atmosphere and place a
pressure on each system.

3. Compare Ap readings at a minimum of three points
representing the range of Ap values to be encountered.
Follow the same procedures on the vacuum side by
venting the pressure side to the atmosphere and by
putting a vacuum on the system.

4. The posttest calibration should be performed at
the average Ap.

4
fi

ny

nN


Slide sequence

106-14

106-15

Key points

1. Place both the reference thermometer and the test
thermometer in an ice bath. Compare readings after
they stabilize.

2. Remove the thermometers from the bath and allow
both to come to room temperature. Agains, compare
readings after they stabilize.

3. The test thermometer is acceptable if its read-
ings agree within 2°F of the reference thermometer
reading at both temperatures.

Dry gas thermometers

The dry gas thermometers should initially be compared
with a mercury-in-glass thermometer which meets the
criteria specified above, and the following procedure:

1. Place the thermometers in a hot water bath 105°
to 1220F. Compare readings after stabilization.

2. Allow thermometers to come to room temperature
and compare readings after stabilization.

3. The dry gas meter thermometers are acceptable
if the values agree within 5.4°F at both points or
if the temperature differentials at both points are
within 5.4°F and the temperature differential is
taped to the thermometer.

Probe heater

The probe heating system should be calibrated prior
to field use according to the procedure outlined in
APTD-0576. Probes constructed according to APTD-0581
need not be calibrated if the curves of APTD-0576 are
used.

Balances

The analytical balance should be checked using
class-S weights. The balance should be adjusted to
agree within +2 mg of the class-S weight.

The trip balance should be checked using class-S
weights and adjusted to agree to within +0.5 grams
of the class-S weight.

Other

Stack temperature sensor calibration per Method 2
Barometer calibration per Method 2

Pitot tube calibration per Method 2

1-53


LECTURE 153
ISOKINETIC SAMPLING

OBJECTIVES

The objectives of this lecture are to define isokinetic sampling and
to discuss the effects of nonisokinetic sampling.

At the conclusion the student can determine potential effect of non-
isokinetic test data and as a result better interpret compliance test data.

1-103


Slide sequence

104-16

104-17

Key points

1. Locate the sampling points according to the pro-
cedures described in method 1:

8 points for a round stack less than 24 in. in
diameter

9 points for a rectangular stack with an equivalent
diameter less than 24 in.

12 points for a larger stack
2. Leak-check the bag and purge the sampling train

3. Sample each point at the same rate and for the
same time increment. Collect 30 to 90 2 of gas
simultaneous with the pollutant emission test.

Flexible bag leak check procedure

1. Connect bag to a manometer and pressurize the bag
to from 2 to 4 in. H20.

2. Allow bag to stand for 10 min. Any displacement
in the water manometer will indicate a leak.

An alternative procedure is to pressurize the bag to
2 to 4 in. H20 and allow it to stand overnight. A
deflated bag indicates a leak.

Integrated sample train leak check procedure

1. Attach a vacuum gauge to the condenser inlet,
draw a vacuum of 10 in. Hg and plug the line where
the bag attaches.

2. Turn off the pump and observe the vacuum reading
for 30 seconds; it should remain stable.

3. If vacuum drops, check the system for leaks and
repair.

These leak checks are optional but highly recommended.



Slide sequence

304-20

304-21

Key Points

MODIFICATION OF SOURCE TO INCREASE VELOCITY

The velocity of a gas stream confined to a duct is inverse-
ly proportional to the cross-sectional area of the duct.

In this approach you increase the velocity by using a
stack extension with a smaller cross-sectional area.

The extent of the cross-sectional reduction will depend
on the original velocity of the gas; an increase to about
600 feet per minute should be achieved.

A lower area limit of about one square foot should be
observed to avoid biased readings due to probe blockage.

A method which is being studied for positive pressure
baghouses consists of:

Measuring velocity and flow at the inlet and calculating
the flow at the outlet.

Set the isokinetic sampling rate based on the calculated
velocity.

Installing a pitot tube at a point of average velocity
in the inlet duct. This pitot tube is monitored during
the test to detect any flow changes.

COMPUTATIONAL METHODS

Within any given fuel category, the ratio of the quantity
of dry effluent gas generated by combustion to the gross

calorific value of the fuel is a constant. This ratio is
known as the dry F (Fy) factor.

Values for F, for numerous types of fuel, have been com-
puted and cal be obtained from a table. Knowing F factor
along with the heat input rate and dry oxygen concentra-
tion of the effluent gas, the volumetric flow rate is
detainable.

Experience has shown that flows calculated using these
methods are significantly lower than measured rates.
Aerodynamic interferences and pitot tube misalignment
are factors which can produce measured values higher
than the actual flow rate.

IlI-21


Slide sequence

208-3

Key Points

The source test report should be prepared in the
following format:

Cover.

1. Plant name and address

2. Source sampled

3. Testing company or agency, name and address
Certification

1. Certification by team leader

2. Certification by reviewer (P.E.)

Introduction
1. Purpose of test
Process tested
3. Test dates
4. Pollutants tested
5. Names of observers (industry and agency)
6. Any other background information
Summary of Results
1. Emission results

2. Process data (as related to determination of
compliance)

3. Allowable emissions

Description of collected samples
5. Visible emissions summary
6. Discussion of errors, both real and apparent
Source Operation
1. Description of process and control devices
2. Process and control equipment flow diagram

3. Process data and results, with example calcula-
tions

4. Representativeness of raw materials and products
5. Any specially required operation demonstrated

II-31


Slide sequence

103-12

103-13

103-14

Key points

Dimensional specification test

Some tolerances in the construction specifications of
a type S pitot tube are allowed without affecting its
Cp. These consist of:

1. from the end view, face opening plane misalignment
a, and a2 must be less than 10 degrees.

2. from the top view, 8:1 and B2 must be less than
+5 degrees.

3. from the side view, z, the distance by which the
legs are unequal less than 1/8 in. and w the dis-

tance between centerlines of the tubes, less than 1/32
in.

To check construction specifications obtain a section
of angle aluminum approximately 8.0 in. long 0.5 x
1.0 in. Mount a bull's eye level (with +1 accurary)
to the angle aluminum.

Check the accuracy of the assembly by leveling the
bull's eye level and place a degree indicating level
parallel to the longitudinal axis, perpendicular to
the longitudinal axis and verticle along the base of
the angle aluminum. The degree indicating level
should not read more than 1~ in any position.


Slide sequence

107-5

Key points

blank at 353 nm of a spectrophotometer. If absor-
bance exceeds 0.1 reject the alcohol for use. Peroxide
may be removed from isopropanol by redistilling or by
passage through a column of activated alumina, however,
reagent grade isopropanol with suitably low peroxide
levels may be obtained from commercial sources.
Therefore, rejection of contaminated lots may be a
more efficient procedure.

Three percent hydrogen peroxide should be prepared
fresh daily.

The barium perchlorate solution should be standardized
against standard sulfuric acid to which 100 ml of 100
percent isopropanol has been added.

The sulfuric acid standard 0.0100 N should be stan-
dardized against 0.0100 N sodium hydroxide which has
been standardized against potassium acid phthalate
(primary standard grade).

CALIBRATION
METER SYSTEM

The sample meter system--consisting of drying tube,
needle valve, pump, rotameter and dry gas meter--

is calibrated before its initial use and the calibra-
tion checked after each field test series.

1. Leak check the metering system by placing a vacuum
gauge at the inlet to the drying tube and pull a
vacuum of 10 in. Hg; plug the outlet of the flow
meter and turn off the pump. The vacuum must
remain stable for at least 30 seconds. Carefully
release the vacuum gauge before releasing the flow
meter end.

2. Calibrate the metering system at the sampling
flow rate specified by connecting an appropriately
sized wet test meter to the inlet of the drying
tube.

3. Make three independent calibration runs of at
least five revolutions of the dry gas meter per
run.

1-65


Slide sequence Key Points

207-12 The use of a standardized data sheet and plant per-
sonnel is the most effective and efficient means of
recording facility operation.

207-13 If the facility operating parameters are set and

recorded properly, the agency has established the
basis for the items noted.

207-14 This note of interest demonstrates why there is a
greater demand for continued compliance using the
existing air pollution control equipment than there
is in adding additional controls.

11-27


Slide sequence Key Points

203-0 | Speaker should give objectives of lecture and point
out reference materials.

203-1 As the official representative of the agency the

observer plays a key role in the performance test
program.
ROLES

1. Preparing and planning the test

2. Observing process operations

3. Observing control equipment operations

4, Observing performance testing methodology
5

. Documenting and summarizing all activities during
the testing program

6. Reviewing test report for completeness and audit-
ing data for accuracy

203-2 The observer's responsibilities include:

1. Specifying all agency requirements during all
phases of the test.

2, Making decisions regarding process and control
equipment operation along with reporting
requirements during the planning phase.

3. Determine representativeness of process and
control equipment operation during the test.

4, Determine if acceptable testing methodology is
being used.

5. Document occurrences during test in observer's
summary report.

6. Review test report for completeness and accuracy
and make recommendations as to the acceptability
of the test report.

I-10


LECTURE 204
ESTABLISHING TEST PROTOCOL

OBJECTIVES

The objectives of this lecture are to familiarize the student with the

test protocol and the performance test guidelines package. Specific items
to be discussed include the following:

1. purpose of test protocol,
2. performance test guidelines package, and
3. information required in the written protocol

At the conclusion of this lecture, the student should be familiar with
the protocol format and the importance of the protocol as a planning tool.

II-13


Slide sequence

101-0 (cartoon or
title)

101-1

101-2

101-3

Key points

Speaker should give objectives of lecture and point
out. reference materials.

The Purpose of Source Sampling

To

the Agency

Provides data to be used to formulate control
strategy

Provide data to evaluate source compliance with
regulations

Provide information upon which control regula-
tion can be based.

Industry

Provide information on process operation
Provide information on existing control device
efficiency

Provide information for designing new process
and emission control equipment.

BASIC TERMINOLOGY

There are three terms which are used to describe
what exists in a stack:

1.

Concentration - The quantity of a pollutant per
quantity of effluent gas. An example of this is:

grains (a weight unit)/cubic foot (a volume unit)

Stack gas flow rate - The quantity of effluent
gas passing up the stack per length of time. An
example of this is:

cubic feet (a volume unit)/hour (a time unit)

Pollutant mass rate - The quantity of pollutant
passing up the stack per length of time. An
example of this is:

pounds (a weight unit)/hour (a time unit)

1-4


Slide sequence

152-6

152-7

152-8

Key Points

These errors are also of a much larger magnitude than
those encountered from Type A misalignment.

If a pitot tube is aligned so that you have Type A
and Type B misalignment simultaneously, the resulting
errors would be approximately the sum of the two
individual errors.

Nonstreamlined Flow

There are two predominant cases of nonstreamlined flow:
1. Case 1 occurs after a bend or an elbow in the duct.

In attempting to measure the upward vector, the error
(with the pitot tube properly aligned with respect to
the stack) will depend on which of the three ports are
used.

2. Case 2 is called tangential or cyclonic flow which
normally occurs after a cyclone or a cyclonic scrubber.

There are only two velocity vectors, axially and tan-
gentially, so that regardiess of which port is used
the error is the same. The larger the tangential vec-
tor, the larger the error.

This curve illustrates the error which results when
the pitot tube is properly oriented with respect to
the stack wall but the gas stream is traveling at a
yaw angle (Type A misalignment).

The error represents the error from Type A misalign-
ment and the cosine of the angle between the flow and
the pitot tube.

Port Y in the diagram with a bend or elbow in the duct
will give errors corresponding to this figure.

Error associated with measuring velocity at a site with
tangential or cyclonic flow is also represented by
this figure.

1-101


Slide sequence Key points

105-0 (cartoon or Speaker should give objectives of lecture and point
title) out reference materials.
105-1 A gas sample is extracted at a constant rate from

the source. Moisture is removed from the sample
stream and determined volumetrically or gravi-
metrically.

The method is applicable for determining the moisture
content of stack gas.

105-2 SUMMARY OF METHODS

The reference method is used for an accurate deter-
mination of moisture content.

This method is usually conducted simultaneously with
a pollutant measurement test.

Results from this method are suitable for calculating
emission data and the isokinetic sampling rate.

The approximation method is used to provide an esti-
mate of percent moisture to aid in setting isokinetic
sampling rates prior to a pollutant emission measure-
ment run.

The method described is a suggested approach; altern-
ative means such as wet bulb-dry bulb, drying tubes,
stoichiometric calculations, etc., are also acceptable.

105-3 The partial pressure method is used to determine
: moisture content when gas streams are saturated or

contain water droplets. In those conditions, the
reference method may yield questionable results.
This method is to be conducted in addition to the
reference method. Moisture content will be calculated
by both methods and the lower of the two methods will
be considered correct.

1-40


Slide sequence

302-9

302-10

302-11

302-12

302-13

Key points

The advantages of the water cooled probe. is that it
will not break easily and it can provide some cooling
to the pitot tube and nozzle.

The disadvantages are 1) it may be reactive with the
effluent, 2) it is very heavy, 3) it requires a con-
stant supply of coolant material, 4) it can be very
dangerous and even explode if a safety valve is not
installed, and 5) in theory it will effect the flow
of the gases since the area around the nozzle is
much cooler than the stack gas temperature.

The best example of a special material probe is the
quartz glass probe shown in this picture.

The nicest feature is that the probe and nozzle is
made into a single unit as shown in this picture.

A green liquid was placed in the probe for picture
taking purposes. The nozzle size must be correct
after construction for isokinetic sampling since it
cannot be changed on site. The tester usually takes
about 5 probes each of two nozzle sizes that should
allow isokinetic sampling.

The advantages of the quartz probe are as noted.

The disadvantages are as noted.

At temperatures above the softening temperature of
the stainless steel pitot tube, the test will have
to be performed by making a quick preliminary tra-
verse with the pitot tube and assuming the flow is
the same for the test. The quartz probe and nozzle
are used without a sheath. An experienced test team
will average breaking less than one per field trip.
An inexperienced field team will likely not be able
to do all three runs with only 5 probes.

III-10


Slide sequence

206-0

206-1

206-2

206-3

Key Points

Speaker should give objectives of lecture and point
out reference materials.

Observing the on-site testing is perhaps the most
important aspect of the observer's responsibilities.
During this time, the attitude and behavior of the
observer are of utmost importancé. The observer
should make any special conditions known to aul
parties involved in the tests.

1. If testing is not to start before the observer
has checked facility operations and given the go
ahead this should be specified.

2. If the observer is going to require a critical
orifice check of the metering system the test
team leader should be notified ahead of time.

The observer should perform duties quietly and thor-
oughly, conversing with the test team and plant
personnel as little as possible.

The ideal emission test is one in which the data gathered
is representative and no discussion of the test procedures
is required.

To assist the observer on-site he should adhere to the
following:

1. Use prepared checklists to observe facility
operations and reference method tests

a. offer a systematic method to check all the
key parameters necessary to ensure good data
quality during the test, and

b. prevent the observer from having to write
Paragraphs, thereby freeing him to spend more
time observing the test team's procedures.

2. Conduct performance and systems audits
A. Performance Audit

The performance audits are quantitative evaluations
of the quality of data produced.

Example of performance audits are:

I-22


LECTURE 154
PRECISION AND ACCURACY OF TEST METHODS

OBJECTIVES

The objectives of this lecture are to give the precision and accuracy
of most of the EPA reference methods and to discuss how the values were ob-
tained and how they can be used.

At the conclusion of this lecture the student will have a better under-
standing of the precision and accuracy of the methods which must be considered
when making decisions on allowing alternative test procedures, evaluating
test data, and determining compliance with the regulations.

1-109


Slide sequence

105-6

105-7

Key points

APPROXIMATION METHOD
This method is presented only as a suggested method.

Apparatus

The same type probe as described for the reference
method.

Two midget impingers, each with 30 ml capacity or
equivalent.

Ice bath, consisting of a container and ice to aid
in condensing moisture in the impingers.

A tube packed with new or regenerated 6- to 16-mesh
indicating silica gel (or equivalent desiccant), to
dry the sample gas and to protect the meter and pump.

A needle valve to regulate the sample gas flow rate.

A leak-free diaphragm or equivalent pump to pull the
gas sample through the train.

A dry gas meter, sufficiently accurate to measure
the sample volume to within 2% and calibrated over
the range of flow rates and conditions actually en-
countered during sampling.

A rotameter to measure the flow range from 0 to 0.11
cfm. The rotameter is calibrated using the procedures
outlined in Method 3.

A barometer as discussed in Method 2.
A 25 ml graduated cylinder to measure the water.

A vacuum gauge capable of indicating at least 30 in.
Hg vacuum, to be used for leak checks.

Procedure
Place 5 ml distilled water in each impinger.

Assemble train and leak-check by placing a vacuum
gauge at the inlet to the first impinger and draw a
vacuum of at least 10 in. Hg. Plug the outlet of the
rotameter and turn the pump off. The vacuum shall
remain constant for at least one minute.

Sample at a constant rate of 0.07 cfm until a sample
volume of about 1.1 ft® is obtained or until visible
liquid droplets are carried over from the first im-
pinger to the second.

Combine the contents of the two impingers and measure
the volume to the nearest 0.5 ml.

1-43