Manual de Operacion Consola Apex-520

APEX INSTRUMENTS, INC.
Isokinetic Source Sampling Handbook
Isokinetic
Handbook
ISOKINETIC SOURCE SAMPLING
Isokinetic Handbook
Apex Instruments, Inc.

204 Technology Park Lane
Fuquay-Varina, NC 27526 USA
Phone 919-557-7300 • Fax 919-557-7110
Web: www.apexinst.com
E-mail: info@apexinst.com
Revision No: 7
Revision Date: February 2018
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TABLE OF CONTENTS
Chapter 1: Introduction 5
System Description 7
Source Sampler Console 8
Electrical Subsystem 8
Thermocouple Subsystem 8
Vacuum Subsystem 9
External Vacuum Pump Unit 11
Probe Assembly 12
Probe Liner 13
Probe Heater 14
Modular Sample Case 16
Umbilical Cable with Umbilical Adapter 17
Glassware Sample Train 18
Chapter 2: Operating Procedures 19

Set-up and Check of Source Sampling System 19
Initial Set-up Procedure 19
Initial Sampling System Leak Check 21
Test Design 22
Site Preparation 22
Mount the Filter Oven and Impinge Assembly 25
Assemble Sampling Equipment and Reagents 28
Preliminary Measurements of Gas Velocity, Molecular Weight and Moisture 28
Method 1 – Determining Sample and Velocity Traverse Points 30
Determining Traverse Points 31
Method 1A – Sample and Velocity Traverses for Small Stacks or Ducts 37
Method 2 – Stack Gas Velocity and Volumetric Flow Rate 39
Stack Gas Molecular Weight and Moisture 40
Using the Pitot Tube 41
Determine Flow Rate 41
Static Pressure 44
Barometric Pressure 44
Calculate Volumetric Flow Rate 44
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Method 3 – Gas Analysis for Dry Molecular Weight 46
Determine Dry Molecular Weight 48
Method 4 – Moisture Content of Stack Gas 49
Reference Method 4 51
Approximation Method 53
Calculating Stack Gas Moisture Content 55
Method 5 – Determination of Particulate Emissions 56
K-Factor Calculations 58
Method 5 Test Procedure59
Recommended Reading List for Isokinetic Sampling 70
Chapter 3: Calibration and Maintenance 71

Calibration Procedures 71
Dry Gas Meter and Orifice Tube73
Metering System Leak Check Procedure (Vacuum Side) 73
Metering System Leak Check Procedure (Pressure Side) 74
Initial or Semiannual Calibration of Dry Gas Meter and Orifice Tube 75
Post-Test Calibration of the Source Sampler Console 78
Calibration of Thermocouples 79
Calibration of Pitot Tube 80
Calibration of Sampling Nozzles82
Initial Calibration of Probe Heater 83
Calibration of Pressure Sensors 84
Maintenance 85
Appendix A 86
Recommended Equipment for Isokinetic Sampling 87
Recommended Spare Parts 90
Equipment Checklist 92
Appendix B 93
Calibration Data Sheets 94
Appendix C 102
Stack Testing Field Data Sheets 103
Appendix D 113
Calculation Worksheets 114
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Chapter 1
Introduction
The purpose of this manual is to provide a condensed understanding of the procedures established by the
United States Environmental Protection Agency (US EPA) in accordance with Reference Methods 1 through
5 – Determination of Particulate Emissions from Stationary Sources.
In addition to providing an easy-to-use guide for Methods 1 through 5, we have provided users with
reference information on system configuration, calibration procedures, maintenance and troubleshooting. Be
on the lookout for helpful tips and training aids throughout this manual.
We trust you will find this guide useful regardless of the sampling equipment you use and will use our
equipment for demonstrations and illustrations.
Isokinetic Sampling is the collection and measurement of a gas sample from a source at the same velocity
as the gas travels in the stack to provide a representative assessment of solid particulate matter that is in the
source.
To perform isokinetic testing, you must have a thorough understanding of the first five test methods
presented in Title 40 Part 60 Appendix A of the Code of Federal Regulations (40CFR60 App. A). While
Method 5 outlines the general sampling train operation protocol, Methods 1 through 4 prescribe techniques
that serve as a foundation for Method 5 sampling activities. Together, these methods outline the basic
protocols for determining particulate concentrations and mass emission rates.
US EPA Description
Method
Method 1 Determination of Sampling Location and Traverse Points
Method 2 Determination of Stack Gas Velocity and Volumetric Flow-rates
Method 3 Determination of Dry Molecular Weight and Percent Excess Air
Method 4 Determination of Moisture Content
Method 5 Determination of Particulate Matter Emissions from Stationary Sources
You can easily adapt the basic Method 5 sampling train to test for many other gaseous and particulate
emissions from stationary sources. Adapting basic test methods allow you to expand testing to include
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parameters of interest such as metals, polychlorinated biphenyls (PCBs), dioxins/furans, polycyclic aromatic
hydrocarbons (PAHs), particle size distributions and an ever-increasing group of other pollutants.
While the different methods are designated by other US EPA method numbers, they actually are variations of
Method 5 procedures. Variations might include using different impinger solutions, organic resin traps,
different filter media, various sampling temperatures, or a range of other alternative procedures.
The manual and the automated source sampling consoles can be used for the following isokinetic test
methods and pollutants:
Method No. Pollutants

5A PM from Asphalt Roofing
5B Non-sulfuric Acid PM
5D PM from Positive Pressure Fabric Filters
5E PM from Fiberglass Plants
5F Non-sulfate PM from Fluid Catalytic Cracking Units
5G PM from Wood Stoves - Dilution Tunnel
5H PM from Wood Stoves – Stack
8 Sulfuric Acid Mist, Sulfur Dioxide and PM
12 Inorganic Lead (Pb)
13A & 13B Total Fluorides
17 Particulate Matter
23 Polychlorinated Dibenzo-p-Dioxins and Dibenzofurans
26A Hydrogen Halides and Halogens
29 Multiple Metals
101 Mercury (Hg) from Chlor Alkali Plants
101A Mercury (Hg) from Sewage Sludge Incinerators
104 Beryllium (Be)
108 Inorganic Arsenic (As)
111 Polonium-210
201A PM10 Particulate Matter (Constant Sampling Rate)
202 Condensable Particulate Matter
206 Ammonia (Tentative)
207 Iso cyanates (Tentative)
306 Hexavalent Chromium from Electroplating and Anodizing Operations
315 PM and Methylene Chloride Extractable Matter (MCEM) from Primary Aluminum
Production
316 Formaldehyde from Mineral Wool and Wool Fiberglass Industries (Proposed)
Waste Combustion Source Methods in EPA-SW-846

Method No. Pollutants
0010 Semi volatile Organic Compounds
0011 Formaldehyde, Other Aldehydes and Ketones
0023A Polychlorinated Dibenzo-p-Dioxins and Dibenzofurans
0050 Hydrogen Chlorine and Chlorine
0060 Multiple Metals
0061 Hexavalent Chromium
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System Description
The first step to successful sampling is to familiarize yourself with the standard equipment. To illustrate the
necessary components of source sampling, we’ve included a diagram of the five main components
demonstrated on the Apex Instruments Isokinetic Source Sampling System, shown in Figure 1-1:
1. Source Sampler Console, which includes a differential pressure transducer (or dual-column
manometers), sample flow control valves with orifice flow meter, dry gas meter, and electrical
controls.
2. Sample Pump External Rotary Vane (or internal diaphragm pump) , including hoses with quick-
connect fittings and lubricator.
3. Probe Assembly includes a stainless-steel probe sheath, probe liner, tube heater, Type-S pitot tube,
stack and heater thermocouples, and an Orsat line.
4. Modular Sample Case includes a filter oven for the filter assembly, an impinger case for the
impinger glassware and electrical connections.
5. Umbilical Cable includes electrical and pneumatic lines to connect the Modular Sample Case to the
Source Sampling Meter Console.
Figure 1-1: Apex Instruments Isokinetic Source Sampling Equipment
Apex Instruments Product Highlight

When looking for a console, consider a user-friendly design
that simplifies field assembly and set-up. The Apex
Instruments XC-500 Series Console Meters place
connections for the sample line, pitot tube lines, vacuum
pump (non-reversible), and electrical (4-pin circular
connector and Thermocouple jacks) all on the front panel
for easy access. You also can remove the front and back
covers of the console to get to what you need. The XC-522
model is programmed for English-standard measurements,
while the XC-572 offers a metric version.
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Description of Component Parts
1. Source Sampler Console
The Source Sampler Console is the operator’s control station. It monitors gas velocity and temperatures at
the sampling location and controls system sampling rate and system temperatures. Housed within the console
are the Electrical, Thermocouple, and Vacuum sub-systems.
Electrical Subsystem:
The electrical subsystem provides switched power to several circuits, including main power, pump power,
manometer zero, timer, probe heater and oven heater. Power rating should be chosen according to your
source of electricity. For example, the Apex Instruments XC-500 Sampling Systems can be configured for
120VAC/60Hz or 240VAC/50Hz electrical power.
Note: When the main power switch is on, the cooling fan should operate. Also, the pump has its own power
cord, which is plugged into the Source Sampler Console.
The electrical system contains circuit breakers that detect and

interrupt overload and short circuit conditions, an important safety Tips from a Stack Tester
feature. If the circuit breaker opens or “trips,” indicating
interruption of the circuit, investigate and repair the electrical fault.
Then reset the breaker by pressing the circuit breaker switch. The
circuit breaker also can trigger a “nuisance trip,” making it difficult
to complete a test.
To reduce the probability
The MANOMETER ZERO switch operates two (2) 3-way solenoid
of nuisance tripping,
valves. When the MANOMETER ZERO switch is ON, the valves
follow this start-up
will produce an audible “click.” These valves open both legs of the
sequence to reduce the
ΔH side of the dual-column manometer to atmosphere so that you
power surge: first, power
can check and, if necessary, adjust the manometer fluid zero
up the sample pump
pressure level.
because it runs on the
The timer will begin to count when the TIMER switch is turned on highest current. Wait a few
and stops when the switch is turned off. The display is reset to zero seconds after the pump has
with a push switch on the face of the timer display. The timer is started, then power up the
factory-set to read hour/minutes/seconds but can read minutes and filter and probe heaters.
tenths of minutes if specified in the purchase order.
To activate the heaters in the filter compartment (Hot Box) and the
probe heater, turn on the switches labeled FILTER and PROBE.
Adjust the dials to approximately 120°C (248°F) and check the temperature display to verify that the heaters
are working. Allow time for the temperatures to stabilize and then verify operation of the circuits.
Thermocouple Subsystem:
The thermocouple subsystem displays, measures and provides feedback for the temperature controls that are
critical to isokinetic sampling operation. The Apex Instruments thermocouple system consists of Type-K
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thermocouples, extension wires, male/female connectors, receptacles, a thermocouple selector switch, and a
digital temperature display with internal compensating junction.
Existing consoles offer automatic and digitally programmable temperature controllers for probe and filter
oven heat. The controllers receive temperature feedback signals to maintain temperatures within range of the
set point. The thermocouple electrical diagram is presented in the electrical schematic, found in the
appropriate operator’s manual.
Vacuum Subsystem:
The vacuum pump assembly provides the vacuum action for extracting the gas sample from the stack and
through the various components of the isokinetic source sampling system.
Typically, the vacuum subsystem consists of an external vacuum pump assembly (or internal diaphragm
pump), quick-connects, internal fittings, two (2) control valves (coarse and fine), an orifice meter, and a
dual-column inclined manometer (or pressure transducer).
A popular method of controlling flow is the dual-valve design that helps the operator obtain very precise
control over the sample flow rate through use of the Coarse Control Valve and the Fine Increase Valve.
● The Coarse Control Valve is a ball valve with a 90°
handle rotation from closed to full open. This valve
controls the flow from the SAMPLE inlet to the
Vacuum Pump inlet. Tips from a Stack Tester
● The Fine Increase Valve is a needle-type valve with
four (4) turns from closed to full open. The Fine
Increase Valve allows flow to re-circulate from the
pump outlet back to the pump inlet. The Fine Increase
Valve is used for precise vacuum control during leak
checks. By observing the orifice
reading (ΔH) on the front
You can zero the ΔH manometer before or during a sampling side of the manometer, you
run by flipping on the Manometer Zero switch found on the can quickly adjust the
front panel. This actuates the solenoid valves to vent the sample flow rate using the
pressure lines to atmosphere. Then, you can adjust the Fine Increase Valve so that
manometer’s fluid level using the knobs located at the bottom the sample is extracted under
of the manometer. isokinetic conditions.
Did you know? You can zero the pitot tube manometer by disconnecting the pitot lines
at the quick-connects on the Source Sampler Console.
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Figure 1-2 below demonstrated the Apex Instruments Model XC-522 Source Sampler Console’s front panel
to provide an example of the layout of Source Sampling Console.
Figure 1-2: Model XC-522 Source Sampler Console Front Panel
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Source Sampler Console Front Source Sampler Console Rear
2. External Vacuum Pump Unit

The External Pump Unit provides the vacuum that draws the sample from the stack. The most common type
of pump assembly attaches to the Source Sampler Console via an electrical receptacle and two (2) 1.524 m (5
ft.) hose extensions with 9.525 mm (3/8 in.) quick-connects (configured with a male connector on the
pressure side and a female connector on the suction side.
Figure 1-3: Picture of XE-0523 (Cased) and E-0523

Apex Instruments (Open Frame) Lubricated Vane Vacuum Pump
Product Highlight
Apex Instruments offers two pump styles: the E-
0523 lubricated rotary-vane pump and the
internal diaphragm housed inside the console.
Both pump assemblies are available in either
120VAC or 240VAC operation and customers
can choose from two enclosure options for the
external pump: a black polyethylene case with
molded handles and removable covers or an
aluminum open frame (seen to the right).
 The E-0523 features a 250-watt motor

with a measured flow of 88 lpm and a
maximum vacuum of 86.4 kPa.
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Tips from a Stack Tester
Pumps that require lubrication, such as the E-0523,

generally are not pre-lubricated and need to be
filled approximately three-quarters (¾) full with
lightweight lubricating oil (Gast AD220, SAE-10
or SAE-5) before first use.
3. Probe Assembly
The main components of a Probe Assembly are:
● Probe Liner: 15.9 mm (5/8 in.) OD tubing made from either Borosilicate Glass, Quartz, Stainless Steel,
Inconel, or PTFE.
● Probe Heater: Removable rigid tube heater with coiled heating element, electric thermal insulation and
thermocouple, with a maximum recommended temperature of 260oC (500oF).
● Probe Sheath: 25.4 mm (1 in.) OD tube with quad-assembly attached that includes a replaceable,
modular S-type pitot tube, stack thermocouple and a 1/4 in. OD stainless steel tube to collect gas samples
for Orsat analysis.
● Small Parts Kit: Fittings to attach nozzle to Probe Assembly. Fittings include 5/8 in. bored union, nut
and ferrules.
Did you know? The most effective probe length in the stack is equivalent to 0.305 m
(1 ft) less than nominal length. Probe lengths vary from 0.914 m (3 ft) to 4.877 m (16
ft) nominal length.
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Figure 1-4, right side, illustrates a standard Probe Assembly (top) and a Probe Assembly with the optional
50.8 mm (2 in.) Oversheath and Packing Gland (bottom).
The left part of the diagram shows the connection between the nozzle and probe using fittings from the small
parts kit.
Figure 1-4: Diagrams of Probes and Probe Assembly
Probe Liner:
Standard Probe Liners are constructed from 5/8 in. OD tubing and have #28 ball joints with an O-ring
groove. Available liner materials are borosilicate glass, quartz, stainless steel, Inconel, and PTFE. You will
need a ball joint adapter if you have a PTFE liner, straight liner, or liner with integrated nozzles. Figure 1-5
shows the potential Probe Liner configurations.
Figure 1-5: Diagrams of Probe Liner Configurations
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Important: Review maximum operating temperatures before selecting a Probe Liner material and
configuration. Table 1-3 shows the temperature limits for Probe Liner materials, while Table 1-4 reflects
temperature limits for various probe configurations.
Table 1-3: Maximum Stack Gas Temperatures for Probe Liner Materials
Maximum
Material Temperature
177°C (350°F)
PTFE Liners and Fittings
260°C (500°F)
Glass-Filled PTFE Fittings
Borosilicate Glass Liners 480°C (900°F)
Stainless Steel Liners 650°C (1200°F)
Quartz Liners 900°C (1650°F)
Inconel or C276 Alloy Liners 870°C (1600°F)
Table 1-4: Probe Configuration Temperature Ratings
Maximum
Probe Assembly Configuration Temperature
480°C (900°F)
Stainless Steel Sheath and Glass Liner
Stainless Steel Sheath and Liner 650°C (1200°F)
Inconel or C276 Alloy Sheath and Liner 870°C (1600°F)
Inconel or C276 Alloy Sheath and Quartz Liner 870°C (1600°F)
Probe Heater: Apex Instruments

Product Highlight
For accurate results, the sample temperature should remain in
the range of 120oC ± 5oC (248oF ± 9oF) as it travels through
With accurate sampling in mind, Apex
the probe.
Instruments Probe Heaters feature a
Important: Exposure to elevated temperatures can damage rigid tube heater with coiled heating
the insulation and shorten the life of the heater. The maximum element, electrical thermal insulation
recommended stack exposure temperature for Probe Heaters with integrated thermocouple, and a
is 260oC (500oF). Partial probe heaters are recommended for power cord sealed in silicone-
temperature above 500ºF. impregnated glass insulation.
Also, our mandrel-type heater design

allows you to replace the liner as
needed without removing the heating
element. Standard heaters are
configured for 120VAC operation;
240VAC configuration is available.
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How to Connect the Probe Assembly to the Modular Sample Case:
The Probe Assembly connects to the Modular Sample Case with the following steps:
1. Mount the probe sheath to the Modular Sample Case using a probe clamp that is attached to the probe
holder.
2. Look for the thermocouple male connector extending from the probe assembly and connect it to the
female thermocouple connector of the Umbilical Cable.
3. Connect the electrical plug to the electrical receptacle on the Modular Sample Case Hot Box.
4. Insert the outlet ball of the Probe Liner through the entry hole of the Filter Oven (Hot Box)
compartment until the back of the sheath is even with the inside of the sample case.
5. Connect the pitot tube quick-connect lines, probe heater thermocouple, stack thermocouple and Orsat
gas sample line to the Source Sampler Console via the Umbilical Cable.
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4. Modular Sample Case
The Modular Sample Case is used for support, protection and environmental control of the glassware in the
sampling train. The Modular Sample Case consists of an insulated heated filter compartment (Hot Box) and
insulated impinger case (Cold Box).
Figure 1-6 illustrates the major components and accessory connections on the Modular Sample Case.
Handle with Safety Clip
Door Latch (both sides)
Hinged Probe
34.3cm Clamp Filter Oven
Umbilical Adapter Clamp
Probe Power Receptacle
31.8cm
Amphenol Connector
24.1cm
Impinger
Oven Thermocouple Connector
Case
Aux. Power Riser
Impinger Case Drain
Figure 1-6: Modular Sample Case Components and Accessories
The impinger case (cold box) holds the sampling train

impingers in an ice bath so that the stack gas sample is
cooled as it passes through the impingers to condense the
water vapor. This process allows you to measure stack gas Tips from a Stack Tester
moisture volume, then use that reading to calculate stack gas
density.
Obtain multiple Impinger

Cases and sets of impingers for
rapid turnaround time between
test runs.
Figure 1–7: From left to right, SB-3, SB-4, SB-4SD, SB- Some companies offer
4SDM2, and SB-5 Impinger Boxes impinger cases for a variety of
different number of impingers.
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5. Umbilical Cable with Umbilical Adapter
The Umbilical Cable connects the Modular Sample case and Probe Assembly to the Source Sampler
Console. The Umbilical Cable typically contains the gas sample and pitot lines, as well as thermocouple and
power lines.
Below is an example of the configuration of the umbilical connections (using the Apex Instruments product
as an example):
● The primary gas sample line (blue, 3/8 in. i.d./12.7 mm (5/8 in. o.d.)) has a male quick-connect on the
outlet, at the opposite end, a 12.7 mm (5/8 in.) female quick-connect on the inlet.
● The two (2) pitot lines, (black and white, 6.35 mm (1/4 in.)), have female quick-connects to the Probe
Assembly and 6.35 mm (1/4 in.) male quick-connects to the Source Sampler Console. There is an
additional gas sample line for Orsat analysis (yellow, 6.35 mm (1/4 in.)), which also can be used as a
spare pitot line.
● Multiple thermocouple extension cables for Type-K thermocouples, which terminate with durable full-
size connectors. The connectors have different diameter round pins to ensure proper polarity, and will not
fully connect if reversed. Each thermocouple extension wire in the Umbilical Cable is labeled and color-
coded for temperature measurement of Stack, Probe, Oven (Hot Box), Exit (Cold Box), and Auxiliary
(spare).
● The AC power cable (for Filter Oven and Probe Assembly heaters) terminates with a circular, military-
style connector on each end.
● The Umbilical Adapter connects the outlet of the last impinger to the Umbilical Cable and contains the
exit thermocouple. This adapter serves to relieve strain between the Umbilical Cable and the glassware
train.
● The body of the circular connector is grounded. A line-up guide is placed on each connector’s end, and
the retainer threads should be engaged for good contact. Figure 1-8 illustrates the circular connector with
pins labeled.
● The Umbilical Cable is covered with a woven nylon mesh sheath to restrain the cable and reduce friction
when moving the cable.
Figure 1-8: Circular Connector and Electrical Pin Designations
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How to Construct a Glassware Sample Train:
The sample glassware train contains the filter holder for collection of particulate matter, glass impingers for
absorption of entrained moisture, and connecting glassware pieces.
Figure 1-9 below illustrates the glassware of the US EPA Method 5 sampling train.
The order in which a typical US EPA Method 5 glassware train is constructed is as follows:
1. Cyclone Bypass (GN-1), Optional: Cyclone (GN-2) and Cyclone Flask (GN-3)
2. 3 in. Glass Filter Assembly (GNFA-3). Assembly consists of the Filter Inlet (GN-3S), Teflon Filter Disk
or “Frit” (GA-3T), Filter Outlet (GN-3B), Filter Clamp (GA-3CA), and Glass Fiber Filter (GF-3 Series).
3. Double “L” Adapter (GN-8), or alternate GN-8-18K with thermocouple assembly
4. 1st Impinger Modified Greenburg-Smith (GN-9A)
5. U-Tube (GN-11)
6. 2nd Impinger Greenburg-Smith with Orifice (GN-9AO)
7. U-Tube (GN-11)
8. 3rd Impinger Modified Greenburg-Smith (GN-9A)
9. U-Tube (GN-11)
10. 4th Impinger Modified Greenburg-Smith (GN-9A )
Figure 1-9: Glassware Sampling Train Schematic
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Chapter 2 Tips from a Stack Tester
Operating Procedures
A drop of penetrating oil
There are several steps to complete before testing for
helps keep the quick-
particulate matter, which include:
connects in good working
1. Set up and inspection of source sampling system, condition. Inspect the pitot
review of calibration records tube openings for damage
2. Test design or misalignment, and
replace or repair them if
3. Site preparation necessary.
4. Sampling equipment calibrations (see Chapter 3)
5. Assembling sampling equipment and accessories,
reagents, sample recovery equipment, and sample storage containers
6. Preliminary measurements of stack dimensions, gas velocity, dry molecular weight, and moisture.
1. Set-up and Check of Source Sampling System

When unpacking your sampling system for the first time, check each part for damage and ensure your
shipment is complete by checking items off the packing list.
If you purchased your product from Apex Instruments, please call us immediately at 800-882-3214 or email
us at info@apexinst.com to seek help with any damaged or missing products.
A. Initial Set-up Procedure

These instructions are for a “dry run” set-up of the complete US EPA Method 5 sampling train.
Important: Do not load a glass fiber filter into the filter assembly or charge liquids and silica gel in the
impingers. The objective is just to set-up the equipment to verify that everything works. Start with these
steps:
1. Remove all items from packaging and place in an open area.
2. Slide the Impinger Case (Cold Box) onto the Modular Sample Case’s heated filter oven (Hot Box),
using the steel slide guides. Check the fit and height of the Sample Case and Umbilical Adapter.
Adjust the steel slides to achieve the desired fit. Engage the spring latch that locks the Impinger Case
into place.
3. Inspect the Probe Liner and Probe Assembly. Wipe clean the quick-connects on the Probe Assembly.
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4. Slide the Probe Liner into the probe sheath. The liner’s plain end (no ball joint) should come out
approximately 1.27 cm (1/2 in.) at the pitot tube end of the Probe Assembly.
5. Insert the Probe Assembly into the probe clamp that is attached to the Filter Oven and tighten. Then,
carefully insert the outlet ball of the Probe Liner through the hole into the Hot Box. The back of the
sheath should be even with the inside of the Hot Box. Next, plug the Probe Heater electrical plug into
the probe receptacle on the Hot Box.
6. To install a nozzle on the Probe Assembly, consult Figure 2-1. Slide the ferrule system onto the plain
exposed end of the Probe Liner. Substitute high-temperature braided glass cord packing for the
ferrule when stack temperatures are greater than 260°C (500°F) or use liner with integrated nozzle.
Apex Instruments’ Probe Assembly Spare Parts Kit (the bag taped to probe sheath) contains fittings for
two (2) different ferrule installation options: 1) Stainless Steel Single Ferrule and 2) Backer Ring with O-
Ring. The recommended configurations for different liner options are detailed below:
 Stainless Steel Liner: Stainless Steel Single Ferrule or Backer Ring with O-Ring
 Glass Liner: Backer Ring with O-Ring, or PTFE Single Ferrule (Optional), or Glass-filled PTFE
Single Ferrule (Optional).
Stainless Steel Nozzle Glass Nozzle
Figure 2-1: Installation of Stainless Steel and Glass Probe Nozzle Connectors
7. Thread the 15.875 mm (5/8 in.) union onto the nut welded to the probe sheath. This is a compression
fitting that is tapered to seal the ferrule system inserted on the Probe Liner.
Important: Tighten the fitting until the liner has a leak-tight seal, but DO NOT OVERTIGHTEN.
8. Connect the glassware sampling train completely in the Filter Oven (Hot Box) and Impinger Case
(Cold Box) (see Figure 1-9 and the related “How to Construct a Glassware Sample Train” at the end
of Chapter 1). Tighten all joints using the Ball Joint Clamps. The final connection is the Umbilical
Adapter, which slides into the clamp on the outside of the Impinger Case. Again, do not load the
Filter Assembly with a filter, and do not fill the impingers because this is a “dry run” set-up.
9. To connect the Umbilical Cable to the Modular Sample Case, first connect the Umbilical Cable
circular connector plug to the receptacle on the side of the Filter Oven (see Figure 1-6). Next, connect
the labeled Umbilical Cable thermocouple plugs into the receptacles on the Filter Oven, Probe
Assembly, and Umbilical Adapter. Then, insert the Umbilical Cable sample line female quick-
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connect into the Umbilical Adapter male quick-connect. Finally, insert the Umbilical Cable female
pitot line quick-connects into the Probe Assembly male quick-connects.
10. To connect the Umbilical Cable to the Source Sampler Console, first connect the Umbilical Cable
circular connector plug to the receptacle on the front panel of the Source Sampler Console. Then,
connect the labeled Umbilical Cable thermocouple plugs into the receptacles on the Source Sampler
Console front panel.
Next, insert the Umbilical Cable sample line male quick-connect into the Source Sampler Console
female quick-connect. Finally, insert the Umbilical Cable pitot line male quick-connects into the
Source Sampler Console female quick-connects (labeled + and −). The pitot lines are colored to
differentiate the positive and negative lines and ensure the connections are consistent between the
pitot tube and Source Sampler Console.
11. To connect the Vacuum Pump Assembly to the Source Sampler Console, first wipe the quick-
connects clean, then connect the pressure and vacuum hoses on the Vacuum Pump Assembly to the
pump connections located on the lower left of the Source Sampler Console front panel. Then, connect
the power cord of the Vacuum Pump Assembly to the receptacle labeled PUMP on the Source
Sampler Console.
12. Plug the Source Sampler Console into an appropriate electrical power source.
B. Initial Sampling System Leak Check

Remember to follow the set-up procedure detailed in the previous section before starting a system check
procedure. The system leak check described below is a “dry” run:
1. Close the Coarse Valve on the Source Sampler Console.

2. Seal the inlet to nozzle.
3. Turn on the Vacuum Pump with the PUMP POWER ON switch.
4. Slowly open the Coarse Valve and increase (which means turn clockwise until close) the Fine
Increase Valve.
5. The pump vacuum, as indicated on the Vacuum Gauge, should read a system vacuum within 10 kPa
(3 in. Hg) of the barometric pressure. Example: If the barometric pressure is 100 kPa (30 in. Hg),
then the Vacuum Gauge should read at least 92 kPa (27 in. Hg).
6. Wait a few seconds for the pressure to stabilize. When the Orifice Tube pressure differential (ΔH) has
returned to the zero mark, measure the leak rate for one minute, as indicated on the dry gas meter
display. The observed leak rate should be less than 0.56 liters per minute (lpm) (0.02 cubic feet per
minute (cfm)). If the leak rate is greater, check the tightness of all connections in the sampling train
and repeat.
21
2. Test Design
Before testing, define the test parameters by answering the following:
● Why is the test being conducted?

● Who will use the data?
● Which stacks or emission points are being tested?
● What process data is being collected and correlated with test results?
● Where are the sample ports located and what type of access is available?
● When is the test scheduled, and what are the deadlines for reporting?
● What is the specific method or procedure to follow?
● How many test runs or process conditions will be tested?
3. Site Preparation
Preparing the site so that sampling equipment can be positioned correctly is frequently the most difficult part
of the sampling process. When the sample ports do not have a platform or catwalk, then scaffolding must be
erected to reach the sampling site. At many sites, operators must use their ingenuity to get the sampling
equipment to the sampling location.
When selecting the site for sample ports, keep in mind that the distance from the probe to the bottom of the
sample case is about 33 cm (13.5 in.). This means that when traversing the stack, the sampling equipment
needs 33 cm of clearance below the port level to avoid bumping into guardrails or other structures.
To calculate the clearance needed along the sample port plane, start with the effective probe length (which is
stack diameter plus port nipple length) and add at least 91 cm (36 in.) to accommodate the length of the
sample case (Filter Oven, Impinger Case, and probe clamp).
Figure 2-2 on the next page illustrates the clearance zones required.
22
Figure 2-2: Clearance Zones at Stack for Isokinetic Sampling Train
23
If you can’t find a solution for sampling train clearance problems, Apex
Instruments can provide one. We offer a Non-Rigid Method 5
sampling train with a separate and/or miniature heated Filter Box (SB-
2M), which allows you to put the Cold Box on the sampling platform,
where it is connected by the sample line and Umbilical Adapter (GA-
104).
Figure 2-3 on the next page illustrates the Non-Rigid Isokinetic

Sampling Train. The midget hot box decreases the clearance needed
between the monorail and guardrail of the stack.
Figure 2-3: Schematic of Non-Rigid Isokinetic Sampling Train
24
A second solution for clearance problems is our Compact

Method 5 sampling train with a Heated Filter Assembly
(SFA-82H) and Power Box Adapter (UA-3J).
Figure 2-4 below illustrates the Compact Method 5 option.

The smaller heated filter assembly allows for greater
flexibility in small sampling areas.
Figure 2-4: Schematic of Compact Isokinetic Sampling Train
Did you know? Although the Isokinetic Source Sampling System is

designed to fit into a 6.35 cm (2.5 in.) sample port, a larger port hole
measuring 7.6 cm (3 in.) or greater allows you to insert and remove the
probe more easily, without damaging the nozzle or picking up
deposited dust.
Mount the Hot and Cold Boxes
There are two ways to mount the isokinetic sampling system (which includes the Filter Oven and Impinger
Case) on a stack:
1. Assemble a monorail system with lubricated roller hook above each sample port, or
2. Construct a wooden platform slide apparatus (where feasible).
25
Figure 2-5 illustrates an isokinetic sampling system mounted on a monorail system above a sample port with
a tee bracket system. Another way to do a monorail mounting is when there is an angle iron, with a hole or
an eyehook, welded to the stack.
Figure 2-5: Illustration of Monorail System for Sampling Train

When no mounting support for a monorail
system exists, you can easily construct one
using the Apex Instruments Monomount
(P501) around the stack, as shown in Figure
2-6 on the next page.
Figure 2-6: Illustration of Apex Instruments

Monomount Monorail System
Illustrated below is a complete stack set-up in two different configurations: Figure 2-7 shows the Hot
Box/Cold Box together (SB-1) and Figure 2-8 shows the Filter Oven and Impinger Case separated (SB-2M
and SB-3).
26
Figure 2-7: Stack Platform Set-up with Modular Sample Case on Monorail
27
Figure 2-8: Stack Set-up with Hot Box on Monorail Separated from Cold Box
Assemble Sampling Equipment and Reagents
Remember to use checklists when assembling the sampling equipment, reagents and auxiliary supplies for a
test. See Appendix A for checklists of recommended equipment, spare parts and reagents for isokinetic
sampling. Keep in mind that you may not need the entire list at the test site. Also, refer to Section 3 of US
EPA Method 5 for the list of reagents required to perform an isokinetic particulate test.
Obtain Preliminary Measurements of Gas Velocity, Molecular Weight and Moisture
Before attempting to calculate the parameters needed for isokinetic sampling – such as probe nozzle size,
ΔH/Δp ratio (K factor), gas sample volume, etc. – you first must determine several preliminary values
described in Table 2-1 on the next page.
Table 2-1: Preliminary Measurements for Isokinetic Sampling
No. Symbol Value Needed Obtain from

1. Before the sample run (best), or
1. Δpavg Average stack gas velocity pressure head
2. A previous test (often erroneous)
2. Ps Stack gas pressure
2. A previous test (very small error)
Dry gas meter pressure
3. Pm Same as barometric pressure

4. Bws Stack gas moisture fraction
5. Ts Average stack gas temperature
Meter temperature rises above ambient
6. Tm Average dry gas meter temperature because of pump heat and is typically
estimated at 14°C (25°F) above ambient
7. Md Stack gas molecular weight
2. A previous test (very small error)
Determined previously from laboratory
8. ΔH@ Orifice meter calibration factor
calibration
28
Obtain most of the

preliminary values just
before the sample run
rather than using old data.
Relying on previous tests
for values such as average
stack gas velocity, stack
gas moisture, and average
stack gas temperature can
lead to erroneous results.
Did you know? Methods 1 through 4 are like building blocks, providing the
preliminary values needed to complete Method 5 sampling. Thus, when you perform a
sampling run using Method 5, you will need to know Methods 1 through 4 procedures
to collect the data needed for Method 5 sampling and calculations.
Through the rest of Chapter 2, we have provided concise and easy-to-use information
for performing US EPA Methods 1 through 5.
Method 1
Determining Sample and Velocity Traverse Points
Method 1 is the first step toward collection of a representative sample to measure a stack’s particulate
concentration and mass emission rate. Method 1 is applicable to gas streams flowing in ducts, stacks and
flues. Since the velocity and particle concentration in the stack are not uniform, you must traverse the cross-
section to obtain a representative sample.
Keep in mind: This method cannot be used when:

1. The flow is cyclonic or swirling and is skewed to one side.
2. A stack is smaller than 0.30 meter (12 in.) in diameter, or 0.071 m² (113 in.²) in cross-sectional area.
29
For stacks and ducts measuring less than 12 in. in diameter, see Method 1A immediately following this
section.
The number of required traverse points depends on the shape - or straightness - of the stack or duct.
Straighter lengths of stack or duct produce flow streamlines that are more uniform, so fewer traverse points
are needed to obtain a representative sample. Conversely, if your sampling site is close to bends in the stack
or other flow disturbances, you will need to use more traverse points to obtain a representative sample.
Method 1 describes procedures to:

● Select appropriate sampling locations on the stack (if sample ports do not already exist).
● Calculate the number of traverse points for velocity and particulate sampling.
● Calculate the location of the traverse points.
We can identify appropriate sampling sites by measuring their distance from any type of flow disturbance in
the stack. Disturbances can be bends, transitions, expansions, contractions, stack exit to atmosphere, flames,
or the presence of internal installations such as valves or baffles.
To calculate distance between the sampling site and flow disturbances, first we measure the internal stack
diameter. Then, we use that length to determine how many “diameters” are in between the sampling site and
the flow disturbance.
Figure 2-9 on the next page depicts how stack diameters are used to measure distance from a flow
disturbance such as a bend. The example on the left shows an acceptable sampling site, which is eight (8)
diameters downstream from a bend and two (2) diameters upstream from the stack exit. The example on the
right is not an acceptable sampling site because it is too close to a flow disturbance (the bend in the stack).
30
Figure 2-9: Visualizing Stack Diameters from Flow Disturbances
Calculate Traverse Points

Calculate the minimum number of traverse
points needed with the following steps:
1. Measure the stack diameter to within

0.3175 cm (1/8 in.).
a. Insert a long rod or pitot tube
into the duct until it touches the Measure the stack diameter from each
opposite wall. sampling port and use the average, since not
all circular stacks are round and not all
b. Mark the point on the rod where rectangular stacks are perfectly rectangular.
it meets the outside of the port
nipple. By measuring through each port, you can
often find in-stack obstructions and take steps
c. Remove the rod, measure and to avoid erroneous measurements.
record this length to the far wall
(Lfw.). If possible, shine a flashlight across the stack
to look for obstructions or irregularities.
d. With a tape measure (or rod if
the stack is hot), measure the If possible, using a gloved hand, reach into
distance from the outside of the the sampling port and check that the port was
port nipple to the near wall and installed flush with the stack wall (and that it
record this length (Lnw). does not extend into the flow.)
31
e. Calculate the diameter of the duct from this port as D = Lfw - Lnw.
2. Repeat for the other port(s) and then average the diameter (D) values.
3. Then, measure the distance from the sample port cross-sectional (horizontal) plane to the nearest
downstream disturbance (designated Distance A).
4. Next, measure the distance from the sample port cross-sectional plane to the nearest upstream
disturbance (designated Distance B).
5. Calculate the number of duct diameters to the disturbances by dividing Distance A (to downstream
disturbance) by the average diameter (D). Do the same for Distance B (to upstream disturbance).
6. Using Figure 2-10 (for particulate traverses) or 2-10b (for velocity traverses), determine where Distance
A (top) intersects the solid traverse points line running through the middle of the graph. Then, determine
where Distance B meets the traverse points line, and select the higher of the two numbers as the
minimum number of traverse points needed for sampling.
Example: The dotted lines in Figure 2-10 represent a Distance A measurement of 1.7 duct diameters and a
Distance B measurement of 7.25 duct diameters. Looking at where the dotted lines intersect the solid
traverse points line, Distance A requires 16 traverse points, while Distance B requires 12 traverse points.
Always choose the higher of the two numbers. In this example, the sampling site requires 16 total traverse
points. The 16 points are arranged in two lines of eight points each which are 90° apart, forming a cross
shape.
Figure 2-10: Example of How to Determine Number of Traverse Points (Particulates)
32
Figure 2-10b: Example of How to Determine Number of Traverse Points (Non-Particulates)
Identify Minimum Number of Traverse Points
● For circular stacks with diameters greater than 60 cm (24 in.), the minimum number of traverse
points required is twelve (12), or six (6) in each of two directions 90° apart (see Figure 2-11). This
applies when disturbances are eight (8) or more duct diameters upstream and two (2) or more
downstream.
● For circular stacks with diameters between 30 and 60 cm (12 and 24 in.), the minimum number of
traverse points required is eight (8), or four (4) in each of two directions 90° apart.
● For stacks less than 30 cm (12 in.) in diameter, refer to Method 1A for calculating traverse points.
● The minimum number of traverse points required for rectangular stacks is nine, or 3 x 3.
For rectangular stacks or ducts, first calculate an equivalent diameter using the following equation:
where De = equivalent diameter of rectangular stack

L = length of stack
W = width of stack
33
Determine the Location of Traverse Points
Circular Stacks
After determining the number of traverse points, you must calculate the location of each traverse point. The
method for locating the traverse points for circular stacks is as follows:
1. Divide the number of traverse points by four (4). The resulting number will give you the number of
concentric circles of equal area to use in your sample point matrix. In the example illustrated in
Figure 2-11, twelve (12) traverse points divided by four (4) equals three (3).
2. Bisect the circles twice, cutting them into quarters, as shown below.
3. Place the sample points in the centroid (center of mass) of each equal area, as shown in Figure 2-11.
Figure 2-11: Traverse Points Located in Centroids for Circular Stack
Pinpoint and Mark Traverse Points
Follow this procedure to locate each traverse point across the

diameter of a circular stack and mark the corresponding point on Tips from a Stack
the probe assembly or pitot tube: Tester
1. On a Method 1 field data sheet (which can be computer or

calculator generated), multiply the stack diameter by the
percentage taken from the appropriate column of Table 2-
2. For example, the 4th traverse point along a diameter You may combine two
with 6 points is equivalent to 70.4% of the stack diameter successive points to
(D x .704). form a single adjusted
point, which must be
sampled twice.
34
2. Add the port nipple length to the value calculated in step 1 for each traverse point.
3. Round each value to the nearest 1/8th (0.125) of an inch for each point (English units only).
4. For stacks greater than 60 cm (24 in.) in diameter, relocate any traverse points closer than 2.5 cm
(1.00 in.) to the stack wall to 2.5 cm and label them as “adjusted” points.
5. For stacks less than 60 cm (24 in.) in diameter, use an adjusted distance of 1.3 cm (0.5 in) to relocate
any points away from the stack wall.
6. Measure each traverse point location from the tip of the pitot tube and mark the distance with heat-
resistant fiber tape or “Wite-Out” correction fluid, as illustrated in Figure 2-13.
Table 2-2 Location of Traverse Points in Circular Stacks
(Percent of stack diameter from inside wall of traverse point)
Traverse point number on a diameter Number of traverse points on a diameter

4 6 8 10 12
4 93.3 70.4 32.3 22.6 17.7
5 85.4 67.7 34.2 25.0
6 95.6 80.6 65.8 35.6
7 89.5 77.4 64.4
8 96.8 85.4 75.0
9 91.8 82.3
10 97.4 88.2
11 93.3
12 97.9
35
After calculating the traverse point locations (before adding

sample port nipple length), you can check your work
quickly by noticing if the first and last traverse point
distances added together equal the stack diameter; then if
the second and next to last equal the same; then if the third
and third from last equal the same; and so on.
For instance, with a stack diameter of 60 cm and 12

traverse points, the 4th point is 10.62 cm (60 cm x 0.177)
from the port and the 9th point is 49.38 cm (60cm x 0.823)
from the port. 10.62 cm + 49.38 cm = 60 cm.
36
Figure 2-13: Illustration of Marking Traverse Points on Probe Assembly
Rectangular Stacks
For rectangular stacks, the centroids for placing the traverse points are much easier to determine, as shown in
Figure 2-12.
Figure 2-12: Traverse Points Located in Centroids for Rectangular Stack
Table 2-3: Cross Section Layout for Rectangular Stacks
Number of Traverse Matrix Layout

Points
9 3x3
12 4x3
16 4x4
20 5x4
25 5x5
30 6x5
36 6x6
42 7x6
49 7x7
37
Method 1A
Sample and Velocity Traverses,
Small Stacks or Ducts
Method 1A is the same as Method 1, except for the special provisions that apply to small circular stacks or
ducts where the diameter is between 4 and 12 inches (10.2 cm (4 in.) ≤ D ≤ 30.5 cm (12 in.)), or for small
rectangular ducts where the area is between 12.57 in. 2 and 113 in.2 (81.1 cm2 (12.57 in.2) ≤ A ≤ 729 cm2 (113
in. 2)).
Important: You must use a standard type pitot tube for the velocity measurements. Do not attach the tube to
the sampling probe.
Did you know? In small diameter stacks or ducts, the conventional Method 5 stack
assembly (which consists of a Type-S pitot tube attached to a sampling probe
equipped with a nozzle and thermocouple) blocks a significant portion of the duct’s
cross-section, resulting in inaccurate measurements. Therefore, for particulate matter
sampling in small ducts, measure the gas velocity either:
➢ Downstream of the sampling nozzle (for unsteady flow conditions), or
➢ In the same sample port alternately before and after sampling (for steady flow
conditions).
The procedure for determining sampling location, traverse points, and flow rate (preliminary or otherwise) in
a small duct is as follows:
1. Use Method 1 to locate traverse points for each sampling site and choose the highest of the four
numbers for the total traverse point number.
2. For measurements of particulate matter (PM) with a steady flow, or velocity with either a steady or
unsteady flow, select one sampling location and use the same criterion as described in Method 1.
3. For PM with a steady flow, conduct velocity traverses in the same port before and after PM sampling
to demonstrate steady state conditions, i.e., within ± 10% (vf/vi ≤ 1.10).
4. For PM with an unsteady flow, monitor velocity and sample PM at two separate locations
simultaneously. The velocity port should be downstream of the sampling port. See the location of the
two ports labeled in Figure 2-14 on the next page.
38
Figure 2-14: Set-up of EPA Method 1A Small Duct Sampling Locations
39
Method 2
Stack Gas Velocity and Volumetric Flow Rate
Method 2 is used to measure the average velocity and volumetric flow rate of the stack gas stream. To
determine the average gas velocity in the stack, you must measure the gas density and the average velocity
head with a Type-S (Stausscheibe or reverse-type) pitot tube. Note: Have a thorough knowledge of at least
Method 1 before proceeding, as some of the steps reference Method 1 procedures.
Method 2 is used to:

➢ Determine the nozzle size and length of the sampling run before a particulate stack test series (also
known as a preliminary velocity determination).
➢ Ensure that the particulate sample is extracted from the stack at isokinetic conditions during each
stack test run.
Did you know? Do not use Method 2 with measurement sites that are less than eight
stack diameters downstream or two stack diameters upstream from a flow disturbance.
Method 2 also cannot be used for direct measurement in cyclonic or swirling gas
streams (see section 11.4 of Method 1 to determine these conditions).
When faced with cyclonic or swirling gas streams, you must use alternative procedures
such as installing straightening vanes, calculating the total volumetric flow rate
stoichiometrically, or moving to another measurement site where the flow is
acceptable.
The
equation
for average gas velocity in a stack or duct is:
Where vs = Average stack gas velocity, m/sec (ft/sec)

Kp = Constant, 34.97 for metric system (85.49 for English system)
Cp = Pitot tube coefficient, dimensionless
(√Δp)avg = Average of the square roots of each stack gas velocity head, mm H2O (in. H2O)
Ts = Absolute average stack gas temperature, °K (°R)
Ps = Absolute stack gas pressure (Pbar + Pg/13.6), mm Hg (in. Hg)
40
Pbar = Barometric pressure at measurement site, mm Hg (in. Hg)
Pg = Stack static pressure, mm H2O (in. H2O)
Ms = Molecular weight of stack on wet basis (Md (1 – Bws) + 18.0 Bws), g/g-mole
(lb/lb-mole)
Md = Molecular weight of stack on dry basis, g/g-mole (lb/lb-mole)
Bws = Water vapor in the gas stream (from Method 4 (reference method) or Method
5), proportion by volume.
Obtain Stack Gas Molecular Weight and Moisture
To calculate the average stack gas velocity (Vs), you must first obtain values for the molecular weight and
moisture (refer to Method 3 and Method 4 sections). The stack gas molecular weight dry basis (M d) is
corrected to the wet basis (Ms) using the moisture fraction (Bws) with the equation:
Figure 2-15 illustrates the relationship of Methods 1, 3 and 4 to Method 2.
Method 3 Method 1
Selection of Traverse Points
Stack Gas Molecular Weight
Options:
 Sample with Orsat analysis
 Sample with Fyrite analysis
 Assign 29.0 if air
Method 2
 Assign 30.0 if combustion Stack Gas Velocity
Method 4
Stack Gas Moisture
Options:
 Reference Method
 Approx Method (Midgets)
 Drying Tubes
 Wet Bulb-Dry Bulb
 Psychrometric chart
 Previous experience
Figure 2-15: Determination of Preliminary Velocity
41
Using the Pitot Tube
Use a pitot tube connected to an inclined manometer to make velocity measurements in a duct. Alternatives
to the inclined manometer are a magnehelic pressure gauge or an electronic manometer, but you must
calibrate each of these devices periodically against an oil-filled inclined manometer (see Calibration in
Chapter 3).
The S-type pitot tube has a fixed coefficient of 0.84 if it is manufactured and maintained to meet the
geometric specifications of Method 2. You may also use a standard or P-type (Prandl) pitot tube with a
coefficient of 0.99 for these measurements.
Insert the S-type pitot tube into the stack with one leg (hole opening) pointing into the direction of gas flow,
as shown in Figure 2-16. The leg pointing into the flow stream measures impact pressure (P i) of the gas
stream, while the opposite leg (pointing away from the flow) measures wake pressure (Pw).
The velocity pressure (Δp) is the difference between the impact and wake pressures:
Figure 2-16: Apparatus for Preliminary Velocity Measurement
42
Determine Flow Rate
The procedure for determining flow rate (preliminary or other) in a stack gas stream is as follows:
1. Fill out the top section of a Velocity Traverse field data sheet.
2. Mark the pitot tube with the traverse points according to Method 1 (see “Pinpoint and Mark Traverse
Points” in the Method 1 section).
3. Assemble the apparatus for flow velocity measurement using one of these configurations:
a. Pitot tube with thermocouple, pitot and thermocouple extension lines, inclined manometer, and
temperature display device, or
b. Probe Assembly, Umbilical Cable, and inclined manometer on Meter Console.
4. Pitot Line Leak-Check: Conduct a pre-test leak-check of the
pitot and lines by blowing lightly into the positive (impact)
side of the pitot tube opening until at least 7.6 cm (3 in.) H 2O
registers on the manometer; then, close off the impact
opening. The pressure should remain stable for at least 15
seconds. Do the same, except suck lightly, for the negative
(wake) side.
5. Level and zero the manometer. If using a separate manometer,
If the pitot tube is dirty or
cup a hand or place a glove over the pitot opening to prevent
chemically contaminated,
wind from affecting the zero adjustment. If using the Source
attach a short piece of
Sampler Console, use the Zero Manometer switch.
flexible tubing to the pitot
Periodically check that the manometer is zeroed and leveled
leg for leak checking, and
between ports.
pinch it closed to hold the
6. Insert the pitot tube into the stack to a marked traverse point pressure.
and seal off the port opening with a rag or towel to prevent
ambient effects. Starting with the farthest points, measure the
velocity head and temperature and record the values on the
field data sheet. Allow the temperature reading to stabilize
before recording it.
7. Move to each
subsequent
Did you know? The S-type pitot tube is most often used in stack
traverse point, testing because it is:
reseal the port
➢ Compact and attaches easily to a Method 5 probe assembly,
and record the
velocity head and ➢ Relatively easy to manufacture,
temperature. ➢ Relatively insensitive to plugging in stack gas streams, and
Switch to the ➢ Relatively insensitive to yaw and pitch errors.
next port and
repeat traverse
sampling.
43
8. Conduct a post-test leak-check (which is mandatory to prove that no leakage occurred) as described in
Step 4 above, and record it on field data sheet.
9. Measure the static pressure in the stack. One reading is adequate.
10. Determine the barometric pressure at the level of the sample port.
11. Calculate the average stack temperature from the traverse readings and record it.
12. Calculate the average square root of velocity head by taking the square root of each velocity head reading
and averaging the square roots (sum the square roots and then divide by the number of traverse points).
Then, record it on the field data sheet.
Important: Ensure that you are using the proper

manometer or pressure gauge for the range of Δp Tips from a Stack Tester
(velocity head of stack gas) values you encounter. If a
more sensitive gauge is needed, swap it in and
remeasure the Δp and temperature readings at each
traverse point, using the above procedures.
Measure Static Pressure

The easiest way to measure static
You can measure static pressure in any of three ways: pressure is to insert a piece of metal
➢ Using a static tap, tubing connected to a U-tube water-
filled manometer into the approximate
➢ Using a straight piece of tubing and middle of the stack, with the other end
disconnecting one leg of the manometer, or open to atmosphere.
➢ Using the S-type pitot tube and disconnecting If the manometer deflects toward the
one leg of the manometer. stack, record this as negative static
pressure (less than barometric
pressure). If the manometer deflects
Measure Static Pressure with an
away from the stack, record this as
S-Type Pitot
positive static pressure.
If you are using an S-type pitot to measure static
If you are using an inclined
pressure, follow these steps:
manometer, then place the connection
1. Insert the S-type pitot tube into the middle of the to the tubing on the negative (right-
stack. hand) side of the manometer to read a
2. Rotate the pitot about 90° until you obtain a zero negative static pressure. Switch it to
or null reading on the manometer. the positive (left-hand) side to read a
positive static pressure. The procedure
3. Holding the pitot in place, disconnect the positive is identical when using a stack static
side from the manometer and read the oil tap.
deflection on the manometer gauge. Record the
static pressure as negative.
4. If the oil travels past the zero mark, reconnect the positive side and disconnect the negative side, then
read the oil deflection in the manometer. Record the static pressure as positive.
44
After recording the static pressure (Pg), you must convert the value from mm H2O to mm Hg (in. H2O to in.
Hg) prior to inputting it into the velocity equation as Ps (absolute stack gas pressure). The density of mercury
is 13.6 times that of water, so the conversion equation is:
where Ps = Absolute stack gas pressure, mm Hg (in. Hg)

Obtain Barometric Pressure Reading

Obtain a barometric pressure reading (Pbar) at the measurement site by using a calibrated on-site barometer,
or by contacting a nearby weather station (within 30 km) to get the uncorrected station pressure (weather
stations report barometric pressure corrected to sea level, so ask for the “uncorrected” pressure). You also
will need to know the station’s elevation above sea level.
Correct the station’s barometric pressure reading by subtracting 0.832 mm Hg for every 100 m that the
weather station is above sea level (0.1 in. Hg for every 100 ft.). To get valid results, you also must know the
sampling site’s elevation.
Calculate the sampling site barometric pressure (Pbar) as follows:
where Pr = Barometric pressure at site ground level or at weather station, mm Hg (in. Hg)
A = Elevation at ground level or at weather station, m (ft. above sea level)
B = Elevation of the sampling site, m (ft. above sea level)
Calculate Volumetric Flow Rate
After calculating the average stack gas velocity (Vs, see the beginning of the Method 2 section), you can find
the volumetric flow rate. Begin by determining the area (As) for a circular stack with this equation:
Where π = 3.14159
45
Ds = Diameter of a circular stack
The formula to find the area of a rectangular stack is:
Where L = Length of a rectangular stack

W = Width of a rectangular stack
Now, you can calculate the stack gas volumetric flow rate (actual, standard, and dry standard) using the
following equations:
Where Qa = Volumetric flow rate, actual, m3/min (acf/min)

Vs = Average stack gas velocity, m/sec (ft/sec)
As = Area of the stack
Qs = Volumetric flow rate, standard, sm3/min (scf/min)
Ks = A constant of 21.553 for metric units (1058.8 for English units), used to convert
time to minutes and P/T (pressure divided by temperature) to standard
conditions
Ps = Absolute stack gas pressure (Pbar + Pg/13.6), mm Hg (in. Hg)
Qsd = Volumetric flow rate, dry standard, dsmm3/min (dscf/min)
Bws = Water vapor in the gas stream (from Method 4 (reference method) or Method
5), proportion by volume.
46
Method 3
Gas Analysis for Dry Molecular Weight
Method 3 is used to measure the percent concentrations of carbon dioxide (CO2), oxygen (O2), and carbon
monoxide (CO) if greater than 0.2%. Nitrogen (N2) is calculated by difference. With this data, you can
calculate the stack gas dry molecular weight, or density, and then apply that data to the equation for stack gas
velocity.
There are three options for determining dry molecular weight:

1. Sample and analyze,
2. Calculate O2 and CO2 concentrations stoichiometrically for combustion sources, or
3. Use a dry molecular weight value of 30.0 if burning fossil fuels (coal, oil, or natural gas).
From the gas composition data, you can calculate the amount of excess air for combustion sources. In
jurisdictions where particulate emissions are regulated on a concentration basis, such as mg/m3, use the gas
composition data to correct the concentration results to a reference diluent concentration, for example 7% O 2
or 12% CO2. Note: Before beginning, you first must have a thorough knowledge of Method 1 procedures,
which are referenced in Method 3.
Options for Collecting Stack Gas Sample

Use one of three options to collect the stack gas sample:
1. Grab-sampling stack gas from a single traverse point with a one-way squeeze bulb and loading it
directly into the analyzer. You also can use this technique to measure gas composition at individual
traverse points to determine if stratification exists.
2. Integrated sampling from a single traverse point into a flexible leak-free bag. This technique
recommends collecting at least 30 liters (1.00 cu. ft.); however, you may collect smaller volumes if
desired. Constant rate sampling is used.
3. Integrated sampling from multiple traverse points in a flexible leak-free bag. Use this technique
when conducting a Method 5 particulate traverse and using the Orsat gas collection line built onto the
probe assembly. Sample volume and rate recommendations are the same.
Analyze gas samples using either an Orsat or Fyrite analyzer. Figure 2-17 on the next page depicts the
options for sample collection and analysis.
47
Gas Analysis
Sampling Options
Options
Single-point
Grab
Sampling Orsat
Analyzer
Single-Point
Bag
Integrated
Sample
Sampling
Fyrite
Multi-Point Analyzer
Integrated
Sampling
Figure 2-17: Method 3 Sampling and Analysis Options
Compare Orsat and Fyrite Analyzers

Both the Orsat Analyzer and Fyrite Analyzer are gas absorption analyzers that measure the reduction in
liquid volume when a gas sample is absorbed and mixed into a liquid solution. They differ in the following
ways:
● The Fyrite Analyzer uses separate gas absorption bulbs for O 2 and CO2, while the Orsat Analyzer
(Model VSC-33) contains all three absorption bubblers for O2, CO2, and CO in a single analyzer train.
● The Orsat provides a more accurate analysis of gas composition, and is required by Method 3B when
pollutant concentration corrections are made for regulatory purposes.
● The Orsat analyzer does not typically measure the CO concentration for two reasons:
○ First, the detection limit of the analyzer is 0.2% by volume (2,000 ppmv), which is well above
most modern combustion source CO concentrations.
○ Secondly, the molecular weight of CO is the same as N 2 (28 g/g-mole). Thus, the balance of
gas can be applied to N2 without any change in calculation of molecular weight.
Figure 2-18 on the next page illustrates an Orsat Analyzer connected to a bag sample collection enclosure.
For a more detailed discussion of gas analysis using an Orsat Analyzer, please refer to Apex Instruments’
Combustion Gas (ORSAT) Analyzer, Model VSC-33, User’s Manual and Operating Instructions, or the
operating instructions provided with the Fyrite Analyzer.
48
Figure 2-18: Illustration of Orsat Analyzer and Gas Sample Bag Container
Determine Dry Molecular Weight

Calculate the dry molecular weight (Md) of stack gas with the following equation:
Where 0.44 = Molecular weight of CO2, divided by 100

%CO2 = Percent CO2 by volume, dry basis
0.32 = Molecular weight of O2, divided by 100
%O2 = Percent O2 by volume, dry basis
1.28 = Molecular weight of N2 or CO, divided by 100
%N2 = Percent N2 by volume, dry basis
%CO = Percent CO by volume, dry basis
49
Method 4
Moisture Content of Stack Gas
Method 4 is used to determine the moisture content of stack gas, which is needed to calculate emission data.
A gas sample is extracted at a constant rate from the source, moisture is removed from the sample stream,
and moisture content is determined either volumetrically or gravimetrically. Before using this method, you
should have a thorough knowledge of at least Methods 1, 5 and 6.
There are two separate procedures for determining moisture content in stack gases:
➢ The Reference Method, which gives accurate measurements of moisture needed to calculate
emission data, and
➢ The Approximation method, which gives a close estimate of percent moisture to aid in setting
isokinetic sampling rates before a pollutant emission sampling run.
The approximation method is only a suggested approach. There are acceptable alternatives for approximating
moisture content, for example:
● Wet bulb/dry bulb techniques (applicable to gas streams less than 100°C),
● Stoichiometric calculations (applicable to combustion sources),
● Condensation techniques,
● Drying tubes, and
● Previous experience testing at a stack.
Equipment Set-Up for the Reference Method

Select either of the following sampling trains when setting up equipment for the Reference Method:
➢ The Isokinetic Source Sampling System (Hot Box and Cold Box), equipped with Probe Assembly
without nozzle, and a filter bypass piece of glassware (GN-13) instead of a filter assembly (you may
use a filter if particulate levels are high), or
➢ The Basic Method 4 Test Kit, which includes a Cold Box, Sample Frame with Probe Clamp (SB-8),
and Umbilical Adapter with power connector (GA-103), as shown in Figure 2-19 on the next page.
With this set-up, you can use either a standard heated Probe Assembly or a heated CEM probe
(without a pitot tube).
50
Although glass impingers are typically used as the

condenser section in Method 4 and other isokinetic
methods, you can replace them with a stainless steel
equivalent coil condenser (S-4CN), which results in a
rugged and reliable system without the fragility of the
traditional glass assembly.
Did you know? The Reference Method is almost always performed simultaneously
with a pollutant emission measurement run. You also can use the Reference Method
when you need to correct to a dry basis your continuous monitoring for pollutants such
as SO2, NOx or O2.
51
Figure 2-19: Set-up of Cold Box with Sample Frame and Probe Clamp
Method 4 Reference Method

Use the following procedure for accurate measurements of moisture content:
Part 1: Preparation
1. Select the appropriate minimum number of traverse points and locate them according to Method 1:
a. Eight (8) traverse points for circular ducts less than 60 cm (24 in.) in diameter.
b. Nine (9) for rectangular ducts less than 60 cm (24 in.) in equivalent diameter.
c. Twelve (12) for all other cases.
2. Transfer about 100 ml of water into the first two impingers. Leave the third impinger empty. Weigh
each impinger to the nearest 0.5 g.
3. Transfer 200-300 g of silica gel into the fourth impinger. Weigh it to the nearest 0.5 g.
4. Select a total sampling time that allows you to collect a minimum total gas volume of 0.60 scm (21
scf) at a rate no greater than 0.021 m3/min (0.75 cfm). Perform moisture sampling simultaneously
with the pollutant emission rate test run (and for the same length of time).
5. If the gas stream is saturated or contains moisture droplets, attach a temperature sensor (± 1.3°C) to
the probe or check the saturation moisture at the measured stack temperature. See Step 4 below.
Part 2: Sampling
1. Assemble and set up the sampling train.
2. Turn on the probe heater and, if applicable, the filter heating system to temperatures of about 120°C
(248°F). Allow time for the temperatures to stabilize. Place crushed ice in the ice bath container
(Cold Box) around the impingers.
3. Optional: Leak-check the sampling train by disconnecting the probe from the first impinger or, if
applicable, from the filter holder. Plug the inlet to the first impinger (or filter holder) and pull a 380
mm (15 in.) Hg vacuum. It is not acceptable to have a leakage rate greater than 4% of the average
sampling rate, or 0.00057 m3/min (0.020 cfm), whichever is less. If the leakage rate exceeds the
52
allowable rate, either reject the test results or correct the Tips from a Stack Tester
sample volume as in section 12.3 of Method 5.
Following the leak check, reconnect the probe to the
sampling train.
4. Position the probe tip at the first traverse point. Sample
at a constant (± 10%) flow rate. Record data on a field
data sheet.
5. Traverse the cross-section, sampling at each traverse Make sure to wipe off
point for an equal period of time. moisture from the outside
6. Add more ice and, if necessary, salt to maintain a of each impinger before
temperature of less than 20°C (68°F) at the silica gel weighing it. Do not weigh
impinger exit. impingers with U-tubes
connected.
7. After the last traverse point of the cross-section, turn off
the sample pump, switch to the next sample port, and
repeat steps 5 and 6 above.
8. After completing sampling, disconnect the probe from the first impinger (or from the filter holder).
9. Mandatory: Leak-check the sampling train, as required at the end of the run (see step 3 above).
Part 3: Sample Recovery

1. Disassemble the impinger glassware and weigh each impinger to the nearest 0.5 g. Record weight
data on a field data sheet.
2. Verify constant sampling rate.
3. Calculate the stack moisture percentage (refer to the stack gas moisture equations at the end of the
Method 4 section).
In the Case of Saturated or Moisture Droplet-Laden Gases:

1. Measure the stack gas temperature at each traverse point. Calculate the average stack gas temperature
by adding all of the readings and dividing by the number of traverse points.
2. Determine the saturation moisture content by either:
a. Using saturation vapor pressure tables or equations, or
b. Using a psychrometric chart and making appropriate corrections if stack pressure is different
from what is found on the chart.
3. Use the lower of these values or the value from Part 3 above.
53
Method 4: Approximation Method
The Method 4 approximation method specifies use of midget impingers and a Source Sampler Console sized
for midget impinger trains, such as the one used for Method 6 sampling of SO2.
Did you know? Many stack testers perform preliminary moisture measurements for
input into their isokinetic calculations nomograph by using a full-size sampling train
and collecting approximately 0.283 sm3 (10scf) of gas sample. These runs take about
15 to 20 minutes.
Use the following procedures to make approximate measurements of moisture content:
Midget Impinger Train

Part 1: Preparation
1. Transfer about 5ml of water into each impinger (2) and weigh each impinger to the nearest 0.5 g.
2. Assemble the sampling train.
3. Connect a pre-weighed drying tube to the back of the impinger train.
Part 2: Sampling
3. Optional: Leak-check the sampling train by disconnecting the probe from the first impinger or, if
applicable, from the filter holder. Plug the inlet to the first impinger (or filter holder) and pull a 380
mm (15 in.) Hg vacuum. It is not acceptable to have a leakage rate greater than 4% of the average
sampling rate, or 0.00057 m3/min (0.020 cfm), whichever is less. If the leakage rate exceeds the
allowable rate, either reject the test results or correct the sample volume as in section 12.3 of Method
5. Following the leak check, reconnect the probe to the sampling train.
4. Position the probe tip well into the stack. Sample at a constant (± 10%) flow rate of twenty-one (21)
lpm until the dry gas meter registers about 30 liters, or until visible liquid droplets carry over from the
first impinger to the second. Record initial and final data on a field data sheet.
5. Add more ice and, if necessary, salt to maintain a temperature of less than 20°C (68°F) at the silica
gel impinger exit.
6. Mandatory: Leak-check the sampling train as described in Step 3 above. After the leak-check,
reconnect the probe to the sampling train.
54
1. Disassemble the impinger glassware and weigh each impinger or drying tube to the nearest 0.5 g.
Record weight data on a field data sheet.
3. Calculate the stack gas moisture percentage (see the equations at the end of this section).
Large Impinger Train

Part 1: Preparation
1. Transfer about 100ml of water into the first two impingers. Leave the third impinger empty and
weigh each impinger to the nearest 0.5 g.
2. Transfer 200-300 g of silica gel to the fourth impinger and weigh to the nearest 0.5 g.
Part 2: Sampling
3. Optional: Leak-check the sampling train from the first impinger inlet or, if applicable, the filter
holder (see leak-check procedures described in the Midget Impinger Train section on the previous
page).
4. Position the probe tip well into the stack. Sample at a constant (± 10%) flow rate of less than twenty-
one (21) lpm (0.75 cfm) until the dry gas meter registers 0.283 m3 (10 cf). Record initial and final
data on a field data sheet.
5. Add more ice and, if necessary, salt to maintain a temperature of less than 20°C (68°F) at the silica
gel impinger exit.
6. Mandatory: Leak-check the sampling train (as detailed in Part 2, Step 3 on the previous page).

1. Disassemble the impinger glassware and weigh each impinger or drying tube to the nearest 0.5 g.
Record weighing data on a field data sheet.
3. Calculate the stack gas moisture percentage (see equations next page).
55
Equations for Calculating Stack Gas Moisture Content
To calculate the stack gas moisture content (Bws), first use the following equations to compute the sample gas
volume (Vm(std)) and gas moisture volume (Vwc(std)):
Calculate sample gas volume:
where K3 = 0.3858 °K/mm Hg (metric units), or 17.64 °R/in. Hg (English Units)

Y = Dry gas meter calibration factor
Vm = Dry gas volume measured by dry gas meter, dcm (dcf)
ΔH = Average orifice tube pressure during sampling, mm H2O (in. H2O)
Tm = Absolute temperature at dry gas meter, °K (°R)
Calculate gas moisture volume:
where K2 = 0.001335 m3/g (metric units), or 0.04715 ft3/g (English units)

Wf = Final weight of water collected, g
Wi = Initial weight of water collected, g
Calculate stack gas moisture content:
where Bws = Proportion of water vapor, by volume, in the gas stream

Vm(std) = Sample gas volume
Vwc(std) = Gas moisture volume
56
Method 5
Determination of Particulate Emissions
Method 5 involves withdrawing particulate matter (PM) isokinetically from the source and collecting it on a
temperature-controlled glass fiber filter. The PM mass is determined gravimetrically after the removal of
uncombined water. To perform Method 5, you must have a thorough understanding of Methods 1, 2 and 3.
To maintain an isokinetic sampling rate, you will need to calculate the appropriate probe nozzle size and the
optimal ratio of orifice tube pressure (ΔH) to stack gas velocity (Δp). This ratio is called K-factor.
Determine nozzle size and K-factor in one of the following ways:
➢ Calculate by hand or on a worksheet (see worksheets in Appendix D).
➢ Use a specially designed stack testing slide rule nomograph (M5A-1M or M5A-1), as shown in
Figure 2-21.
➢ Use a pre-programmed handheld calculator (M5A-C).
➢ Input figures into specialized spreadsheets for data collection and reduction (ISOCALC 2.0) using a
personal or laptop computer, as shown in Figure 2-21.
Figure 2-21: Stack Sampling Slide Rule and Laptop Computer with IsoCalc 2.2
Preliminary Data Needed For Isokinetic Sampling

The following preliminary information is needed before you can determine the nozzle size and calculate the
K-factor:
➢ Δpavg: Average stack gas velocity head. Measure this before the sample run, or take it from a previous
test.
➢ Bws: Stack gas moisture fraction, or percent (%H2O). Determine this from a preliminary run, previous
test, or calculate it (see Method 4).
➢ Md: Stack gas dry molecular weight. Use a value from a preliminary run, previous test, or estimate it
(see Method 3).
57
➢ Ps: Stack gas pressure. Measure this before the sample run, or use barometric pressure if the static
pressure of the stack is very low (such as when sample ports are near the stack exit).
➢ ΔH@: Source Sampler Console orifice calibration factor. This is determined from the laboratory
calibration and should be readily available on-site (see Calibrations).
➢ Tm: Meter temperature. Temperature at the meter rises about 14°C (25°F) above ambient temperature
due to heat from the vacuum pump. Measure the ambient temperature at the Source Sampler Console
site.
➢ Pm: Meter pressure. Same as barometric pressure.
Probe Nozzle Size Calculation

The equation most commonly used for calculating the probe nozzle size is:
where Dn = Nozzle diameter, mm (in.)

K5 = 0.6071 (metric units) or 0.03575 (English units)
Qm = Test meter volume flow rate reading, m3/min (ft3/min)
Pm = Test meter average static pressure, mm Hg (in. Hg)
Tm = Average DGM temperature, °K (°R)
Cp = Pitot tube calibration coefficient, dimensionless
Bws = Water vapor in gas stream (Method 4 or alternative), proportion by volume
Ts = Average stack gas temperature, °K (°R)
Ms = Molecular weight of stack gas, wet basis, g/g-mole (lb/lb-mole)
Ps = Absolute stack or duct pressure, mm Hg (in. Hg)
Δpavg = Average stack gas velocity head
58
K-Factor Calculations
After selecting the appropriate nozzle from the Nozzle Set (shown in
Figure 2-22), calculate the K-factor ratio used to maintain an
isokinetic sampling rate at each traverse point for the sampling test
run. K-factor refers to the ratio of ΔH/Δp such that ΔH = KΔp. Use
the following equation:
where ΔH = Average orifice tube pressure during

sampling, mm H2O (in. H2O)
Figure 2-22: Probe Nozzle Set
Δp = Average stack gas velocity head
K6 = 0.0000804 (metric units) or 849.842 (English units)
Dn = Nozzle diameter, mm (in.)
ΔH@ = Source Sampler Console orifice calibration factor
Cp = Pitot tube calibration coefficient, dimensionless
Bws = Water vapor in gas stream (Method 4 or alternative), proportion by volume
Md = Molecular weight of stack gas, dry basis, g/g-mole (lb/lb-mole)
Tm = Average DGM temperature, °K (°R)
Ps = Absolute stack or duct pressure, mm Hg (in. Hg)
Ms = Molecular weight of stack or duct gas, wet basis, g/g-mole (lb/lb-mole)
Ts = Average stack gas temperature,
°K (°R)
Pm = Test meter average static Tips from a Stack Tester
pressure, mm Hg (in. Hg)
Important: Check the total sampling time (number of

traverse points multiplied by minutes per point) as well as the
final estimated gas sample volume (Vm(std)) against any
applicable environmental regulations to see if you have met You may need to
acceptable minimum sampling times and volumes. experiment with selecting
K-factors and/or nozzle
sizes that will yield an
acceptable sampling
volume and time.
59
Method 5 Test Procedure
Part 1: Pre-Test Preparation (Before Traveling to Site)
1. Check filters visually against light for irregularities, flaws or pinhole leaks. Label the filters on the
back side near the edge using numbering machine ink.
2. Desiccate the filters at 20° ± 5.6°C and ambient pressure for more than 24 hr. Then weigh them at
intervals of greater than 6 hours to a constant weight (less than 0.5 mg change from previous
weighing). Record results to the nearest 0.1 mg. During each weighing, do not expose the filter to the
laboratory atmosphere for more than 2 minutes, or to a relative humidity of more than 50%.
3. Optional: If you are measuring condensable or back-half particulate matter, run analytical blanks of
the deionized/distilled water to eliminate a high blank on actual test samples.
4. Clean the Probe Liners and Probe Nozzles internally by brushing first with tap water, then
distilled/deionized water, followed by reagent-grade acetone. Rinse the Probe liner with acetone and
allow to air-dry. Inspect visually for cleanliness and repeat the procedure if necessary. Cover the
Probe Liner openings to avoid contamination. Keep nozzles in a case to avoid contamination or
damage to the knife-edge.
Note: Special cleaning procedures may be required for other test methods (for example, metals or
dioxin).
5. Clean the Glassware (Filter Assemblies, Impingers and Connecting Glassware) internally by wiping
grease from the joints, washing with glass cleaning detergent, rinsing with distilled/deionized water,
and then rinsing again with reagent-grade acetone, before allowing to air-dry. To avoid
contamination, cover all exposed openings with parafilm, plastic caps, serum caps, ground-glass
stoppers or aluminum foil (do not use foil with metals).
Note: Special cleaning procedures may be required for other test methods (for example, metals or
dioxin).
Part 2: Preliminary Determinations

1. Select the sampling site, measure the stack or duct dimensions and determine the number of traverse
points (see Method 1).
2. Determine the stack gas pressure, range of velocity pressure heads and temperature (see Method 2).
3. Select the proper differential pressure gauge (see Method 2).
4. Determine or estimate the dry molecular weight (see Method 3).
5. Determine the moisture content (see Method 4).
6. Select a suitable Probe Assembly length such that all traverse points can be sampled.
7. Select a nozzle size and determine the K-factor for an isokinetic sampling rate. Important: Do not
change the nozzle size during the sampling run.
8. Select the total sampling time and standard gas sample volume specified in the test procedures for the
specific industry. Select equal sampling times of more than 2 minutes per traverse point.
Part 3: Preparation of Sampling Train
60
1. Mark the Probe Assembly with heat-resistant tape or “Wite-Out” to denote the proper distance into
the stack or duct for each sampling point (See Method 1).
2. Insert the Probe Nozzle into the probe sheath union and hand-tighten the union fitting. Avoid over-
tightening to prevent cracking of the glass probe liner. Keep the nozzle tip and ball joint on the glass
probe liner covered until you complete the train assembly and are about to begin sampling. Secure the
Probe Assembly to the Sample Case by tightening the probe clamp.
3. Prepare each set of impingers for a sampling run:
a. Impingers 1 & 2: 100 ml water in each
b. Impinger 3: Empty
c. Impinger 4: 200 to 300 g of silica gel
TIP: You can prepare more than one sampling run at once by using multiple sets of glassware!
4. Weigh each impinger to the nearest ± 0.5 g using a top-loading electronic balance (BAL-1200) and
record initial weights on a field data sheet.
Figure 2-23: Top-Loading Electronic Balance
5. Assemble the impingers in the Cold Box with U-tubes, Double “L” Adapter, and the Sample
Case/Umbilical Adapter, using Ball Joint Clamps or Clips. See Figure 2-24.
Figure 2-24: Top View of Assembled Impingers
61
Figure 2-25: Exploded View of Filter Assembly
6. Using tweezers or clean disposable surgical gloves, place the tared filter on the grooved (inlet) side of
the Teflon Frit (TFE) filter support in the Filter Holder. Check the filter for tears after placement, and
center it on the filter support. Assemble the Filter Holder (as shown in Figure 2-25), and tighten the
clamps around the Filter Holder to prevent leakage around the O-ring. Record filter number on the
field data sheet.
7. Using Ball Joint Clamps, connect the Filter Holder and Cyclone Bypass (GN-1) in the Hot Box to the
Probe Liner ball joint and to the “L” Adapter. Close the Hot Box doors and fasten shut.
Figure 2-26: Assembled Sampling Train Before Umbilical Hookup
8. Connect the Umbilical Cable electrical and pitot tube lines to the assembled sampling train and to the
Source Sampler Console. If applicable, also connect the Orsat line.
9. Place the assembled sampling train near the first sample port, either on the monorail or with other
support.
10. Turn on and set Probe and Hot Box heaters. Allow the Hot Box and Probe to heat for at least 15
minutes before starting the test, and then make periodic checks and adjustments to ensure the desired
temperatures. Check all thermocouple connections by dialing through each selection and noting
ambient or heated temperatures. Place crushed ice and a little water around the impingers.
62
11. Optional: Leak-check the sampling train (see Leak-Check Procedure for Isokinetic Sampling Trains
in Reference Method 4 on page 50, and Pitot Tube and Line Leak-Check Procedures in Method 2 on
page 41).
Part 4: Sampling Run Procedure

1. Open and clean the portholes of dust and debris.
2. Level and zero manometers that gauge Δp (avg. stack gas velocity head) and ΔH (avg. orifice tube
pressure).
3. Record data on a field data sheet. Record the initial dry gas meter (DGM) reading.
4. Remove the nozzle cap, verify that the Hot Box/filter and probe heating systems are up to
temperature, and check alignments and clearances for the pitot tube, temperature gauge and probe.
5. Close the Coarse Valve and fully open the Fine Increase Valve. Position the nozzle at the first
traverse point. Record the clock time, read Δp on the manometer, and determine ΔH from the
nomograph.
6. Immediately start the pump and adjust the flow to set the orifice tube pressure (ΔH), first by adjusting
the Coarse Valve and then the Fine Increase Valve.
Note: If necessary to overcome high negative stack pressure, turn on the pump while positioning the
nozzle at the first traverse point.
7. When the probe is in position, block off the openings around the probe and porthole using duct tape,
rags, gloves or towels (make sure the materials are flameproof for hot stacks).
Figure 2-27: Blocking off the Porthole During Sampling
8. Record readings for the ΔH manometer and pump vacuum, as well as temperatures for stack gas,
DGM, filter box, probe, and impinger exit.
9. Record the ID numbers for the DGM, thermocouples, pitot tube, and Sample Box.
10. If simultaneously running a Method 3 gas bag collection, turn on the Orsat pump. Turn Orsat pump
off during port changes.
63
11. Traverse the stack cross-section for the same time period at each point without turning off the pump,
except when changing ports.
Important: Do not bump the probe nozzle into the stack walls.
a. Make periodic adjustments to maintain the Hot Box temperature (around the filter holder) at
the proper level.
b. Monitor the Δp (gas velocity head) during sampling of each point. If the Δp changes by more
than 20%, record another set of readings.
c. Periodically check the level and zero of the manometers and readjust if necessary.
d. Record DGM readings at the beginning and end of each sampling time increment, before and
after each leak-check, and when sampling is halted.
e. Take other readings (ΔH, temps, vacuum) at least once at each sample point during each time
increment to ensure the ΔH/Δp isokinetic ratio is maintained.
f. Add more ice and, if necessary, salt to maintain a temperature of less than 20°C (68°F) at the
silica gel impinger exit.
12. At the end of the sample run, turn off the Coarse Valve, remove the probe and nozzle from the stack,
turn off the pump and heaters, and record the final DGM reading.
13. Mandatory: Leak-Check the sampling train (See Method 4, page 50) at the maximum vacuum
achieved during the sample run. Record leak-check results on field data sheet.
14. Mandatory: Leak-Check the pitot lines (See Method 2, page 41). Record results on field data sheet.
15. Allow the probe to cool. Wipe off all external particulate material near the tip of the probe nozzle and
cap the nozzle to prevent contamination or sample loss.
Hint: Open the Hot Box doors to allow the filter holder to cool.
16. Before moving the sampling train to the clean-up site, disconnect the probe from the Cyclone Bypass
inlet and cover both ends. Avoid losing any condensate that might be present. Disconnect the Filter
Holder from the “L” Adapter and cap off the Filter Holder.
17. Disconnect the Umbilical Cable from the Sample Box and cover the last impinger outlet and first
impinger inlet. Disconnect the Cold Box from the Hot Box. Now, the Probe/Nozzle Assembly, Filter
Holder, and impinger case are ready for sample recovery.
18. Transfer the probe and filter-impinger assembly to an area that is clean and protected from the wind.
Part 5: Variations and Alternatives

1. Acceptable alternatives to glass probe liners are metal liners; for example, 316 stainless steel,
Inconel, or other corrosion-resistant metals made of seamless tubing. These liners can be useful for
cross-sections over 3 m (10 ft.) in diameter.
2. For large stacks, consider sampling from opposite sides of the stack to reduce the length of the probe.
3. Use either borosilicate or quartz glass probe liners for stack temperatures from 480° to 900°C (900–
1,650°F). The softening temperature for borosilicate glass is 820°C (1,508°F); for quartz, it is
1,500°C (2,732°F).
4. Rather than labeling filters, label the shipping containers (glass or plastic petri dishes) and keep the
filters in these containers at all times except during sampling and weighing.
64
5. Use more silica gel in impinger 4, if necessary, but ensure that there is no entrainment or loss during
sampling.
Hint: Loosely place cotton balls or glass wool in the neck of the silica gel impinger outlet stem to
avoid spillage.
6. If you are using a different type of condenser (other than impingers), measure the amount of moisture
condensed either volumetrically or gravimetrically.
7. For moisture content, measure the impinger contents volumetrically before and after a sampling run.
Use a pre-weighed amount of silica gel in a shipping container. Then, after the run, empty the silica
gel back into the container for weighing at another time.
Figure 2-28: Recover Silica Gel for Weighing Figure 2-29: Determine Moisture Volumetrically
8. If you expect the total particulate catch to exceed 100 mg or more, or when water droplets are present
in the stack gas, use a Glass Cyclone between the probe and Filter Holder.
9. If you have difficulty maintaining isokinetic sampling due to high pressure drops across the filter
(with a high vacuum on the gauge), replace the filter.
10. Use a single train for the entire sampling run, except when:
a. Simultaneous sampling is required in two or more
separate ducts, or
b. Simultaneous sampling is required at two or more
different locations within the same duct, or
c. Equipment failure necessitates a change in trains.
In all other situations, obtain approval from the regulatory
agency before using two or more trains.
11. When using two or more trains, analyze separately the front- Whenever practical, make
half and (if applicable) impinger catches from each train, every effort to use
unless you used identical nozzle sizes on all trains. In this borosilicate glass or quartz
case, you may combine the front-half catches (and the probe liners. Metal liners
impinger catches) and perform one analysis of the front-half will bias particulate matter
catch and one analysis of the impinger catch. Consult with results higher than actual.
65
the regulatory agency for details concerning
the calculation of results when using two or Tips from a Stack Tester
more trains.
12. If using a flexible line between the first
impinger or condenser and the Filter Holder,
disconnect the line at the Filter Holder and let
any condensed water or liquid drain into the
impingers or condenser. Instead of trying to catch the probe
13. Do not cap off the probe tip too tightly while rinse with a glass funnel and sample
the sampling train is cooling down as this container (which can easily result in
would create a vacuum in the Filter Holder, sample loss), clamp an Erlenmeyer
which may draw water from the impingers into flask outfitted with a female ball joint
the Filter Holder. on the probe liner ball joint when
conducting the probe rinse procedure.
If the probe is short, one person can
Part 6: Sample Recovery perform the brushing and rinsing.
Note: Sample Recovery is an extremely important step
that requires a high level of precision. If sample loss
occurs, your results will be biased low, and if sample
contamination occurs, your results could be biased high.
1. Place 200 ml of acetone from the wash bottle you are using for clean-up in a glass sample container
labeled “Acetone Blank.”
2. Inspect the train prior to and during disassembly and note any abnormal conditions on the data sheet.
3. Container No. 1: Filter
a. Using a pair of tweezers (TW-1) and/or clean disposable surgical gloves, carefully remove the
filter from the Filter Holder and place it in its identified petri dish container. If necessary, fold
the filter so that the particulate matter cake is inside the fold.
b. Using a nylon bristle brush (DB-3) and/or a sharp-edged blade (LS-1), carefully transfer to the
petri dish any particulate matter (PM) and/or remaining pieces of filter or filter fibers that
adhered to the filter support or gasket.
4. Container No. 2: Acetone Rinses Tips from a Stack Tester

Note: Recover all of the rinses listed here in a
single glass container.
a. Recover any PM from the internal
surfaces of the Probe Nozzle, swaged
union fitting, front half of the Filter
Holder, cyclone (if applicable), and
probe liner (use a glass funnel to aid in You can opt to use another filter
transferring the liquid wash to the assembly, rather than changing the
container, see figure 2-30). filter itself. Remember to conduct a
leak-check before installing a new
filter. Add the filter assembly catches
to the total particulate matter weight.
66
b. Before cleaning the front half of the Filter Holder, wipe all joints clean of silicone grease.
c. Rinse with acetone, brush with a small nylon bristle brush, and rinse with acetone again until
there are no visible particles (see figures 2-31 and 2-32). Make a final acetone rinse.
d. For the probe liner, repeat the rinse-brush-rinse sequence at least three times for glass liners
and six times for metal liners.
e. Make a final rinse of the probe brush with acetone.
f. For the Probe Nozzle, use the nylon nozzle brush and follow the same sequence of rinse-
brush-rinse as with the probe liner.
g. After completing the rinse, tighten the lid on the sample container. Mark the height of the
fluid level and label the container.
Figure 2-30: Sample Recovery from Probe Liner
Figure 2-31: Rinsing Probe Nozzle Figure 2-32: Brushing Probe Nozzle
67
Figure 2-33: Front Half of Acetone Rinse Samples
5. Container No. 3: Silica Gel

a. Determine whether silica gel has been completely spent, and note its condition and color on
the data sheet.
b. Discard and reload the impinger. Alternatively, you can reuse the impinger in the next run,
using the final weight from this run as the initial weight for the new sampling run.
6. Impinger Water
a. Note on the data sheet any color or film in the liquid catch.
b. Discard the liquid, unless you are required to do an analysis of the impinger catch. Store as is
appropriate.
Note: Whenever possible, ship sample containers in an upright position.
Calculations at the End of the Sampling Run
At the conclusion of each sampling run, it is prudent to calculate the stack gas moisture (for the next
sampling run), as well as the average isokinetic rate.
To calculate the stack gas moisture content (Bws), use the following equations to compute the sample gas
volume (Vm(std)) and gas moisture volume (Vwc(std)):
Sample Gas Volume:
where K3 = 0.3858 °dK/mm Hg (metric units), or 17.64 °R/in. Hg (English units)

Y = Dry gas mater calibration factor
Vm = Dry gas volume measured by dry gas meter, dcm (dcf)
ΔH = Average orifice tube pressure during sampling, mm H2O (in. H2O)
Tm = Absolute temperature at dry gas meter, °K (°R)
Gas Moisture Volume:
68
where K2 = 0.001335 m3/g (metric units), or 0.04715 ft3/g (English units)
Wf = Final weight of water collected, g
Wi = Initial weight of water collected, g
Stack Gas Moisture Content:
where Bws = Proportion of water vapor, by volume, in the gas stream

Vwc(std) = Gas moisture volume (see equation above)
Vm(std) = Sample gas volume (see equation at top of page)
Average Stack Gas Velocity:
Next, calculate the average stack gas velocity. The equation for average gas velocity in a stack or duct is:
where Vs = Average stack gas velocity, m/sec (ft/sec)

Kp = Constant, 34.97 for metric system (85.49 for English system)
Cp = Pitot tube coefficient, dimensionless
(√Δp)avg = Average of the square roots of each stack gas velocity head
Ps = Absolute stack gas pressure, mmHg (in. Hg), calculated with the equation:
Ps = Pbar + Pg/13.6
Ms = Molecular weight of stack on wet basis, g/g-mole (lb/lb-mole), calculated with
the equation: Ms = Md (1-Bws) + 18.0 (Bws)
Md = Molecular weight of stack on dry basis, g/g-mole (lb/lb-mole)
69
Bws = Proportion of water
vapor, by volume, in the gas stream
Isokinetic sampling rate:
The average percent isokinetic

sampling rate is calculated as:
During port changes, many stack testers scan or
quickly average values for p, H, stack gas
temperature, and DGM temperature to calculate %I
before the sampling run is finished (this all assumes
that Bws will not change substantially). Some
sophisticated calculator programs and most laptop
computer programs monitor %I for each point and
where K4 = 4.320 (metric units) cumulatively.
or 0.09450 (English units)
Ts = Absolute average
stack gas temperature, °K (°R)
Vm(std) = Sample gas volume
Ps = Absolute stack gas pressure, mmHg (in. Hg), calculated with the equation:
Ps = Pbar + Pg/13.6
Vs = Average stack gas velocity, m/sec (ft/sec)
An = Cross-sectional area of the nozzle, m2 (ft2)
θ = Sampling time, minutes
Bws = Proportion of water vapor, by volume, in the gas stream
70
Recommended Reading List for Isokinetic Sampling
● Code of Federal Regulations. Title 40. Part 60, Appendix A. Office of the Federal Register. National
Archives and Records.
● Compliance Test Coordination and Evaluation. Workshop Manual. U.S. Environmental Protection
Agency. APTI 01-94a. 1994.
● Jahnke, J. A., et al. Source Sampling for Particulate Pollutants. Student Manual, APTI Course 450.
Edition 3.0. Raleigh, NC: North Carolina State University, 1995.
● Manual for Coordination of VOC Emissions Testing Using EPA Methods 18, 21, 25, and 25A. U.S.
Environmental Protection Agency. EPA 340/1-91-008. September 1991.
● Quality Assurance Handbook for Air Pollution Measurement Systems. Vol. 3. Stationary Source
Specific Methods, Section 3.4. U.S. Environmental Protection Agency. EPA-600/4-77-027b. 1988.
● Rom, J. J. Maintenance, Calibration, and Operation of Isokinetic Source Sampling Equipment.
Publication No. APTD-0576. Office of Air Programs. U.S. Environmental Protection Agency.
Research Triangle Park, NC. 1972
Chapter 3
Calibration and Maintenance
Establishing and adhering to a routine maintenance program is beneficial in two ways. First, properly
maintaining the isokinetic sampling system helps to ensure trouble-free operation. Secondly, carefully
documenting your maintenance and calibration system will help you obtain the most accurate results during
stack testing activities.
This chapter describes calibration, maintenance and troubleshooting procedures for the various subsystems
of the isokinetic sampling system.
71
Calibration Procedures
It is critical to create and maintain a regularly scheduled calibration and record-keeping protocol for your
stack testing program. If you fail to ensure proper calibrations, you will not be able to verify that the test was
conducted isokinetically and your stack emission test results will be meaningless.
The results of a particulate sampling test cannot be checked for accuracy because no independent technique
or test atmosphere exists to provide a standard or known particle concentration. Collaborative testing
conducted by the US EPA has determined that the interlaboratory standard deviation is ± 12.1%. Only
through careful calibration, maintenance and record keeping can you ensure that the data collected during the
stack test is representative of the site’s particle concentrations and mass emission rate.
The particulate sampling system components that require calibration are:
1. Dry Gas Meter and Orifice Tube,
2. Thermocouples (Stack, Probe, Filter Box, Impinger Exit, and Dry Gas Meter) and Digital
Temperature Indicator,
3. Pitot Tube,
4. Sampling Nozzles, and
5. Probe and Filter Box Heater System.
Table 3-1 presents a summary of the components that require calibration and the equipment used to do so, as
well as acceptable calibration factor limits, recommended calibration frequency, and steps to take if your
system fails to meet calibration acceptance limits.
Calibration Factor Action If

Component Calibrated Against Y Acceptance Limits Frequency Unacceptable
Dry Gas Meter 1. Wet Test Meter Yi = Y ± 0.05Y Semiannually Recalibrate, repair
Initial 5-point 2. Secondary or replace
Reference DGM
Post-test 3-point 1. Wet Test Meter Y = Y ± 0.05Yavg After each field Recalibrate at 5-
2. Reference DGM test points
3. Critical Orifices
Orifice Tube Measured during DGM ΔH@ = 46.7 ± 6.4 mm With DGM Repair or replace
calibration H2O (1.84 ± 0.25 in.
H2O)
Thermocouples and Certified Hg-in-glass Stack: ±1.5% °K After each field Recalibrate, repair
Digital Indicator thermometer in ice DGM: ±3°C test or replace
72
Probe: ±3°C
slush and boiling water
Filter: ±3°C
Exit: ±1°C
Pitot Tube 1. Standard pitot tube If part of Probe Quarterly, or after Recalibrate, repair
in wind tunnel and Assembly, calibrate each field test or replace
calculate Cp (pitot tube with assembly.
coefficient)
σ (avg. deviation) ≤
0.001 for side A & B
2. Measure with angle α1 ± 10° Quarterly, or after Recalibrate, repair
indicator to α2 ± 10° each field test or replace
demonstrate meeting β1 ± 5°
geometric β2 ± 5°
specifications and Z = ≤ 0.125”
assign Cp = 0.84 W = ≤ 0.031”
PA - PB ≤ 0.063”
0.188” ≤ DT ≤ 0.375”
Sampling Nozzles Micrometer with at Average of 3 inner Before each field Recalibrate,
least 0.025-mm (0.001- diameter use reshape, or
in.) scale measurements; ΔD ± resharpen when
0.1-mm (0.004-in.) dented or
corroded
Probe and Filter Box Gas thermocouple Capable of Initially Repair or replace,
Heater System maintaining 120°C ± and verify
14°C at 20-lpm flow calibration
rate
Table 3-1: Sampling System Equipment Calibration and Frequency
1. Calibration of Dry Gas Meter and Orifice Tube

Calibrate the dry gas meter and Orifice Tube simultaneously (reference US EPA Method 5, Section 5.3 for
the calibration procedure). In short, you should:
 Conduct an initial (or full) calibration at five (5) selected flow rate (ΔH) settings.
 Repeat the procedure once every 6 months, or if the results of a post-test 3-point calibration show
that the dry gas meter calibration factor (Y) has changed by more than 5% from the pre-test
calibration value.
73
When performing quarterly or post-test calibrations, use the abbreviated calibration procedure described in
Section 5.3.2 of Method 5, which includes three (3) calibration runs at a single intermediate flow rate (ΔH)
setting.
The dry gas meter (DGM) calibration factor (Y) is the ratio of the wet test meter’s measured volume to the
dry gas meter’s measured volume. The DGM calibration factor is part of calibrating the Source Sampler
Console.
The Orifice Tube calibration factor (ΔH@) represents the pressure drop across the orifice for a sampling flow
rate of 21.2 lpm (0.75 cfm), which is the standard sampling rate for solving the isokinetic equation and
setting up the nomograph (sets of equations) for testing.
Find the true Orifice Tube calibration factor with the following equation, where Km is the orifice calibration
factor:
ΔH@ = 0.9244/Km2
Described below are both the initial and intermediate calibration procedures. Prior to conducting a
calibration run, perform a leak-check on the portion of the sampling train from the pump to the Orifice Tube
in the Source Sampler Console, as described below.
Metering System Leak-Check Procedure (Vacuum Side):

The following steps describe the leak-check procedure for the Vacuum Side of the Source Sampler Console.
See Figure 3-1 for a plumbing diagram of the MC-500 Series Source Sampler Console.
1. Connect the Vacuum Pump to the Source Sampler Console.

2. Close the Coarse Valve on the Source Sampler Console.
3. Insert a plugged male quick-connect into the SAMPLE quick-connect inlet.
4. Turn on the pump.
5. Open the Coarse Valve and fully close the Fine Increase Valve.
6. The Vacuum Gauge should read 92-kPa (27 in. Hg) for a barometric pressure of 100 kPa (30 in.
Hg).
7. After the ΔH manometer has returned to the zero mark, note whether the leak rate exceeds 0.28
lpm (0.01 cfm) using the dry gas meter gauge and a wristwatch or timer. If the leak rate is too
high, turn off the Pump and check tubing and piping connections on the Pump, Vacuum Gauge,
and Metering Valves. Also check the tubing for leaks.
8. Close the Coarse Valve and observe the Vacuum Gauge. If there is no vacuum loss, the vacuum
side of the Source Sampler Console is leak free.
9. Perform the Pressure Side Leak-Check next by following the directions in the next section.
Note: The Rockwell Dry Gas Meter in the MC-522 (English version of the MC-572) will indicate a leak by
running backward on the Pressure Side when completing the Vacuum Side Leak-Check. However, the
Kimmon Dry Gas Meter in the MC-572 will not run backward, thus requiring a Pressure Side Leak-Check.
74
Figure 3-1: Source Sampler Console Plumbing Diagram for Leak-Check
Metering System Leak-Check Procedure (Pressure Side):

There are several techniques for performing a “back-half,” or pump discharge, Source Sampler Console leak-
check. The following procedure is based on US EPA recommendations in Section 5.6 of Method 5:
1. Connect the Vacuum Pump to the Source Sampler Console.
2. Plug the outlet of the Orifice Meter with a rubber stopper.
3. Insert both pitot (Δp) manometer plastic connectors into the right side of the dual-column
manometer.
4. Insert both orifice (ΔH) manometer plastic connectors into the left side of the dual-column
manometer.
5. To pressurize the system, remove one of the ΔH plastic connectors and then blow lightly into the
tubing until the ΔH reads 177.8 to 254 mm (7 to 10 in.) H2O.
6. Pinch off the tubing securely, and insert the ΔH plastic connector back into the manometer. Allow
the manometer oil time to stabilize.
7. Observe for one minute. If you note any loss of pressure during this minute, you have a leak
which must be corrected. Check all connections and tubing for leaks.
75
Initial or Semiannual Calibration of Dry Gas Meter and Orifice Tube:
Calibrate the Source Sampler Console (Dry Gas Meter and Orifice Tube) by connecting the Source Sampler
Console to a wet test meter or secondary reference dry test meter, according to the set-ups shown in Figures
3-2 and 3-3.
Conduct a series of five (5) calibration runs at differing flow rates (ΔH settings) that bracket the range of
expected sampling rates during particulate sampling tests.
If using a wet test meter as the calibration standard, it should have a meter correction factor of 1.000.
Alternatively, you may use a properly calibrated secondary reference dry gas meter to calibrate the Source
Sampler Console’s dry gas meter.
The calibration steps are as follows:

1. Before starting the calibration, record the following data on a meter calibration data sheet (or a
computer spreadsheet) as shown in Appendix C:
a. Barometric pressure at the start of calibration,
b. The Source Sampler Console and wet test meter identification numbers
c. Date and time of calibration, and
d. Confirmation of acceptable leak-checks on the Source Sampler Console.
2. Connect the outlet of the wet test meter to the inlet (SAMPLE) of the Console Meter.
3. Turn on the Vacuum Pump and adjust the Coarse and Fine Control Valves on the Source Sampler
Console until you obtain an orifice pressure (ΔH) of 12.7 mm (0.5 in.) H2O at a vacuum of 8 to 15
kPa (2 to 4 in. Hg) on the Vacuum Gauge. Allow both meters to run in this manner for at least 15
minutes to let the meter stabilize and the wet test meter to wet the interior surfaces.
4. Turn off the Vacuum Pump.
5. Record initial settings of ΔH, dry gas meter volume reading, wet test meter volume reading, dry gas
meter temperature, and wet test meter temperature.
6. Start the Vacuum Pump and quickly adjust the ΔH to the desired setting. Start the Elapsed Timer on
the Source Sampler Console at the same time you start the pump.
7. Let the Vacuum Pump run until a dry gas volume of approximately 140 liters (5 cubic feet) is
indicated on the dry gas meter. Allow the calibration run to continue until the next minute elapses,
and then stop the Vacuum Pump and Elapsed Timer.
8. Record the final dry gas meter volume reading, wet test meter volume reading, dry gas meter
temperature, and wet test meter temperature. Calculate the dry gas meter and wet test meter volumes
by subtracting initial readings from final readings. Calculate the average dry gas meters and wet test
meter temperatures.
9. Repeat the calibration run at each successive setting of ΔH, recording the same data as before.
Suggested ΔH values are 13, 26, 39, 52, 65 and 78 mm H2O (0.5, 1.0, 1.5, 2.5, 3.5 and 4.5 in. H2O).
76
10. At the conclusion of the five calibration runs, calculate
the average Y value to obtain the dry gas meter Tips from a Stack Tester
calibration factor, as well as the average orifice pressure
(ΔH@). The tolerance for individual Y values is ± 0.02
from the average Y. The tolerance for individual ΔH@
values is ± 6.4 mm (0.25 in) H2O from the average ΔH@.
11. If the Y and ΔH@ are acceptable, record the values on a
label on the front face of the Console Meter. If you don’t obtain a value
of ± 6.4-mm (0.25-in) H2O
from the average ΔH@,
adjust the orifice opening
or replace the Orifice
Tube.
Figure 3-2: Set-up for Calibrating the Source Sampler Console Against Wet Test Meter
77
Figure 3-3: Illustration of Console Meter Calibration with Secondary Reference Dry Gas Meter
With a critical orifice set

as shown in Figure 3-4,
you can do a post-test
calibration in the field
before departing the test
site. Follow the same
Figure 3-4: Critical Orifice Used for Calibration directions described on the
next page, except
substitute the critical
orifice for the wet test
meter and ensure that the
vacuum is 25 to 50 mm Hg
(1 to 2 in. Hg) above the
critical vacuum.
78
Post-Test Calibration of the Source Sampler Console:
Conduct a post-test, or 3-point, calibration of the Source Sampler Console after each test series or trip to and
from the field to ensure that the dry gas meter correction factor (Y) has not changed by more than 5%.
Conduct the post-test calibration check at the average ΔH and highest system vacuum observed during the
test series. The steps are as follows:
1. Before starting the calibration, fill out a meter calibration data sheet (it can be a computer
spreadsheet) as shown in Appendix C. Record the following:
a. Barometric pressure at the start of calibration,
b. Identification numbers for the Source Sampler Console and wet test meter (or secondary
DGM or critical orifice),
c. Date and time of calibration, and
d. Confirmation of acceptable leak checks on the Source Sampler Console.
2. Connect the outlet of the wet test meter to the inlet (SAMPLE) of the Source Sampler Console, as
depicted in Figure 3-2. Insert a valve between the wet test meter and the inlet of the Source Sampler
Console to adjust the vacuum to the desired level. If using a Critical Orifice, simply insert the male
quick-connect end of the critical orifice into the inlet (SAMPLE) of the Source Sampler Console.
3. Turn on the Vacuum Pump and adjust the Coarse and Fine Control Valves on the Source Sampler
Console until you obtain an orifice differential pressure (ΔH) reading equivalent to the average ΔH
observed during the test series. Set the calibration system vacuum to the highest vacuum observed
during the test series. Allow both meters to run like this for at least 15 minutes to let the meter
stabilize and the wet test meter to wet the interior surfaces.
4. If using a Critical Orifice, select an orifice with ΔH properties similar to the average ΔH observed
during the test series. Note that the vacuum will be independent of the vacuum observed during the
test series, due to the physics of the critical orifice requiring the vacuum to be greater than the
theoretical critical vacuum. Theoretical critical vacuum can be estimated at one-half (1/2) of
barometric pressure. It is recommended to sample at maximum vacuum with the Coarse Valve fully
opened and the Fine Valve fully closed.
5. Turn off the Vacuum Pump.
6. Record initial settings of ΔH, dry gas meter volume reading, wet test meter volume reading, dry gas
meter temperature, and wet test meter temperature.
7. Start the Vacuum Pump and quickly adjust the ΔH to the desired setting. Start the Elapsed Timer on
the Source Sampler Console at the same time that the pump is started.
8. Let the Vacuum Pump run until the dry gas meter indicates a volume of approximately 140 liters (5
cubic feet). Allow the calibration run to continue until the next minute elapses, and then stop the
Vacuum Pump and Elapsed Timer.
9. Record the final dry gas meter volume reading, wet test meter volume reading, dry gas meter
temperature, and wet test meter temperature. Calculate the dry gas meter and wet test meter volumes
by subtracting initial readings from final readings. Calculate the average dry gas meter and wet test
meter temperatures.
10. Calculate the meter correction factor Y. Repeat the calibration two (2) more times at the same ΔH
and system vacuum settings and calculate the average Y for the three runs.
79
11. Calculate the percent change in the meter correction factor Y.
12. If the dry gas meter Y values obtained before and after the test series differ by more than 5%, either
void the test series or perform calculations for the test series using the lower Y value (which would
give a lower sample volume, and therefore higher concentration values).
2. Calibration of Thermocouples
Apex Instruments suggests the following procedures for calibrating thermocouples and temperature display
readouts:
● Check thermocouples for calibration at three temperatures. For example, ice-point and boiling point
of water and ambient temperature. Thermocouples that are used at higher temperatures than boiling
water, such as the stack gas thermocouples, can be checked for calibration using a hot oil bath.
● Another more modern technique is to use a Thermocouple Simulator Source (M5C-22), as shown in
Figure 3-5. The M5C-22 can calibrate without external compensation or ice baths, with a temperature
range from 0° to 2,100°F in divisions of 100°F, resulting in 22 precise test points.
A temperature sensor calibration form is provided in Appendix C.

Acceptable reference materials are:
● ASTM reference thermometers,
● NIST-calibrated reference thermocouples/potentiometers,
● Thermometric fixed points, e.g., ice bath and boiling water
● NIST-traceable electronic thermocouple simulators.
Figure 3-5:
Thermocouple Calibration Procedure: Thermocouple Simulator for
Temperature Display Calibration Check
1. Prepare an ice-water bath in an insulated container (such
as the Cold Box).
a. Insert the thermocouple and a mercury reference thermometer into the bath.
b. Allow the readings of both to stabilize and record the temperatures on a thermocouple
calibration data sheet, as shown in Appendix C.
c. Remove the thermocouple and allow it to stabilize at room temperature.
d. Reinsert the thermocouple into the bath and record another reading.
e. Repeat Steps c and d.
f. Calculate the average of the thermocouple readings and the average of the reference
thermometer readings. The averages should differ by less than 1.5% of the absolute
temperature (°K) for the stack thermocouple.
2. Place a beaker of distilled water on a hot plate, and then add a few boiling chips and heat to boiling.
a. Insert the thermocouple and a mercury reference thermometer into the beaker and repeat Step
1, b through f, above.
80
3. Set the thermocouple you are checking and a mercury reference thermometer side-by-side at ambient
temperature and allow the readings to stabilize.
a. Repeat Step 1, a through f, above.
4.
4.
Did you know? Apex Instruments provides both geometric and wind tunnel 4.
calibrations of type-S pitot tube assemblies for a reasonable fee. Contact us at (800) 4.
882-3214 to learn more. 4.
4.
4.
4.
4.
4.
Place a container of oil on a hot plate and heat to a temperature below the boiling point. DO NOT BOIL.
a. Insert the thermocouple and a mercury reference thermometer into the container and repeat
Step 1, b through f, above.
Calibrate Temperature Display:
The temperature display requires additional calibration procedures. To check the linearity of the temperature
display, use a thermocouple simulator (such as Apex Model M5C-22 pictured in Figure 3-5). Connect the
simulator to the temperature display and record the display reading at each temperature setting on a
calibration data sheet.
3. Calibration of Pitot Tube

Carefully check the construction details of the S-type (or Stausscheibe) pitot tube when you receive it and
prior to calibration. There are two options for calibrating a S-type pitot tube:
Calibration
Of
S-type Pitot Tube
Check that it meets Calibrate against

geometric standard p-type in a
specifications and
OR wind tunnel and
assign Cp = 0.84 calculate new Cp
Option 1: Since few stack testers have access to a wind tunnel facility, the US EPA allows you to assign a
co-efficient of Cp = 0.84, if the pitot tube meets geometric specifications. Keep in mind that using the
agency’s standard co-efficient will likely bias your velocity and flow rate measurements high.
81
Option 2: When using a wind-tunnel calibration procedure, the pitot tube coefficient (C p) will typically
range from 0.77 to 0.82. This means that your subsequent measurements of stack gas velocity will likely be
between 2% and 8% lower due to increased accuracy associated with wind-tunnel calibration. Consequently,
your measurements of the stack gas volumetric flow rate and emission rate also will be lower. The
procedures for conducting a wind tunnel calibration are described in detail in US EPA Method 2.
Geometric Specifications Pitot Calibration:

1. Before starting the calibration check, fill out a pitot tube
calibration data sheet as shown in Appendix C (or enter it
in a spreadsheet).
2. Clamp the pitot tube so that it is level, verify its level
position and record it.
3. Confirm that the pitot openings are not damaged or
obstructed and record it.
4. Using an angle indicator, measure the angles (α 1 and α2)
between the pitot tube opening plane and the horizontal
plane when viewed from the end, and record the angles
(see third image in figure 3-6).
5. Measure the angles (β1 and β2) between the pitot tube
opening plane and the horizontal plane when viewed from
the side, and record the angles (see fourth image in the
figure).
6. Calculate the difference in length between the two pitot
tube legs (Z) by measuring the angle γ and record it (see
the last image in the figure).
7. Calculate the distance that the pitot tube legs are rotated
(W) by measuring the angle θ and record it (see the fifth
image in the figure).
8. Measure and record the vertical distances (PA and PB)
between the plane of each pitot tube opening and the
center line of the pitot tube (see the second image in the
figure).
9. Measure and record the tube external diameter (DT) and
calculate the minimum/maximum values of PA and PB (see
first image in figure). Figure 3-6
Probe Pitots measurements pertaining
to the geometric specifications
calibration check
82
4. Calibration of Sampling Nozzles
Inspect and calibrate probe nozzles in the field immediately before each use to verify that they were not
damaged in transport or shipment. We recommend the following procedure, illustrated in Figure 3-7:
1. Before starting the calibration check, fill out a probe nozzle calibration data sheet as shown in
Appendix C (or use a computer spreadsheet).
2. Using venier or dial calipers with at least 0.025 mm (0.001 in.) tolerance, measure the inside diameter
of the nozzle by taking three readings approximately 45-60° apart from one another, and record them.
3. Calculate the average of the three readings.
4. If readings do not fall within 0.1 mm (0.004 in.) of one another, the nozzle must be reshaped,
resharpened and recalibrated.
5. With a permanent marking tool, identify each nozzle with a unique number.
Figure 3-7: Calibration of Sampling Nozzle
83
5. Initial Calibration of Probe Heater
Apex Instruments calibrates the probe heater assembly before shipping according to procedures outlined in
US EPA APTD-0576. Probes are constructed according to specifications given in US EPA APTD-0581,
which is the original 1971 document entitled “Construction Details of Isokinetic Source-Sampling
Equipment,” by Robert M. Martin. (Available from National Technical Information Service (NTIS) as
document PB-203 060.)
The procedure outlined in APTD-0576 involves passing heated gas at several known temperatures through a
probe assembly, and monitoring and verifying that the probe assembly is capable of maintaining 120°C ±
14°C, as shown in Figure 3-8.
Figure 3–8: Set-up for Probe Heater Calibration
84
6. Calibration of Pressure Sensors
The gauge-oil inclined manometer and a mercury-in-glass manometer are primary measuring devices, and
thus do not require calibration. When using a differential pressure gauge (magnehelic gauge), U-tube
manometer, or electronic manometer, they must be calibrated against a primary measuring device.
To check the calibration of differential pressure sensors other than inclined manometers, use the following
procedure:
1. Connect the differential pressure sensor to a gauge-oil inclined manometer as shown in Figure 3-9.
2. Vent the vacuum side to atmosphere, and place a pressure on each system.
3. Compare Δp (velocity head of stack gas) readings of both devices at three or more levels that span
the range, and record on a calibration data sheet.
4. Repeat Steps 1 through 3 for the vacuum side. Vent the pressure side and for the vacuum side, place a
vacuum on the system.
5. The readings at the three levels must correspond within ± 5% of the reference sensor.
To pressure source or 1 2 4 .6
vented to atmosphere OR
Magnehelic
Valve
To vacuum system or
vented to atmosphere
Manometer
Figure 3-9: Set-up for Differential Pressure Sensor Calibration Check
85
Maintenance Procedures
For maintenance procedures, check your appropriate user’s manual for the equipment that you are using for
your stack test.
If you are using Apex Instruments equipment, call 1 (800) 882-3214 to speak with a member of our
Technical Services Group (TSG) to aid you in your maintenance needs. Additionally, you may use our
website www.apexinst.com to find a user’s manual for your specific equipment that needs maintenance.
86
Appendix A
Equipment Lists for Isokinetic Sampling
87
Recommended Equipment for Isokinetic Sampling
Apex Instruments, Inc. Method 5 Source Sampling System recommended items:
Qty Part# Description

1 XC-5000 Automated Isokinetic Method 5 Meter Console includes DGM with Optical Encoder, Barometric
Pressure Transducer, Internal Flash Memory, Type K Thermocouples, PID, Standard or Metric Units
1 XE-0523 External Pump Assembly, Double Diaphragm Pump, SS Quick Connects, 5 FT Power Cord &
Hoses, 240V (120V option), Black UHMW Polyethylene Case
1 SB-2M Miniature Heated Filter Oven with 2 Access Doors & Probe Clamp, 240V (120V option)
1 SBR-10 Riser for SB-2M, Impinger Box Adapter, 10 IN Riser with Insulated Reservoir
1 SB-3 Impinger Box / Insulated Coolant Reservoir, Holds 4 Impingers
1 PS-3H 3 FT Method 5 Probe Sheath with Tube Heater, 120V (240V option)
1 PL-3S 3 FT SS Probe Liner, 5/8” o.d. with #28 Grooved Ball
3 PLN-3G 3 FT Glass Probe Liner, 5/8” o.d. with Unground #28 Grooved Ball
1 US-30-10 30 FT Split Umbilical Cable, Method 5, with 1/4” Pitot QCs, Stainless Steel Quick Connects
1 US-60-10 60 FT Split Umbilical Cable, Method 5, with 1/4” Pitot QCs, Stainless Steel Quick Connects
1 USL-15-SST 15 FT Unheated Sample Line, PTFE with SS over braid, #28 Socket Elbow Fitting Both Ends,
Includes TCA-06F
1 SB-8 Modular Sample Frame with Probe Clamp & Impinger Box Slides
1 GA-107-12 Sample Line Adapter (for SB-2M), Includes Bracket and 1/2” ID Sample Line Clamp
1 GA-100 Umbilical Adapter (Gooseneck), #28 Socket with Thermocouple, Mounting Bracket, 1/2” Male QC
1 NS-SET Set of 7 Stainless Steel Nozzles - Sizes 4,6,8,10,12,14,&16, Includes Case and Four 5/8” tube nuts
1 NG-SET Set of 7 Glass Nozzles - Sizes 4,6,8,10,12,14&16, Includes Case & Three 5/8” Glass Filled PFA
Ferrules
1 GN-DGS Basic Method 5 Glassware Set with Unground Joints & 3” Filter Assembly
1 GF-3TPG 82mm PTFE Coated Glass Fiber Filters - Hydrophobic, Low Absorption of Acid Gases such as SOX,
or NOX, 50/box (MFS PG60)
1 GF-3 3” Glass Fiber Filters, 100/box (Whatman 934AH-82.6mm)
1 PBX-S Modular Probe Brush Extension Kit, Nylon Brushes with Stainless Steel Extensions
1 NB-SET Nozzle Brush Set (sizes 3, 5, & 8) in Carrying Tube
1 P1000-6 Monorail , 6 feet, with Chain, L-Bracket & Hardware
2 P1000-9 Monorail , 9 feet, with Chain, L-Bracket & Hardware
2 P2751 Swivel Frame Trolley with Eye-bolt, 12” Chain & Quick Link
1 TX-XC5 Transport Case, XC500 Series
1 M5CO-SET Calibration Orifice Set, 5 Calibrated Critical Orifices & Spreadsheet Diskette for Method 5
88
It is also recommended to have additional Probe Assemblies to best suit your testing needs. Apex
Instruments, Inc. recommends a 4 foot and 8 foot Probe Assembly in addition to the standard 6 foot which is
included in the above listed system.
Apex Instruments recommended method 17 additional accessories.

3 SFA-2590 Method 17 SS In-Stack Filter Unit
1 GFA-2590 Glass Fiber Thimble, 25X90mm Tapered, 10/box
1 PLS-6S-QCF6 Method 17 6 ft SS Probe Liner with 3/8” Male QC
1 USL-15-QST 15 ft Unheated Sample Line, PTFE with SS Overbraid
1 UA-3J Power Box Adapter, 3 Receptacles
1 SB-8 Sample Frame w/ Probe Clamp & Impinger Box Slides

2 GNM-HC Horizontal Condenser, #28 Socket both ends, Water Jacket Hose Barbs
2 GN-9AKS Knock-Out Impinger Assembly, Unground
8 GNM-T XAD Trap, #28 Unground Socket & O-Ring Ball, Water Jacket Hose Barbs
4 TL-7/5 Surgical Tubing, 3/8 IN (2 FT.)
1 MM5-P220 Submersible Coolant Pump, 220V (120V option)
1 PBC-6 6 ft Extendible Aluminum Probe Brush with PB-5/8 Nylon Brush
1 NTG-10U 5/8” Glass-Filled Teflon Union with Nuts and Ferrules
1 PBT-5/8 Teflon Probe Brush, 5/8” Diameter, 4” Length, 8-32 Thread
1 PBX-8T 8 FT Flexible TFE Probe Brush Extension, Brush Not Included
1 T-TFE24 Teflon Tape, High Density, 1.5” x 520” per roll
89

1 GN-9AK Knock-Out Impinger, Short Stem, 500ml, Unground O-Ring Joints
1 GF-3QH 3” Quartz Fiber Filters, 100/box (MFS QR100 82 mm)
1 PBT-5/8 Teflon Probe Brush, 5/8” Diameter, 4” Length, 8-32 Thread
1 PBX-10T 10 FT Flexible TFE Probe Brush Extension, Brush Not Included
1 NBT-1/2 Nozzle Brush, Teflon, ½”
1 NTG-10U 5/8” Glass-Filled Teflon Union with Nuts and Ferrules
1 T-TFE24 Teflon Tape, High Density, 1.5” x 520” per roll
1 NG-SET Set of 7 Glass Nozzles - Sizes 4,6,8,10,12,14&16, Includes Case & Three 5/8” Glass Filled
PFA Ferrules
Apex Instruments recommended method 201A (PM10) additional accessories.

1 PM2.5-10K PM 2.5/10 Cyclone Kit, Includes PM10 Kit, PM2.5 Cyclone Body, Adapters, Pitot & Case
1 UA-3J Power Box Adapter, Includes 1/2 IN Mounting Clamp and 4 Pin Amphenol to 3 Receptacle
1 MPT-6-421-OFF Extended Pitot Tip for PM10/2.5 Sampling, Tube Diameter 3/8 IN, Length 421mm, Offset
1 GF-47Q 47mm Quartz Fiber Filters, 25/box (Pallflex 47mm).
1 PM2-K PM2.5 Cyclone Set, 12 Nozzles, (PM2-NS), Filter (SFA-47), Cyclone Body, Manual and Case.
90
Recommended Spare Parts for Isokinetic Sampling
Apex Instruments, Inc. recommends stocking the following spare parts:
Qty Part # Description

Console Meter Parts (MC-572)
1 TC-765KF Thermocouple Display, panel mount, LED, 120V/240V
1 M313102A Thermocouple Switch, 7-Channel
1 M-31302K Knob for 7-Channel Selector Switch
1 M-1400 Temperature Controller, analog, Love Model 140EF
2 SSR-330-25 Relay, SSRT, 25A, 120/240V
1 M-CB10A Electrical Circuit Breaker, 10A, 120V, panel-mount
2 M-CB3A Electrical Circuit Breaker, 3A, 120V, panel-mount
1 M-49BK Electrical Receptacle, snap-in, screw-term, 120V
1 AM-MCP Amphenol Connector, MC Panel, pre-wired sub
1 M-SV3131 Solenoid Valve, 3-way, brass, 120V
1 DGM-SK25 Dry Gas Meter, SK-25, Metric
1 QC-BHF4-B Quick Connect, bulkhead, ¼”- ¼” tube, female, brass
1 QC-F8-B Quick Connect, ½”- ½ ” tube, female, brass
1 QC-M6-B Quick Connect, 3/8”- 3/8 ” tube, male, brass
1 QC-BHF6-B Quick Connect, bulkhead, 3/8”- 3/8 ” tube, female, brass
1 M-42210 Dual Column Manometer, inclined vertical
1 QC-MAN-F3 Quick Connect, Manometer, female, 1/8” MNPT, stainless steel
2 QC-MAN-M2 Quick Connect, Manometer, male, 1/4” HB, P/C, PVC
2 M-422DS Manometer Displacer, with knob
1 HC83314SS Cabinet Spring Catch for Meter Console
1 HS83314SS Keeper Latch, short shank for Meter Console
External Pump Parts (E-0523)
1 GP-BL50-2 Mini Lubricator
4 AK731 Gast Vanes, Model E-0523 (4 Required)
1 QC-M6-B Quick Connect, 3/8” – 3/8” tube, male, brass
1 QC-F6-B Quick Connect, 3/8” – 3/8” tube, female, brass
Sample Case Parts (SB-1)
1 AM-SBP Amphenol Connector, SB panel, wired
1 TC-PJK Thermocouple Jack, Type K, panel
1 AM-SB500W Hot Box Heater, 500W, 240V
1 PC-1 Hinged Probe Clamp, stainless steel, (2.54 cm OD probes)
91
Recommended Spare Parts for Isokinetic Sampling
(continued)
Qty Part # Description

Umbilical Cable Parts (UC-60)
1 QC-F4-B Quick Connect, ¼” – ¼” tube, female, brass
1 QC-F8-B Quick Connect, ½ ” – ½ ” tube, female, brass
1 QC-M4-B Quick Connect, ¼” – ¼” tube, male, brass
1 QC-M8-B Quick Connect, ½ ” – ½ ” tube, male, brass
4 TC-LPS-K Thermocouple Plug, Type K, cord
4 TC-LJ-K Thermocouple Connector, Type K, female
1 AM3101A Amphenol Body, 4-pin cable
1 AM3106B Amphenol Body, 4-socket, cable
2 AM3057 Amphenol Body, strain relief, cable
10 EXP-20 Expando, 1-1/4 inch 500 black
25 PT24004BK PE Tubing, ¼ inch OD, weathered, black, 1000’ roll
25 PT24004NA PE Tubing, ¼ inch OD, weathered, Natural, 1000’ roll
25 PT24004YW PE Tubing, ¼ inch OD, weathered, yellow, 1000’ roll
General Repair and Supply Parts
50 WK-PP-24S Wire, Thermocouple extension, yellow, feet

25 WK-TT-24 Wire, Thermocouple, Type K, TFE insulation, feet
10 4F-B Ferrule, ¼ inch tube, brass
10 6F-B Ferrule, 3/8 inch tube, brass
10 8F-B Ferrule, ½ inch tube, brass
10 10F-B Ferrule, 5/8 inch tube, brass
1 O-113-DZ Silicone O-ring, 5/8 inch, 12 per pack
3 NTG-10F Single Ferrule, 5/8 inch
1 3M-69 Glass Tape, Scotch 69, ¾”. 66 ft. roll
92
Equipment Checklist
93
Appendix B
Calibration Data Sheets
94
95
96
97
98
99
100
101
102
Appendix C
Stack Testing Field Data Sheets
103
104
105
106
107
108
109
110
111
112
113
Appendix D
Calculation Worksheets
114
FEDERAL REFERENCE METHOD 1
Sample and Velocity Traverses for Stationary Sources
Plant __________________________________________ Date _______________________
Location __________________________________________ Test No. _______________________
INPUT PARAMETERS
Sketch of Stack Geometry
Circular Stack:
Interior duct cross-section diameter = _______________ m or ft.
Sampling port diameter = _______________ cm or in.
Sampling port nipple length = _______________ cm or in.
Stack cross-sectional area = _______________ m2 or ft2
Rectangular Stack:
Length of stack location (L) = _______________ m or ft.
Width of Stack location (W) = _______________ m or ft.

2LW
De =
Equivalent diameter (L + W ) = _______________ m or ft.
Sampling Site:
Diameter downstream of disturbance = _______________ m or ft.
Diameter upstream of disturbance = _________________
Minimum number of sampling points = _________________
Total sampling time = ______________ min
Individual point sampling times = ______________ min
Sample and Velocity Traverses for Stationary Sources

(continued)
115
Location of Sampling Points:
CIRCULAR
Sample point Circular stack Distance from

number % diameter sample port
opening, in.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
RECTANGULAR

Determination of Stack Gas Velocity and Volumetric Flow Rate
(Type S Pitot Tube)
116
Plant ______________________________________ Date _________________________
Location ______________________________________ Test No. _________________________
INPUT PARAMETERS
Area of stack (m2) or (ft2) = r2 or  (D/2)2 or L x W = As = _________________
Pitot tube coefficient = Cp = _________________
Stack gas temperature (K) = °C + 273° or (°R) = °F + 460° = Ts = _________________
Average of square root of velocity head (mm. H2O)1/2 or (in. H2O)1/2 = (√∆p)avg = _________________
Barometric pressure (mm. Hg) or (in. Hg) = Pbar = _________________
Stack gas static pressure (mm. H2O) or (in. H2O) = Pg = _________________
Absolute stack gas pressure (mm. Hg) or (in. Hg) = Ps = _________________
Note: Ps = Pbar + Pg (mm. H2O)/13.6 or (in. H2O)/13.6
Stack gas moisture (fraction) = Bws = _________________
Stack gas dry molecular weight (g/g-mole) or (lb/lb-mole) = Md = _________________
Stack gas wet molecular weight (g/g-mole) or (lb/lb-mole) = Ms = _________________
Note: Ms = Md (1 – Bws) + 18.0 Bws
CALCULATIONS
vS = Stack gas velocity, m/s or ft/s
T s( avg )
v s = K p x C p x ( √ Δp )avg x
√ Ps M s
vs = Kp x ( ) x ( ) x
√ (
( )
)x( ) = __________________________m/s or ft/s
Kp = 34.97 (Metric Units)

= 85.49 (English Units)
Qa = Volumetric flow rate, acmm or acfm
Qa = 60 x v s x A s
Qa = 60 x ( ) x( ) = _____________________acmm or acfm
Determination of Stack Gas Velocity and Volumetric Flow Rate

(continued)
Qd = Dry volumetric flow meter, scmm or scfm
117
Qd = 60 x (1 − Bws ) x v s x A s
Q d = 60 x ( 1 − ( )) x ( ) x ( ) = ____________________scmm or scfm
Qsd = Volumetric flow rate, dscmm or dscfm
T std P
Qsd = 60 x (1 − B ws ) x v s x A s x x s
Ts P std
T std ( )
Q sd = 60 x ( 1 − ( )) x ( ) x ( ) x x
( ) Pstd
= ____________________dscmm or dscfm
118
Gas Analysis for the Determination of Dry Molecular Weight
Plant ___________________________________________ Date _____________________
Location ____________________________________________ Test No. _____________________
INPUT PARAMETERS
Percent Oxygen (O2) by volume, dry basis = %O2 = ______________________
Percent Carbon Dioxide (CO2) by volume, dry basis = %CO2 = ______________________
Percent Carbon Monoxide (CO) by volume, dry basis = %CO = ______________________
Percent N2 = 100 – (%O2 + %CO2 + %CO) = %N2 = ______________________
CALCULATIONS
Md = Dry molecular weight, g/g-mole or lb/lb-mole
M d = 0. 44 (% CO 2 ) + 0. 32 (% O 2 ) + 0.28 ( % N 2 + % CO)
M d = 0. 44 ( ) + 0 . 32 ( ) + 0 . 28 ( + ) = __________g/g-mole or lb/lb-mole
Ms = Wet molecular weight, g/g-mole or lb/lb-mole
M s = M d (1 − B ws ) + 18.0 ( Bws )
M s = ( ) (1 − ( ) )+ 18 . 0 ( ) = __________ g/g-mole or lb/lb-mole
%EA = Excess Air, %
(% O2 ) −( 0 .5 % CO )
% EA = x 100
0 . 264 ( % N 2 ) − (% O2 − 0 .5 % CO)
( ) −( 0. 5 ( ) )
% EA = x 100
0 . 264 ( ) − ( ( )− 0 .5 ( )) = ______________________________%
119
Determination of Moisture Content of Stack Gases
Plant _______________________________________________ Date _______________________
Location _______________________________________________ Test No. _______________________
INPUT PARAMETERS
Volume of gas sampled through dry gas meter = Vm = ________________
Dry gas meter (DGM) calibration factor = Y = ________________
Average DGM temperature (K) = °C + 273° or (°R) = °F + 460° = Tm = ________________
Average DGM orifice pressure differential (mm H2O) or (in. H2O) = ∆H = ________________
Volume of water collected, condensed, [Vf - Vi], ml = Vlc = ________________
Volume of water collected in silica gel (Wf – Wi), g = Vwsg = ________________
Barometric pressure (mm. Hg.) or (in. Hg) = Pbar = ________________
CALCULATIONS
Vm(std) = Volume of gas sampled at standard conditions, dscm or dscf
T
P bar + (13ΔH. 6 )
( )
V m( std ) = V m Y std x
Pstd Tm
T std
( )+ (13( . 6) )
V m( std ) = ( ) ( )
( )
Pstd ( )
= _____________dscm or dscf
Vwc(std) = Volume of water vapor condensed at standard conditions, scm or scf
V wc ( std ) = K 2 ( V f −V i )
V wc ( std ) = K 2 ( ) = _______________scm or scf
K2 = 0.001333 (Metric Units)

0.04706 (English Units)
120
Determination of Moisture Content of Stack Gases
(continued)
Vwsg(std) = Volume of water vapor collected in silica gel
V wsg ( std ) = K 3 ( W f −W i )
V wsg ( std ) = K 3 ( )
= ______________scm or scf

0.04706 (English Units)
Bws = Mole fraction of water vapor
V wc( std ) + V wsg (std )

B ws =
V wc( std ) + V wsg( std ) + V m( std )
( )+ ( )
B ws =
( )+ ( )+( ) = ________________________
%H2O = Percent moisture
%H 2 O = 100 x B ws
%H 2 O = 100 x ( ) = _______________________%
121
Nozzle Size Selection Worksheet
Note: The most commonly used equation for estimating isokinetic sampling nozzle diameter is the following (assumes that
moisture fraction at dry gas meter equals zero.):
Dn( est) =
√ K 1 Qm P m
√ Ts Ms
T m C p ( 1 − Bws ) P s Δpavg

Source Name ________________________________________ Date _______________________
Facility ________________________________________ Calculated by ___________________
INPUT DATA
Barometric Pressure (mm. Hg) or (in. Hg) = Pbar = ________________
Stack Static Pressure (mm. H2O) or (in. H2O) = Pg = ________________
Stack Gas Pressure (mm. Hg) or (in. Hg)

Pg
Ps = Pbar +
13.6
( )
Ps = ( )+
13 . 6 = Ps = ________________
Dry Gas Molecular Weight (g/g-mole) or (lb/lb-mole) = Md = ________________

assume 30.0 for combustion of coal, oil or gas
assign 29.0 if mostly air
assign 28.0 if mostly purge nitrogen
or use preliminary Orsat® or Fyrite® data
Stack Gas Moisture (fraction) = Bws = ________________

use preliminary moisture data
use wet bulb/dry bulb if < 212°F
BE CAREFUL: fraction Bws = %H2O/100
Wet Gas Molecular Weight (g/g-mole) or (lb/lb-mole)

M s = M d ( 1 − B ws ) + 18 . 0 ( B ws )
Ms = ( ) (1 − ( ) ) + 18 .0 ( ) = Ms = ________________
Stack Gas Temperature (K) or (°R) = Ts = ________________
°C + 273° = K or °F + 460 = °R
Pitot Tube Coefficient = Cp = ________________
122
(continued)
Average Velocity Head (mm. H2O) or (in. H2O) = ∆pavg = ________________
v = calculation of inside square root term
Ts Ms
v=
√ P s Δp avg
)x(
v=
√ (
( )x(
)
) = v = ________________
Sampling Flow Rate (cfm or lpm) = Qm = ________________

assume 0.75 cfm
assume 21.24 lpm
Dry Gas Meter Temperature (K or °R) = Tm = ________________

use ambient temp + 25°F + 460 = °R
Dry Gas Meter Pressure (mm Hg or in. Hg) = Pm = ________________

use Pbar + (∆H@)/13.6
CALCULATION OF NOZZLE SIZE
Estimated Nozzle Diameter (mm or inches)
Dn( est) =
√ K 1 Qm P m
√ Ts Ms
T m C p ( 1 − Bws ) P s Δpavg
K1 x ( ) x( )x(
D n( est ) =
√ ( )x( ) x (1 − (
)
)) = Dn(est) = ________________

Actual Nozzle Diameter Chosen (mm or inches) = Dn = ________________
123
(continued)
K-FACTOR CALCULATION
∆H = Isokinetic Rate Orifice Pressure Differential

ΔH=Kx Δp
ΔH M T P
K= = K 6 D 4n ΔH @ C2p ( 1 − B ws ) 2 d m s
Δp M s T s Pm
ΔH ( )( )( )
K= = K6 ( )4 ( ) ( )2 ( 1 − ( ) )2
Δp ( )( )( ) = _________________
K6 = 8.038x10-5 (Metric Units)

CHECK CALCULATIONS FOR SUFFICIENT SAMPLE VOLUME AND ISOKINETIC RATE 90-110%
Stack Gas Velocity (m/s or ft/sec) = vs = ________________

from preliminary velocity run
convert to m/min or ft/min vs x 60 sec/min = vs(fpm) or(mpm) = ________________
Estimated Sampling Time (minutes) = θ = ________________
multiply number of traverse points by minutes/point = _________total min.
CALCULATION OF ACTUAL SAMPLING RATE
Qm(std) = Actual Sampling Rate (dscmm or dscfm)
100 ( 1 − Bws ) Ps v s( fpm) or (mpm) D2n

Qm( std ) =
1039 T s
100 ( 1 − ( )) ( ) ( ) ( )2
Qm( std ) =
1039 ( ) = ________________
Vm(std) = Total Gas Sample Volume to be Collected (dscm or dscf)
V m( std ) = Q m( std ) x θ
= ________________
Based on applicable regulations for this source:
Will there be sufficient sample volume (dscf)? yes no
Will there be sufficient sampling time (minutes)? yes no
124
(continued)
Check Intermediate Isokinetic Sampling Rate
100 T s V m( std ) P std K 4 T s V m ( std )

%I i= =
60 T std v s θ A n Ps ( 1 − B ws ) Ps v s A n θ ( 1 − Bws )
K4 ( )( )( )
%I i =
( )( )( ) ( ) (1 − ( )) = ________________

Check Final Isokinetic Sampling Rate
π 2
D
An = Nozzle Area 4 n = __________in2 or mm2
V m( tot )
%I f =
[ (
100 T s (avg ) K 3 V lc +
T m (avg ) ) (P bar +
ΔH
13. 6 )]
60 θ v s( avg) Ps A n
%I f =
[
100 ( ) K 3 ( ) +
( )
( )(
( )
( )+
( )
13 .6 )]
60 ( ) ( ) ( ) ( ) = ________________

125

Manual de Operacion Consola Apex-520

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APEX INSTRUMENTS, INC.

Isokinetic Source Sampling Handbook

Apex Instruments, Inc.

Chapter 2: Operating Procedures 19

Chapter 3: Calibration and Maintenance 71

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

Method 3 Determination of Dry Molecular Weight and Percent Excess Air

Method 4 Determination of Moisture Content

Method 5 Determination of Particulate Matter Emissions from Stationary Sources

Method No. Pollutants

Waste Combustion Source Methods in EPA-SW-846

Figure 1-1: Apex Instruments Isokinetic Source Sampling Equipment

Apex Instruments Product Highlight

1. Source Sampler Console

The electrical system contains circuit breakers that detect and

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

2. External Vacuum Pump Unit

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

 The E-0523 features a 250-watt motor

Pumps that require lubrication, such as the E-0523,

Figure 1-4: Diagrams of Probes and Probe Assembly

Figure 1-5: Diagrams of Probe Liner Configurations

Table 1-4: Probe Configuration Temperature Ratings

Probe Heater: Apex Instruments

Also, our mandrel-type heater design

Handle with Safety Clip

Door Latch (both sides)

Probe Power Receptacle

Impinger Case Drain

Figure 1-6: Modular Sample Case Components and Accessories

The impinger case (cold box) holds the sampling train

Obtain multiple Impinger

Figure 1-8: Circular Connector and Electrical Pin Designations

Figure 1-9: Glassware Sampling Train Schematic

1. Set-up and Check of Source Sampling System

A. Initial Set-up Procedure

Stainless Steel Nozzle Glass Nozzle

B. Initial Sampling System Leak Check

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

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

● Why is the test being conducted?

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

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

A second solution for clearance problems is our Compact

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

Figure 2-4: Schematic of Compact Isokinetic Sampling Train

Did you know? Although the Isokinetic Source Sampling System is

Mount the Hot and Cold Boxes

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

Apex Instruments Product Highlight

Figure 2-6: Illustration of Apex Instruments

Assemble Sampling Equipment and Reagents

Obtain Preliminary Measurements of Gas Velocity, Molecular Weight and Moisture

Table 2-1: Preliminary Measurements for Isokinetic Sampling

No. Symbol Value Needed Obtain from

1. Before the sample run (best), or

Obtain most of the

Keep in mind: This method cannot be used when:

Method 1 describes procedures to:

Calculate Traverse Points

1. Measure the stack diameter to within

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

Identify Minimum Number of Traverse Points