# REX TECHNICAl**SERYICE~** 

# llC 155 Highland Park Drive • Bloomfield, Conneccicuc 06002 • (860) 242·3863



### COMPLIANCE TEST REPORT 

## HARD AND DECORATIVE CImOME PLATING LINES WHYCO FINISmNG TECHNOLOGIES, LLC THOMASTON, CONNECTICUT

Prepared By: Jeremy N. Bidwell 

### REX TECHNICAL SERVICES, LLC

August, 2005
Project No. C-02-19

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1.1 Summary 1 1.2 Test Program Organization 1



### Z.1 Thin Dense Chrome Line Z.2 Precision Plating Line 3 2.3 Plating Liquor 4 

### 2.4 Control Devices 4

3.1 Reporting of Results 8

4.1 Thin Dense Chrome Exhaust Duct Sampling Location 12 4.2 Precision Plating Line Exhaust Duct Sampling Location 12

5.1 Hexavalent Chromium Measurement 16 S.2 Oxygen Determination 18 5.3 Sample Gas Velocity Measurements 18 5.4 Exhaust Gas Moisture 18

6.1 Quality Assurance 19 6.2 Sample Identification and Custody 19
6.3 Blank Collection 20 

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J 1.0 INTRODUCTION


### 1.1 Summary
Rex Technical Services, LLC (Rex Tech) was retained by Wbyco Finishing Technologies, LLC (\Vhyco) ofThomaston, Connecticut to conduct compliance emission testing on two chrome plating lines and the associated emission control devices. The testing for these sources was required as a condition of the Permit to Operate, which was issued by the State of Connecticut Department of Environmental Protection (CTDEP), Bureau ofAir 

### Management. Hexavalent Chromium emissions were measured and compared to the CTDEP regulatory 

### limits for these sources, which are the Maximum Allowable Stack Concentrations (MASC) 

### limits, in 

### units of micrograms ofCr+ 6 

### per cubic meter ofexhaust gas at actual stack conditions (uglACM). All three tests at eaCh ofthe two sources yielded emission rates ofhexavalent chromium, which were below the CTDEP MASC 

### limits.


### 1.2 Test Program Organization
The following are names and phone numbers of individuals primarily responsible for the organization ofthis test program:
State of Connecticut Department ofEnvironmental Protection Bureau ofAir Management Carl Ekroth, Field Test Coordinator (860) 424-3894 

### Dennis Demchek (860) 214-2155 

### Rex Technical Services, LLC Jeremy Bidwell, Project Manager (860) 242-3863

Whyco FiI1iJbing T.clulologies. LLC R.pon 

### Whyco Finishing Technologies, LLC Barbara Lewis, E,H & 

### S Manager (860) 283-5826



### Environmental Health laboratories, 

### Inc. Jim Kenny Client Services Representative (860) 635-6475
Augus12005


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( 2.0 PRO CESS DESCRIPTIOi'(

The \Vbyco Tcclmologies fa c ility in Thomaston, Connec ticu t is ajob s hop which emp loys decorative and hard chrome plating stations 

### in (he manufacture of bearing housings, fue l injectors and other parts fo r various manufacturing industries. The chrome plating stati o n s, which are l oca ted within multip le c hrome plating tanks, e mit wal er vapor and s ulfuric acid fumes which are co ll ected at the edges of the 

### tanks via fume sweeps. These gas streams pass through mist eliminators and are exhausted to atmosphe re approximately 30 

### feCI above grade through ro ofto p induced draft fans and exhaust stacks.

Two production li nes were separat e ly tested for emissions o f hexavalent chromium. These two li nes are the Thin D e n se Chrome li ne which is a decorative c h rome plating p r ocess, and t h e Precis i on Plating Line which is a hard chrome plating process. Each l ine is described below.



### 2

. 1 Th in Dense C hro me Line

e--Thin Qense OlI'ome 

### (IDC) process is desigru!teo as a decorati e chro m e**at n{~rql** **ess.** This process was compliance te sted for Cr+6 emissio n s 

### in March of 200 1. At that time, li nes A, B , C and 

### 0 were ve nted through one stack, whi le lines E, F and G we re vented th rough a sec ond s tack. Both stacks were tested se parate ly. Since lhat compliance test, the co nJi gura tio n of the flrst stack is unchanged; howeve r two additional lin es have been added to those vented by the second stack. The two new lines are H and "fix tures", The second stack has now been r e t

este d w i th its current process co nfi guration of lines E, F, G, H and Fixtu res.

The E , F, G and H lines of the TOC process are all u s ed to chrome plate auto motive fue l injectors. The Fixt ures line is used to plat e the s upp ort substrates used in other baths as supports fo r the fuel injecto rs during plating. The following table summarizes the operating param e t ers of eac h line in the TOC process:**'Nhy ~Q**  Fuu .b"' 8 T

. t M olo gi ••• LL C R epo rt 2

# ( Table 2-1 Thin 

### Dense Chrome Process Parameters For lines feeding Stack #2 Line Designation E 

### F G 

### H 

### Fixtures



# . Rectifier capacity (Amps) 500 500 250 300 600 Max typical current applied (Amps) 80 80 80 210 120 Avg typical current applied (Amps) 80 80 80 210 120 "Dummy" parts or live jobs used Dwnmy Dummy Dummy Live Live during Testing? Amps applied during testing 350 475 225 270 100 # ofplating bays in line 5 5 5 2 1 Total volume ofplating baths (gal) 100 100 100 75 34

Electrical DC current is supplied to each line by a dedicated Dynatronics Company rectifier at the ratings shown above. The total capacity ofthese rectifiers is 2150 Amps. Turnaround time is approximately 30 minutes between runs, with two 8-hour shifts active per day. Periodically, steel "dummy" cylinders are loaded into the bath and a current is applied. The dummy cylinders receive
no chrome plating but rather serve to remove iron from the solution.
Gaseous emissions from the chrome plating tanks 

### are collected by perimeter fume sweeps, routed through a mist eliminator and vented to atmosphere via a roof mounted stack. Figure 2-1 shows a conceptual layout of the plating line, its control devices and the exhaust stack.



### 2.2 Precision Plating Line
The Precision Plating Line (PPL) process is designated as a hard chrome plating process. It is comprised of one 800 gallon capacity tank 

### with a surface area of 40 square feet. The tank. 

### has 16 plating bays, 8 per side, where bearing housings of various sizes are chrome plated. Electrical

Why.:o Fini'NnS Technologies. LLC ReJlon 3

### ( current is applied at a typical rate of 2.5 Amps per square inch ofplated surface. Electrical DC current is supplied to the two sides of the tank by a pair of Dynatronics Company rectifiers, each with a 4000 Amp rating. The rated capacity ofthe process, based on shunt bar capacities, is 3,200 Amps. The total capacity ofthese rectifiers is 8000 Amps. Testing was conduct 

### with a total rectifier output of 6,600 to 6,400 Amps, using "dummy" parts. Turnaround time is approximately 30 minutes between runs, with two 8-hour shifts active per day. Periodically, steel "dummy" cylinders are loaded into the bath and a current is applied. The dummy cylinders receive no chrome plating but rather serve to remove iron from the solution.

Gaseous emissions from the chrome plating tank are collected by perimeter fume sweeps, routed through a mist eliminator and vented to atmosphere via a roof mounted stack. Figure 2-2 shows a conceptual layout of the plating line, it's control devices and the exhaust stack.


### 2.3 Plating Liquor

The plating liquor used in both the IDC and PPL tanks is an aqueous sulfuric acid (H2S04) solution. Heef2S Chrome Plating Solution is added to the PPL bath, to maintain a chromic acid content of250 gIliter. Chromic acid is added to the TDC bath, to maintain a chromic acid content of 800 glliter. The plating liquors are monitored once daily by colorimetric chromium content analyses at Whyco's in-house lab. Barium Carbonate is then added to adjust the sulfate to 0.36 ozlgal. Chromium content is monitored using a floating density indicator which is placed directly into the bath. Sulfuric acid content is monitored by periodic analysis of an aliquot ofbath liquid, using a Kocur Co. sulfate test 

### kit. The solution surface tension is measured once per shift using a stalagmometer. The surface tension is maintained above 4S dynes per cm 2 by addition of Dupont Zonyl FS-62 mist suppressant.



### 2.4 Control Devices

Chromium emissions from the two sources being tested are controlled by two separate ViroWhyt:o FiDisbiDg Teclulolosies. LLC Report 

### 4

## r ( Chrome 9000 composite mesh pad three section mist eliminators manufactured by the Viron 

# I Company. Each Viron scrubber utilizes three (3) in-line mesh pads, which are equipped with a bank of spray heads for periodic washdown. The scrubbers are equipped with Magnehelic pressure 

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# I I gauges across the mesh pads to measure the pressure drop ofeach pad during operation. The exhaust systems are each driven by a ten HP roof mounted induced draft (ID) 

### fan with a maximum exhaust rate of 5,000 cfm. Technical specifications on the Viron scrubbers are provided in the appendix ofthis document.

Whyco I'inubing Technologies. UC Report 

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I. roof

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### Thin Dense Chrome Process Conceptual Layout Whyco Finishing Technologies, LLC Thomaston, Ct.

August, 2005

Viron Scrubber

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roof

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Whyco Finishing Technologies, LLC Report 

### Figure 2-2 Precision Plating Line Process Conceptual Layout Whyco Finishing Technologies, LLC Thomaston, Ct.

August, 2005

stack ) 

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Viron Scrubber

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### Tank PPL - 01A

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# I I ' ( T able 3 -1 

### H

exava le nt C hro mium Emissio n

### Measurement~ redsi on ) 1ating me -**~**

# cd Whyco Finis hin g Techno lo gies Th oma s ton , Connecticut JULY 12 , 2005
Test # 1 Tes t # 2 Proce ss Co n d itions P lating A m perage 6,6 00 6 , 600 Stack Tem p era t ure (Deg.F) 101.1 102

. 8 F low , "atc (ACFl.\'l) 3532 369 1 Flow r a tc (DSCFiVl) 3257 3394 F lowr:ltc (AC"I/scc) 1.666 7 1.7419 

### Cr Emi ss ions Co n ce n tra ti o n ( m gIDSCM ) 0.00155 0.00143 Act. Stack Conc. o r ASC ( u g/ AC iV I) 1.4688 1.4320 iVlASC l imi t (ug /ACl\1) 11.0715 10.6355

E mi ss io n Rate (TPy) 0.000081 0.000078 Cr Emiss io n Ra tes i n other unit s Mg/ h r 

### 8.3403 8

.0310 Lb/ h r 0.000018 0.000018

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. LLC R'P0 ;1 9 Test # 3 Average
6,600 6,600 101.7 101.9 3654 3625 3370 3340 1. 7245 1.7110

0.00172 0

. 00156

1.6805 1.5271 10

. 7331 10.8133 0 .00009 3 0.000084

9.5874 8.6529 0.000021 0.000019

A

ugu.t 200' 

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. 0 RESULTS OF TESTI NG

The purpose of the test program was to evaluate the hexava lent cluomiwn 

### (Cc" 6) emiss i on rate of the chrome plating lines during thier hi ghest l eve l of ac ti vity, by :

• Co llecting triplicate isokinetic gaseous samples from the e xhau s t duct samp li ng location s in accordance with EPA Method 306, to determine the in-stack Cr gaseous concentrations in units of milligrams per cubic meter (mglfvI J) and parts pe r million (p pm).

• Measuring volumetric " f1owrate and moisture co ntent at the exhau st du c t samp ling loca ti ons in accordance with E P A Method 1-4, 40CFR60, Appendix A. Flows and moisture determinations were pe rformed to calcul ate the total chromium em is sion rates in unit s of pounds per h o ur (lb/hr) and tons per year (TPY). Tripl i cate 2 hour t ests were perfomlcd. During the da ta collection period o f eac h test , plating line operatio nal parameters were monitored. These include amperage , Baume grav it y and contro l device pressure drop s.



### 3.1 R ep o rting o f R es ult s T h e hard chrome pl ating line at the Whyco Fini s hin g Technologie s faci lity in Thomaston, 

### C t. passed the ChrOnllWll emissions comp liance test, in that the exhau st stack c hromium concentration
were demonstrated to be be low the applicable regulatory linlits for both of the s ources tested. The three te sts of eac h so urce s howed good ag ree ment between te sts fo r all measured parameters, with
no samp ling o r process up sets. Qua lity Assurance steps taken ( iso kinetic calculat ions, analy s is of blank samples , meter box p os t ca librat i on, etc .) were all well within allowed tolerances. Table 3

- 1 and 3

- 2 , be low show the res ults of the te s ts . Raw data and redu ced data summari es can be found in the appendix sect ion of this report.

A ugu!! 200' 

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## ( Tab l e 3

- 2 Hexavalen t Chrom ium Emissio n Mea s urement s



### _ ense Clirome Pl a li n C ine Whyco Fini s hin g Te c hnolo g i es 

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### Thoma s ton , Connecticut 

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# ' ve JULY 13,20 05

P rocess Condi tions Pl a ti ng A m perage S tac k Te lllIJ e r a t u r e (dcg. F) Flowratc (ACFM) F l owrate (DSCFM) Flowra tc (ACl\'l/scc) Cr Em issio n s Co n ce nt ra tion (mg/DSCM) Act. Stack Co n c. or ASC ( u glACiVO i \1A.SC limit (ug/ACM)

E mi ss io n Rate (T l)y) Cr E mi ss io n Ra te s in ot h e r IIlI its Mg/ h r

ACFM ::::: ac tual c ubi c fee t per minute DSCF M == dry standard cu b ic feet pe r minute Lb / h r Test 1# 1

1,420 73.8 245 1 2372 1.1565

0 .0 00 32 0.3508 73.529 1 0.000012

1.2 420 0 .00 000274 Test # 2 Tes t # 3
1,42 0 1,42 0 73.7 73.6 264 6 431 5 2578 4217 1.2 4 89 2.0366

0.00024 0.00019 0.2 768 0.2809 68.2325 42.50 0 2 0. 000010 0. 000013

1.009 7 1.)645 0

.00000223 0.000003 01

AClvU se c = actual cub i c meter s pe r seco nd (ac tual con diti o ns ar e we t, at s lack temperature and stack s tati c pre ssu re) mgIDSCM = milli gra ms per dry s tanda rd c ub ic meIer uglAC M = mi crograms per a ctual c ubi c me te r T PY = ton s pe r yea r Avcraoe
1,420 73.7 3137 3056 1.4806

0 .00025 0 .3 028 61.4206 0

. 000012

1.2054 0.00000266

The 8 ho ur hazard limiti ng value fo r Hexavalen t chromiu m as Cr is 0.25 u g/tv e , fr o m tabl e 29 -1 of the CTDE P re gulation s, Sect ion 22a-1 i4- 29. The exhau s t point i s le ss than 10 meter s ab ove grade.

'Nhy co Fin"jung**Teohr.o o~** **ie** •. U.C Repan "'"B"' l l00' 

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The fo ll owing calc ul atio n s were used for pollutant co ncentration s and emiss ion ra t es: m glAC M = ( m g catch 

### )/ (y o l MJ)(f,fT,.,)(PmlP

. )(lOO/( lOO- % H ,Olll



### Where: ppm = [ ( mg ca tch 

### )(lIm.w.)(24 .004 6/1000) ( I ( vo ll) (52SfT m)«p,.,+P,)/29 .92 )M( Iblbr = 

### (ppm)( m .w.)(DS CFM)( 15 .58 x**IO )** 

m g catch 

## = total C r+ 6 in sa mpl e T s = Stack Temperarure, o R T m= Meter temperature o R 

### Pm= Meter pre ss ure , in H g P

b= 

### Barometric Pre ssure, in I

- I g vol = s ample vo lum e 

### in liter s or cub ic meter s 

### P

s= Stack Pres s ure, 

### in Hg % H2 0= Moi s ture Conte nt of Exhaust Gas M. W.= Cr+6 m o lecu lar weight = 51.996 glmol 

### y = dry gas meter cal ibration fac to r

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# I 4.0 DESCRIPTION OF SAl\1PLING LOCATION
4.1 Thin Dense Chrome Exhaust Duct Sampling Location


### Five (5) sampling ports were located along the same plane, equally spaced apart in a straight section of 23" wide by 17. 5" deep rectangular PVC ductwork. The ports were 3 inch holes sealed with duct tape. The ports were located 40 inches (2.0 duct diameters) downstream from a set of fan outlet straightening vanes and 21.5 inches (1.08 duct diameters) upstream from a stack tip transition. All measurements were taken at these five ports. Based on the above parameters, EPA Method 1 required 25 sampling points (5 per port). Isokinetic Method 306 samples and the associated flowrate measurements were taken on the five traverses at the points shown in 

### Table 4-1. Figure 4- 1 shows the outlet stack sampling location.

(2 Precision Plating Line Exhaust Duct Sampling Location


### Two (2) sampling ports were located 900 

### apart in a straight section of23" diameter round PVC ductwork. The ports were 3 inch holes sealed with duct tape. The ports were located 41.4 inches (2.3 duct diameters) downstream from a square to round transition and 14.4 inches (0.8 duct diameters) upstream from the tip of the stack. All measurements were taken at these two ports. Based on the above parameters, EPA Method 1 required 24 sampling points (12 per port). Isokinetic Method 306 samples and the associated tlowrate measurements were taken on the two traverses at the points shown in Table 4-2. Figure 4-2 shows the outlet stack sampling location.

Wbyco Fwshing Technologies. LLC Report AugusI200' 

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### Point # 

### 1 

### 2 

### 3 4 

### 5

Point # 

### 1 2 

### 3 4 

### 5 6 

### 7 

### 8 9 

### 10 

### 11 

### 12 Table 4-1 Location of Traverse Points Thin Dense Chrome Sampling Location
Calculated Depth Depth With Port 2.3 2.3 6.9 6.9 11.5 11.5 16.1 16.1 20.9 20.9



### Table 4-2 Location of Traverse Points Precision Plating Line Sampling Location
Calculated Depth Depth With Port 0.483 0.483 1.541 1.541 2.714 2.714 4.071 4.071 5.75 5.75 8.188 8.188 14.812 14.812 17.25 17.25 18.929 18.929 20.286 20.286 21.459 21.459 22.517 22.517



## * denotes sampling points which have been moved in from the stack walls, as per EPA Method 1
Port depth 

## = 0 inches for both locations

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Wl\yco firultwlg T«MO!Og1el, LLC Rcpotl Figure**4~** I Exh aust S tack Sampling Locations Thin Den se C hrome Pro cess \Vh yco Finishing Techno lo gie s, LLC Th omaston, Ct. July , 2005

"A"**Oim~MIon.** 21. 5" (l.1ll Equ",.t.nl Ol.m.to

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AUJlI>l200S 

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# 1

1 Figure 4-2 Ex.haust Stack Sampling Locati o n s Precision Plating Line 

### Whyco Finishing Technologie s, LLC Thomaston, Ct. July , 2005

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Augu. 12 005 

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## ( 5.0 SAlVlPLING AND ANALYSIS l\11ETHODOLOGY
The purpose of the test program was to demonstrate compliance ofthe plating lines with the CTDEP Cr+6 MASC limit for this source in ugiACM. 

### Total chromium emissions were measured and compared to these Cr+ 6 

### Iimits.
5.1 Hexavalent Chromium Measurement 

### Sampling Train The sample gas hexavalent chromium (Cr+ 6) 

### content was measured in accordance with EPA Method 306, as described in 40 CFR, Part 63, Appendix A. Triplicate tests were conducted, with each test consisting of a 2 hour sample. A minimum of 60 cubic feet of sample gas 

### was collected. This train consisted of a glass nozzle, unheated Teflon probe and flexible sample line, two impingers containing 100 milliliters (ml) 

### each of 0.1 N NaOH, a third empty impinger and a fourth impinger containing 200 grams of silica gel. A vacuum pump, dry 

### gas meter, orifice flowmeter, pitot tube, thermocouple and inclined manometers completed the sampling train.
As per the method, a glass fiber filter was not used, nor was the probe heated. The method also did not require the use of a probe brush, and none was used. An 

### emission sample was withdrawn from the sampling location at an isokinetic rate through a glass nozzle. The method was modified to use a Teflon lined probe and a flexible Teflon sample line to connect the probe and impingers. The probe was equipped with a pitot tube and a thermocouple, as well as the glass nozzle and Teflon probe liner. A block diagram of the sampling train is presented in Appendix A.

A programmable calculator was used as an electronic nomograph to detennine isokinetic sampling rates, which allows for quick updating ofassumed values (such as stack and meter temperatures) during a test.

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# C- Pretest preparations



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# \ I Prior to the field sampling effort, all glassware, nozzles, probe liner and flexible line were cleaned with alconox cleanser, tap water rinsed three times, reagent water rinsed three times and soaked for
a minimum of 4 hours in a 10 % 

### v/v nitric acid (HN03) 

### solution. After soaking, the train 

### components were rinsed three times with reagent water, air 

### dried and sealed with parafilm.
At the site, the impingers were charged and weighed on a triple beam balance to the nearest 0.5 g. The 

### train was assembled and leak checked at 15 inches of mercwy (in. Hg). Sample Recovery After sampling and a post test leak check, the impingers were re-weighed and the train recovered with all sample media except silica gel combined into one precleaned 1000 m1 

### wide mouth HOPE container. This 

### included impinger contents and rinses of all 

### glassware and the probe/flexible line assembly. Sample containers were marked at the height ofthe fluid level, to indicate the possible
occurrence of sample leakage during transport. All rinses were with 0.1 N NaOH. All reagents used for this test program were from the same lot number. Samples were stored in Rex Tech's refrigerator and delivered, on blue ice the next day, to the analytical laboratory. The silica gel was inspected and, if viable as determined by color change, was 

### reused for the next test. Laboratory Analysis Samples were analyzed by the laboratory, following the Method 306 guidelines, for hexavalent chromium by ion chromatography with post-column reaction (ICIPCR) with 

### preconcentration. The standard operating procedure (SOP) for this method, as employed by the laboratory, was reviewed and approved by USEPA Region 1 and serves as a QA guideline for analysis. The analytical detection limit for ICIPCR is 1.6ugIM3, based on 60 

# Fe sampled. This LOO is below the anticipated MASC limit of 12 ugIM3 for TOC and 52**ug/~ve** 

### for PPL.

Wbyco Finishing TcclInolo8lH, LI.C Report August 200' 17 

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### 5.2 Oxygen Determination


### The stack gas Oxygen (02) and Carbon Dioxide (C02) content were assumed at 20.9 % 

### and at 78.9 %, 

### respectively, since the system was essentially exhausting ambient air.
5.3 Sample Gas Velocity :Measurements 

### Sample gas velocities were measured at points chosen in accordance with EPA method 1, taking into account duct size, shape and local flow disturbances, as described in section 4 of this report. An S type pitot tube and an inclined manometer were used to measure velocity pressure in accordance with 

### EPA method 2. 

### Included in the Appendix section is a schematic ofthe velocity sampling train. 

### A thermocouple and potentiometer were used to measure stack gas temperatures. The thennocouple was attached to 

### the pitot tube assembly. Pitot tubes and thermocouples were calibrated prior to the sampling program 

### in accordance with EPA Method 2. 

### Gas velocity measurements were conducted simultaneously with the three compliance tests.
5.4 Exhaust Gas Moisture


### The stack gas moisture content was measured as part ofthe Method 306 

### samples. The gas sample was extracted at an isokinetic rate from the exhaust stack (a minimum of 60 

### cubic feet of stack gas was sampled). The sample stream moisture was determined volumetrically and gravimetrically. The measured stack gas moisture was used to correct actual sampling conditions to dry 

### standard conditions.

Wbyeo Finisbutg Technologies, LLC Report AUlJIISt 200' 

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## ( 6.0 QAlQC 

### ACTIVITIES
6.1 Quality Assurance


### The QA program at Rex Technical Services, LLC is based on the procedures outlined in the Quality Assurance Handbook for Air Pollution Measurement Systems Volume ill. 

### Stationary Source Specific Methods (EPA 600/4-77-027b).
The checkout and calibration of the source sampling equipment is performed prior to and at the completion ofeach project. Referenced calibration procedures are strictly followed and the results properly documented and retained. A calibration package was available at the jobsite prior to testing, showing the pretest calibrations of applicable equipment. This data, along with post test calibration data, was included in the appendix of the Final Test Report. The following calibrated and/or certified equipment was used during the test program: Type-S Pitot Tubes Sampling Nozzles Type-K Thermocouples Dry Gas Meters Quality control for the various organic and inorganic analytical procedures is established using field blanks, method blanks, trip blanks, surrogate spiking, and internal standards for quantification. Where applicable, percent recoveries are calculated and determined.
6.2 Sample Identification and Custody 

### Sample custody procedures for this program are based on EPA recommended procedures. The project manager is responsible for ensuring that proper custody and documentation procedures are followed for the field sampling and field analytical efforts. The project manager is assisted in this effort by key sampling personnel involved in sample recovery. All sampling data, including information regarding sampling times, locations, and any specific considerations associated with

Wbyco Finishit.g Tcclmologies. LtC Rcpon 

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## C sample acquisitions are recorded in black ink on pre-fonnatted data sheets. Field notebooks are maintained to docwnent individual test programs and specific field occurrences. Following sample collection, all samples are given a unique alphanumeric sample identification code. Sample labels and integrity seals are completed and affixed to the sample container. Samples are stored in a secure area until shipment. The sample volumes are detennined and recorded and the liquid levels on each bottle are marked. All samples are packed and shipped according to Department ofTransportation (DOl) guidelines. As the samples are packed for shipment to the appropriate laboratories, chain-of-custody fonns are completed for each shipment box and enclosed therein.

6.3 Blank CoUection
The following blank samples was collected and sent to the analytical laboratory along with the live samples. The blanks was analyzed along with the samples.

• Field Blank

- an aliquot ofNaOH collected in the field during the sampling effort, designated on the chain of custody fonn as Reagent Blank,
• Final Train Blank

- an aliquot ofNaOH used to rinse down the sampling train after testing was complete, designated on the chain of custody form as Test 7.

Wbyco FiJlululIS Technologies, !.!.C Repon August 200' 

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### APPENDIX A 

### Field Data Sheets, Reduced Data Sheets and Sampling Train Schematics



## l( I

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# REX TECHHt::X-TEC H NICAL"SE RVICES. LTI:;**MA~ual** rvretFiods

### L>afa Sheet .'**~.** Da\ I Z. ..t Test No.JI'T'

### ~ '" Stack Static Press

.

### ...,()~ • .;;:;u,;:;;....
__ - Sampling**LocatiOr('-L''p~PIL~~**__**Cllent"o.1~** 0 Module No. 

### -tt:-',.. 

## «)t)''JJ Initial Pitot Leak Check**~,(X)l)** DGM Y value t.O.O ., Final Pilot Leak Check**~Q'bO** DGM AH@value to l,..8' Initial Train Leak Check 

## (Q"i ft3@ Wn.Hg Barometric Press.**~·~u..O~O~7**__ _ Stack Absolute Press. _"'

__ '

___ _ Project No. 

## 1: _07.-- l't Job Location**'T"tD~~~,~.** 

### '-'t Testers 

## ,tJ R. /-0[" Probe 10 l..I A)___ fyo\"'. Final Train Leak Check 0**.o.~** ft3@ in.Hg Pilot Cp ("')

. "is''f Initial. Sampling Time 

### 045.., Nozzle 1.0. G I**c;..1~** ti. '-4**Fi~:,1** Sampling Time 

### _1

....

I::....u..:::b"--

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### I (min)



# o iD L

£j'. 

## lD 25' 

## J5 i'fo SD

. 

## 1.55.

7.1

LOO (OoS uO 

## ,'to " 7 ( "1 Clock Pi tot Orifice DGM Temp DGM Temp Stack Sample Gas Impinger Heater Probe Filler Time Pressure Pressure IN OUT Temp Volume S.G. temp Box Temp Temp OuUet i{hrs:mln} (AP, in H20 (MI, in H2O Tm, dea F) l(Tm, deg F) l(Ts, deg F) (Vm, ft3) !(dea Fl I(dea F) I(deg F) I(deg F) 

### 1/():Oo ;l

### ~ 

### T L/ 'fl) 1 

## Kob IOf 

### 8'lfS. 

# as" ,s7;

10: 'J> 

## 7 

## ,:3' 1,5 

# 'f.**,.~** (00 'll){. 

### 3 

## 0 S' ""

l/ll.S"Z 

## ,1..1 7. (ij 

## '17 10 1/0/ F//6. '10 

### .fCf 1C1:s7 

## ,28' 2.' ,'y. 90 00 'fiZI. 

### If) 

## s1

/I,:C(.J 

## '.1; Ii, I 

## 11**~ i~1**  

### 1//)'( 

## If&·, fo '17

IZ',/O 

# .3> 1:\,,, '19 7 

# z.**{~'fS** 

### (t'. 1.(,)
Averaged IO.S":}'lO Z,193i t.tS-,f{**~S IO(.f~**  '600 1f1C1f .-finalvol values I{AvQ.vD.P) I{AvQ.Mf) (Avg. Tm)qoz..,..I{AvQ. Ts) .-inll vol Pump Vac. 

### Ian. Ha}



# -.ro -1I.5 

## -S.o -.1.0 

## -,s.O -'/,3

- tf, 

## lJ -q,S



## -5.0 Stack Diameter _---- Stack Area

___-- Ambient Temp

____ _
Comments

I "l.**~.** 'l..**~t:P.-sampled** vol Nomograph Assumed Data Filler 1.0.

______ _ Sample 1.0.

______ _ Review by On-Site Regulatory Rep

________ _ Signature Dale Avg.Ts

__ _ Avg. Ps _---._ Avg. Pb

__ .,- Avg.·.lm·'

__ _ %H20_-._ Avg.VllP.

__ _ DGMY

__ _ .DGMAH@

__ _RtX I**t:Cfn~Il,;ALSE:HVJt,t:-S,** LlCDc. 

# '+/f1./t!1<;- TesINo.· 

## I-L Module No.**~.L ~0C'l13** 

### samprm.l~:~**&f~** Pro;,dNo.

# 'r~ Job location**_~~_.{j** Testers f.J 

### l 

# =-. OGM Y value ---il!,-=-, (S()...,......y1-w-

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## 'c.G1.'L /),.,1 Probe 10**_~~,.-,..,.....::::;-....;...r** ... -...-.,,"",, Pitot Cp 

### 0

. 'iN



### .. 7 

### t Noz;e I 0 

## r;**t;s~** 

### #4 

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### --iQar---- Final Pitot leak Check 

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## '''0 Slack Slatic Press.

### _-~Q:..!:::,l~'~

## __ Barometric Press.**_,,-.;;;.O~. O;;;...f"~** __ Slack Absolute Press.

____ _ Slack Diameter

____ _ Slack Area _-:'-_--'--_ Ambient Temp

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## 0**J2.:~** O.'-{<:-**Y.4~** 

## q, LtD 102' 

### OOO.'lS7- 

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## J.c, 'I 

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## ":to DI/-S 

### lf 'I 

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### 20 1)'15 

### D 

## 'L't 'f,JO 

## 111 '1.3 (1J;j 

# -z.5.11 'is S'.s 

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### Io''i.l 

## '/,0 '''L 

## to ( '13 to::!. 

### )1 L" LIS 

### t,S 7**~l)** 13'2,$**~.** 

### 2.j 

### l.ff'.s 101 

### 1'1 103 

### 37.0.:5 lf4 

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### 30 

## ().2'**~,t.s** 

### /01 

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### IJ:35 

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### 03'-1 

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### ill.L**y~** 

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### 3 70 IL/;o> 

### 6. Z't 2.. 

## r]" to:) 

## '1'1' 162- 

### 7lZ7 l{'( 

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## 75 l L·(:tO 

### 16.**~O** 

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### 115**O.~~** 3.'l.D 

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### 0.30 lc**~** 

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### '33 12- c<; O. J 

### 7 I**~o** 

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### 7S' D.jV 

### s 8"0 

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### 7 

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# , 100 

### 1041 to lc1 

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### Ot**~'3** 12 (I**~** 

### 0.11 I 

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### . . Orifice DGMTemp Pressure IN (AH.in H2O I/Tm,degF)



### '-(.ot- 

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## 118**-Cf~** 

# 3.'"**q~f** 

### 1:(3 '/.S**4.~** 

## q..5 "3 

## 171 t;5 

## 2. '13 

### elf 1',1'".3 

## fC. 7.71 'If( Z,13 

### q( 

### 11.2 

# z.. '1'6 J,ll.. 

### ((., 2. YJ. e(7 

### 1.r3 

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### 2. 

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### 1.. 

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## 16 J.'j/ 

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### CJ'L 

## to'l q, 107 

## -'17 (0 

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# tZ ID) 

### () 7 

### I() '7_ 

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### 7 I/)7 

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### IOz..**tf~** 1()2 

## 13 C{)l.**~3** 

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## '1"1 IDI. 

# rs UJt**~.j** 162 

### 1.s /o"l.. 

## fJ lO2... 

# '1/ 101 

### 1'1.3 10 I



### 1 

## Z tOI 

### q'L 

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### _~O~

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...**~..-in.Hg** Final Train Leak Check 0.0.0 1: ft3@ \\ in.Hg

Initial Sampling Time 

## I S"':"l2.**F1n~SamPJlng** Time**'~'~** L 

### • Sample Gas Impinger Heater Probe Filter Pump Volume S.G. temp Box Temp Temp Outlet Vac. Vm, ft3) :Cdeo F) i(deo F} I(deg F) Ideg F) Inn. Hg)**1~7** 

## 11-'**~(** 

### C;**.,,~,** 

### 90 

### lAOf 

## Cf ;'f'f 

### 5' 

## f' I./j 

# , 1.$0. 0 [; 

## q¥ <I 

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## S '1:3 ''/ 16l, 3 Z 'fZ, 

## R.r It.<Y.? 

### Y '12 

## 7.0 

## 17>.' :2 l(2 

## 26 171': 

### 'Z 

### 7 L{I 

## 60S

,. 8" 

## J t.J.s c.{( 

## t·7**fcj~** 1'1 Coif 7() 11 

### J • ') 

## i.f L.(( ")0 Iff. 

## to 'IS 

### 70 20.1 77 'if 

### .,0

### 17"~6Y l.{t 

### 7.0 l/3 

## 63 l/"L ).0 

### 7/'1',Co 

## Z. 't3 7,0 21.3.(( 

# 'lJ "J.<; 

### 22'1,01 'Ie.{ trt1:l 

### 2**3l(.~q** 

## 1.('1**~lO** 

### i4(')_UO 

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## f2.e

. Llf.Cc.lo 

## ttt5'"**g.~**

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# l1' 41. 7, ) 

### 1. S7 

### fit 

## 'l.5 7,5 

### ---... \ Stack Static Press.**_6.:;...L.21e~~**

## __

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_____ _ Ambient Temp

Comments

Averaged**O,~)T** 

### '3.y48 

### 'tLf'-L 

### ItJ f 

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______ _ Avg.Ts

__ _ %H20

___ _ Avg.Ps

__ _ Avg.Pb

__ _ Avg

..Jt1P

__ _ DGMY

__ _ Sample 1.0.

______ _ Review by On-Site Regulatory Rep

________ _ Avg.Tm

__ _**DGM~H@** __ _ Signature Date7/131d1' Date**~~I£-** __ _ T

.... t No. -+
__**~**__ _ Initial Pilot Leak Check ---::():.-

__ _ Stack Static Press. 

### _-_U-r'**.~1.;..;;,O,..,.-** __ Barometric Press. _::J!-$:of) ...:.'**O~6~_** Sampling Location**-rr..-1~"'='-­** Client**-L!PLftL~---n...-­** Project No Module No.

__**1._~**

## __ DGM Y value ---l.(.,L.:'**o~o~q~**

### __ OGM 6H@value**--!Lf.)-',IL.!:_glliL-~** .--nr-:r Probe 10**~~~,~",,** __**=-....;f::..;.~=** Final Pilot Leak Check**-al",L...--~,....** Initial Train Leak Check 0 001.,.. ft3@-.!£.ln,Hg Final Train leak Check tJ 

### 00::1 ft3@ftln Hg

Initial Sampling Time 

## 0 

## c:r-: 04 Stack**~solute** Press.

____ _ Stack Diameter Job Location**--..~-r:oLO~_=:..,-:~:TL-tD'\,-6t** Stack Area

____ _ Testers**~/t>L** Pilot Cp 

### 0 , ;("4**No~e** 1.0. (y{**4'~** t:t-y 

### h .,. . 

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### t I • 

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____ _
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## :fJ6**~.5~** 

## 7'1 Zf 7:J 126'-11.3 '17 

## to ';l/ 

## 5 7.0 I 1. S .l 

# s 

# so**~.o,** 

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## g-o i 

## Y 7 

### I 

### z17. 6 ; 

## &('1 3 

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# z It.{,.lS· 8"'l 

## 7"1 

## 17£f 2114,1. 't S I 

### f 

## 75 If),o/ D.J' 

## 8'1t 8':'0 17," 

### JtJO,' ( f' 'S '2.. (5 

### 5


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### liS 

# o.t i 

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## lL 7.3 13'1.1/ 

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______ _ Review by On-Site Regulatory Rep

________ _ Signature Date Filter Outlet [deg F) Pump Vac. (in. Hg) 

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__ _ %H20

__ _ Avg.Ps

__ _ Avg.-.JAP

__ _ Avg.Pb

__ _ DGMY

__ _ Avg.Tm

__ _ DGMAH@

__ _Date Test No. Sampling Location Client Project No. Job location Testers 'averse Sample ort/Point Time lemin) 

### ( ( 

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# a.a" f) (n 

### Ot./)7 O.t**~** 

### at.:3 tl ()' 

## ll

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### O./i 6.0'1 

### 0.0/ 0(12 

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### (9,1**~** f!),**z~** Module No. 

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1 (118. in H2O l(lm,deg Fl Tm.degF) [ITs. dea F} Nm.ft3) Initial Pilot leak Check 

### 0

. bO Final Pilot Leak Check O.OD Initial Train Leak Check 0.090 ft3@.I.:l:

. ..Jn.Hg Final Train leak Check Q ,oaD ft3@JCin.Hg

Initilll $ampllng Time**---!\~l '-,,'i~'** 

### __ _ Anal Sampling Time 

### ,3.

. 

# c::"

''f Impinger Heater Probe Filter Pump S.G.temp Box Temp Temp Outlet Vac. I(deg F) ledeg F) 11degF) Ildea F) I(in. Hg) 

### /, 'f 

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# ,-,**>~'TJz..1... ~I**  

# -v. --;;- (). lS 1'() 

## 77 71 75l.S' 

### SS'**~,** 

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## Iff 

# 77 

# 71 .1 

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# r; SI ? /) 1" &/. 

### 7 

## f?'f 

## 73' 

## 73 "lSI: 

### tfZ- 

### '17 lS.O**~.C r~·**  

## 78' 7'1 {j('S.10 

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# ,..2 7K' 

# 7¥ 'J7J.OO t.(7 '1. 

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# ,I;.. 3 9 

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## 1 

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### 7"1**7~ J1~,2..3**  

## 'l:3 7.1' 1.4. 

# r B'{ 

## 77 '1'L**~f/,.** t( 

## 7 4ft 

## ?if) III 

# so**~3** 

## 7Y 7'1**1.{1JZ.,~o** 

## 43 IS 1'3( 

### 8'7- 

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# 7"'-**7~** 1I11. "f 

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## '''''1.2'1 f(.:J tf.t;**6,~1j** 

### g'( 

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# r, tt
...**II~** 

# t..'**~s** 

## 714 

# 7" litf.tf $I' 

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### 9.0 

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# 71**!4{'J1~** 

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## S.6 ,),'f'f 

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### 'fj 

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### 7 C, 'l.fj 

## 17. J 

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### 7-'" 

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### "Z.. Barometric Press. 30 1'),<. Stack Absolute Press.

____ _ Stack Diameter _---- Stack Area Ambient Temp --.::113lJ,..."..,......

. ---
Comments

; 

### , "l.f fit 

## 8c>.:S 73.£"**Iq·z.~tto** '1/,/,{, 7 g**~finalvol ~**  I (Ava:"AP) IIAva.MIl (Avg. 

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______ _ Avg.Ts

__ _ Avg.Ps

__ _ Avg.Pb

__ _ %H20

__ _ Avg:'/l\P

__ _ DGMY

__ _ Sample 1.0.

______ _ Avg.Tm

__ _ DGM£\H@

__ _ Review by On-Site Regulalory Rep

__**~___** _ __ Signature Date MeIbocl5 0

.... Shut. FOkMSl. 1120191

### RE)(TECHNicACSERVICES, LLc' M,P.D..t]al Methods Data Sheet Date Stack Static Press. of-O.lO

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### 30', 

## &2*?:' Module No. ( 

### S.U 30 'If J Initial Pilot Leak Check 

## tJ. () 0 DGM Y value I ( 

### 00 'I Final Pilot Leak Check --"-i:------ Test No. --...+11':---- Sampling Location**---f-~~..---­** Client Project No. ·O:-:iz.P,'-'-t:.l-=--- DGM t.H@value I 

## (zt Initial Train Leak Check Q VO :) In.Hg Slack Absolute Press.

____ _ Job Location**~~I:Iforn~=.l-­** Testers -=<--;;.....:..0'-

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# .----> Theoretical Critical Vacuum:···> 03/12104 29.65 (in. Hg) 13.99 (in. Hg)**fPORTAN~** For valid test results, the Actual Vacuum should be 1 to 2 in. Hg greater than the Tbcon:tical Critical Vacuum shown above.**IPORTAN~** The Critical Orifice Coefficien!, K', must be enlered iu Eoglish units, (tt)"3·(deg R)"O.5/«in.Hg)·(JDin». I!!!!!

----- DRY GAS METER READINGS -CRITICAL ORIFICE READINGSVolunu: Volume Volume nitial Temps. Final Temps. Orifice K' Orifice Actual

- Ambient Temperaton: •• DeliaH Time Initial Final Total Wet OUdet Wet Oudet Serialll Coefficient Vacoum Initial Final (in H2O) (min) (cu tt) (CD tt) (CD tt) (degF) (degF) (degF) (degF) (number) (see above) (in Hg) (degF) (deg F)

0.27 10.00 592.000 595.114 3.114 77.0 77.0 78.0 77.0 140·0 0.2299 26.0 75.0 77.0 0.45 10.00 595.300 599.287 3.987 78.0 77.0 78.0 77.0 140·1 0.3004 25.0 77.0 77.0 0.87 10.00 599.700 605.164 5.464 78.0 77.0 78.0 77.0 140-2 0.4127 23.5 77.0 77.0 1.75 10.00 605.401 612.937 7.536 78.0 77.0 79.0 78.0 140-3 0.5746 21.0 77.0 77.0 2.30 10.00 613.300 622.076 8.776 79.0 78.0 80.0 78.0 140·4 0.6680 20.0 77.0 77.0  ·** ****·*****·*···*******·****************·**IUEStnLTS •••••• * ••••••***••*.************ ••••••• *****.*****.
DRY GAS METER-

-- ORIFICE--

- DRY GAS METERIOLUME VOLUME VOLUME VOLUME VOLUME CALIBRATION FACTOR**IRRECTE[~ORRECTED** CORRECTE[CORRECTEI:NOMINAL Y Vm{sld) Vm{sld) VCI(sld) VCI(sld) Vcr Value (cu tt) (liters) (CD tt) (liters) (cu tt) (number) 3.034 85.9 2.944 83.4 3.017 0.971 3.884 110.0 3.844 108.9 3.946 0.990 5.328 150.9 5.280 149.5 5.422 0.991 7.358 208.4 7.352 208.2 7.548 0.999 8.568 242.7 8.547 242.1 8.775 0.997 Average Y •••••••> 0.990 lie; For Calibration Factor Y, the ratio of the reading ofthe calibration meier to the dry gas meier,

acceptable tolerance ofindividual values from the average is +·0.02. Variation (number) ·0.019 0.000 0.001 0.010 0.008

For Orifice Calibration Factor dH@, the orifice differential pressure in inches ofH20 that equates to 0.75 cfin ofair at 68 F IlDd 29.92 inches ofHg, acceptable tolerance ofindividual values from the average is +-0.2. SIGNED:

____________________ _ --ORIFICE

-- CALIBRATION FACTOR DclfaH@ Value Value Variation (in H2O) (mmHlO) (in H20)

1.707 43.36 ·0.009 1.669 42.40 ·0.047 1.710 43.44 ·0.006 1.773 45.03 0.056 1.722 43.75 0.006 1.716 43.60 <: •• _. Avernge dH@

Dale:

__________ _ Average (degF)

76.0 77.0 77.0 77.0 77.0

# .. . 

# I 

# \

(

## I~ 

# I

\

# I~ 

# INDUSTRDNICS S E RV 

## r C E 

## COMPANY 489 Sullivan Avenue, South Windsor, 

## cr 06074, 860·289·1551, Fax 860·289.3526 www.induscronics.com



### SENSOR CALIBRATION REPORT

CUSTOMER: 

### REX TECHNICAL SERVICE 61 HOSKINS ROAD 

### BLOOMFIELD, CT 06002 REPORT 

### #: 

### 082404-SCC

CUSTOMER 

### P.O: ITEM CALIBRATED:

DATE CALIBRATED: 

### 0408-03 TYPE"K"TIIERMOCOUPLE AC-K-125-G-A-P-33 AUGUST 24, 2004

This 

### report may 

### not be reproduced, except in fuU; 

### unless permission for the publication of an 

### approved abstract is 

### obtained in writing 

### from the calibration organization issuing 

### this report. Calibrated 

### in accordance with SOP-009. 

# sm 041 TEST TEMP 

### 32DEGF 212 500 TIC 

## READS 32.7DEGF 212.5 5020 

### ERROR OF INDICATION

+0.7 

### +0.5 +2.0
Calibrations performed within 

### the Lab's Scope ofaccreditation are indicated by the presence of the A2LA Logo and Certificate Number on this Certificate and are performed in 

### compliance with 

### ISOlIEC 17025. 

### Any measurements on an accredited calibration not covered 

### by that Lab's scope are noted 

### within the data andlor accompanying paperwork. Equipment used conforms to: ISOIlEC 17025, MIL-H-6875 H, 

### AMS 2750C, MIL STD. 45662A, 

### ANZI Z540, SAC 5621-K, 10 CFR 21, ASTM E-220 AND ASTM E-230, ASTM207& AN.Sf/NSCL Z540-1-1994.



# I**UI\~** ... vumT , QA4.11.09 (7103) Page 10f2 ('" A I 

### Tn» &**TT(\N~** tJ1j' ATINC 14'1**I4'Ml?NT~**

# I 

# L " 

## ,., ,.'



### REPORT 

### #: 082404-5CC



### Equipment used to calibrate the above is as follows: FLUKE 8810A 

### SERIAL NUMBER: 2370 

### I 05 

### CALffiRATED: SEPTEMBER 26, 2003 

### DUE: SEPTEMBER 26, 2004 

### N.I.S. T. REFERENCE NUMBER: 11-UT3KL-J-I PLATINUM-PLATINUM 10% 

### RHODIUM TEST THERMOCOUPLE SERIAL NUMBER: 268226 CALffiRATED: FEBRUARY 24, 2003 

### DUE: FEBRUARY 24, 2005 

### N.I.S.T. TEST NUMBER: 268226 

### FLUKE 2190A 

### SERIAL NUMBER: 2180061 CALffiRATED: SEPTEMBER 26, 2003 

### DUE: SEPTEMBER 26, 2004 

### N.I.S.T. REFERENCE NUMBER: ll-UT3KL-l-1 Copies of

### these calibration results 

### are on 

### file at Industronics Service Company. We hereby 

### certifY that the above 

### is a true copy of our records, traceable to 

### the National Institute of Standards 

### and Technology. This calibration was performed by

# ~**~1U'f'#k'J/ ~**  and applies only 

### to results associated to item named above.

.

lNDUSTRONICS SERVICE COMPANY

# ~~41~ Andrew R. 

### Monsees Manager, Thermocouple Department

QA4.11.09 (7/03) Page 2 of2