THE C-5000 SOURCE SAMPLING

SYSTEM

OPERATING MANUAL

Version 2
January 2008
ENVIRONMENTAL SUPPLY COMPANY
708 E. Club Blvd.
Durham, North Carolina 27704
800-STACKS-5 (782-2575) (919) 956-9688
FAX: (919) 682-0333
 TABLE OF CONTENTS

1 INTRODUCTION ............................................................................................................... 5
1.1 Operational Overview of the System ..................................................................... 5

2 MAINTENANCE................................................................................................................. 6
2.1 OPERATIONAL OVERVIEW OF THE SYSTEM ..................................................... 6
2.1.1 Maintenance Access ........................................................................................... 6
2.1.2 Pump ................................................................................................................... 6
2.1.3 Thermometer....................................................................................................... 8
2.1.4 Quick Connects................................................................................................... 8
2.1.5 Dual Inclined Manometer..................................................................................... 8
2.1.6 Pitot Tube Lines .................................................................................................. 8
2.1.7 Null Switch .......................................................................................................... 8
2.1.8 Maintenance Access ........................................................................................... 9
2.1.9 Maintenance Access ........................................................................................... 9
2.1.10 Vacuum System .................................................................................................. 9
2.2 SAMPLE CASE .......................................................................................................10
2.2.1 Heated Filter Compartment ...............................................................................10
2.2.2 Impinger (Cold) Box ..........................................................................................10
2.2.3 Impinger Glassware ..........................................................................................11
2.2.4 Filter Assembly Pressure Drop Check...............................................................11
2.3 PROBE ASSEMBLY ...............................................................................................11
2.3.1 The Probe Sheath and Probe Liner ...................................................................11
2.1.9 Probe Test .........................................................................................................12
2.3.3 Probe Cleaning..................................................................................................12
2.3.4 S-Type Pitot Tube Maintenance ........................................................................12
2.3.4 Nozzle................................................................................................................12
2.4 UMBILICAL CORD and adapter ............................................................................12
2.4.1 Quick Connects.................................................................................................13
2.4.2 Umbilical Adapter Thermocouple Check ...........................................................13
2.4.3 Umbilical Adapter Check Valve .........................................................................13
2.4.4 Sample and Pitot Lines .....................................................................................13

3 CALIBRATION & MAINTENANCE .................................................................................14

3.1 CONTROL CONSOLE ............................................................................................14
3.2 PITOT TUBE CALIBRATION..................................................................................14
3.3 FIELD OPERATION ................................................................................................14
3.4 FIELD OPERATION ................................................................................................15
3.4.1 Site Selection ....................................................................................................15
3.5 VERTICAL AND HORIZONTAL TRAVERSING.....................................................16
3.6 SAMPLE CASE SUPPORT ....................................................................................16
3.6.1 ESC Suspension Rail System ...........................................................................17
3.6.2 Slide Box ...........................................................................................................17
3.7 PRESAMPLING CALCULATIONS .........................................................................18
3.8 SAMPLE COLLECTION ASSEMBLY ....................................................................18
3.8.1 Sample Case Assembly .....................................................................................18
3.8.2 Probe Assembly ................................................................................................18
3.9 MOUNTING THE PROBE .......................................................................................18
 3.10 LEAK TEST ......................................................................................................... 19
3.11 WARM UP PROCEDURE ................................................................................... 19
3.12 SAMPLE RUN ..................................................................................................... 19
3.13 SHUTDOWN........................................................................................................ 20
3.14 SAMPLE CLEAN-UP .......................................................................................... 20
3.15 ANALYSIS ........................................................................................................... 21
3.16 CALCULATIONS ................................................................................................. 22
3.16.1 Average Dry Gas Meter Temperature ................................................................ 22
3.16.2 Dry Gas Volume ................................................................................................ 22
3.16.3 Volume of Water Vapor ..................................................................................... 22
3.16.4 Moisture Content .............................................................................................. 22
3.16.5 Stack Gas Velocity ............................................................................................ 23
3.16.6 Volumetric Flow Rate........................................................................................ 23
3.16.7 Total Particulate Weight.................................................................................... 23
3.16.8 Concentration in gr./s.c.f. ................................................................................. 23
3.16.9 Emission Rate in Pounds/Hour......................................................................... 24
3.16.10 Percent Isokinetic ......................................................................................... 24
3.16.11 Acceptable Isokinetic Sampling Results ....................................................... 24
3.17 ORSAT SAMPLE SYSTEM (OPTION -O) ......................................................... 24

4. PLUMBING AND ELECTRICAL DRAGRAMS .............................................................. 26

4.1 Plumbing Assembly............................................................................................... 26
4.2 Electrical Diagram ................................................................................................. 27
 1. INTRODUCTION

1. INTRODUCTION
The Environmental Supply Company C-5000 Source Sampling System is engineered for
optimal performance of isokinetic source sampling procedures. The C-5000 Source
Sampler performs under severe operating conditions encountered by stack sampling
professionals to satisfy the requirements as specified by the Environmental Protection
Agency in the Office of Air Programs Publication No. APTD-0576 and for legal and scientific
documentation of source particulate sampling methods. The system employs an array of
features designed in response to the suggestions and requests of stack sampling
professionals for accuracy, reliability and ease of use in operation, maintenance and
calibration.

1.1 OPERATIONAL OVERVIEW OF THE SYSTEM

1) Stack gases enter the probe nozzle at or near isokinetic conditions and into the
heated, insulated probe liner.
2) An S-Type Pitot tube is attached to the probe sheath with the high pressure Pitot
opening positioned even with or above the probe nozzle entry plane. The Pitot
constantly monitors stack gas velocity by the Pitot differential pressure (∆P)
determination in the area of the nozzle. The ∆P across a calibrated orifice in the
control console is used in calculating the desired nozzle flow rate.
3) The stack gases exit the probe liner through a glass fiber filter holder assembly
that is contained in a heated compartment. The gases are then routed through
glass impingers held in an ice bath to dry and cool the gases before entering the
umbilical cord to be carried from the sampling site to the console.
4) A fiber vane vacuum pump draws the stack gases through the sampling train to
a dry gas meter for volume measurement. A calibrated orifice and manometer
provide adjustment indications for the manual coarse and fine adjustment valves
used to control the sampling rate.

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C-5000 Source Sampling System Operating Manual

2. MAINTENANCE
2.1 CONTROL CONSOLE
Periodic inspection of the C-5000 Source Sampler console components is essential to
maintain proper operation of the system.
Regular maintenance will insure a long system
lifetime.

2.1.1 Maintenance Access

The C-5000 console components are
designed to be easily accessible by removal of
only the rear panel for periodic inspections and
maintenance. Having the plumbing and
electrical panels mounted independently will
be much appreciated. The front and rear
covers can be removed by releasing the eight
cover latches (four on each). It is seldom
necessary to remove the casing wrap,
however, if this becomes necessary, first
unscrew the eight electrical and plumbing
panel-securing screws located on the sides
and top of the casing wrap. Second, the
ventilating fan wires must be disconnected at
the terminal plug located on the side of the fan
housing. Finally, unscrew the 6 base securing
screws and remove the casing wrap by lifting
straight up with care not to disturb the
remaining assembly. To maintain stability of
the console plumbing and electrical panel
assemblies the screws securing these panels
to the base should remain in place.
Alternatively, the plumbing and electrical panel
assemblies may be individually removed for
specific maintenance procedures by unscrewing the top, side and base panel securing
screws. For ease of removal, unscrew the 3 casing wrap-to-base securing screws on the
side corresponding to the electrical or plumbing panel that is being removed. Pull the lower
edge of the casing wrap slightly away from the base to release the panel from behind the
curled edge of the casing wrap and maneuver the panel carefully towards the front of the
unit.
Check the general condition of all components and make necessary repairs. The oil level in
the small oiler bottle must be maintained to prevent damage to the vacuum pump.

2.1.2 Pump
A Gast fiber vane vacuum pump draws the stack gases through the sample train. This
rotary pump is a precision instrument with .002 clearance at the top and .0025"--.0035" total
at the ends of the rotor. The vanes self-adjust with wear and should last 5,000 --15,000
hours depending upon operating conditions. It is designed for pumping dry air and should

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 2. MAINTENANCE

be protected against dirt and excessive moisture. With proper treatment and regular
lubrication this pump requires little additional maintenance to insure a long working life.
Regular Pump Maintenance
There is a small hole in the top of the rear panel for regular inspection of the knockout jar.
This jar should be emptied when accumulated oil interferes with the normal flow of air to the
dry gas meter.
Frequent removal and cleaning of the oiler jar is required when the oil level is low or the oil is
dirty. An inspection port and removable panel are located on the right rear side of the unit.
Unscrew the oiler jar and fill with clean oil as recommended in the table below. Use the
correct amount and type of oil; inadequate lubrication is far more damaging than excessive
lubrication. For installations below freezing, dilute oil with up to 25% kerosene. Do Not
Reuse Oil.

Recommended Lubricating Oils (single grade)

SAE #10 SAE #20
Ambients < 100°°F Ambients > 100°°F
Gast AD220
American S-1 #10 S-1 #20
Citgo C-310 C-320
Gulf Gulflube HD-10 Gulflube HD-20
Humble Encolube HDX-10 Encolube HDX-20
Mobile Delvac 1110 Delvac 1120
Shell Rotella #10 Rotella #20
Sinclair Super TBT #10 Super TBT #20
Sun Sunvis 610 Sunvis 620
Texaco URSA S-1 #10 URSA S-1 #20
Motor Humming or Failure to Start: Check motor current, correct current is 5 to 6
amperes. Examine plug and switch for malfunctions. If the pump is cold, bring to room
temperature and attempt starting again. If motor defect is suspected, return the unit to pump
manufacturer for repair.
Flushing: A noisy or inefficient pump is frequently nothing more serious than a vane stuck
in rotor slot due to excessive oiling or presence of foreign debris. Remove motor from
console; add several teaspoons of solvent (Loctite Safety Solvent, Inhibisol Safety Solvent,
Dow Chemical Chlorothane, or Kerosene) slowly at the intake while unit is running. Lay unit
on side with outlet downward to allow the solvent to eventually drain out. Once the problem
is corrected place the pump in correct operating position add three drops of oil at the intake,
and attach accessories.
Foreign Matter In Pump: If debris has entered the pump, try the flushing procedure above.
If this does not eliminate the problem, remove only the end plate and the four vanes. (DO
NOT remove the rotor.) Wash the vanes, end plate, and pump chamber with solvent. Dry
and lightly re-lubricate.
Rotor-Body Top Clearance Adjustment: If proper vacuum or pressure cannot be
achieved, the top clearance between the rotor and body may have increased. Alternatively,
a metallic clanging is evidence of decreased clearance (rotor and body are touching).
Remove end plate only and set the top clearance to .002" by tapping lightly on the pump
body in the direction to reverse the diminished or enlarged clearance. Turn the rotor while

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C-5000 Source Sampling System Operating Manual

setting the clearance so that all points on the circumference of rotor will clear. Total end
clearance for both sides of rotor may vary from .0025" to .0035".
Overheating: Dirty or clogged filter felts can be responsible for inability of the pump to build
up pressure or produce vacuum, and can lead to overheating. It is not unusual for exhaust
air temperature to reach 230°F when running continuously. If this temperature is exceeded
or is reached during intermittent operation, remove the filter felts and wash in solvent. If
overheating is not repaired by this procedure, stop operation immediately and send the unit
to the manufacturer for repairs. When corresponding or ordering spare parts, please give
complete model and/or serial number.

2.1.3 Thermometer

Check the dry-gas meter thermometer against room temperature using a standard mercury-
in-glass thermometer.

2.1.4 Quick Connects

Keep quick connects clean by wiping with a clean rag and lubricating with a drop of
penetrating oil.

2.1.5 Dual Inclined Manometer

Make sure by a visual check that the Pitot and orifice manometer lines are free of fluid and
void of leaks, especially around the fluid-level zeroing controls and drain screws. Clean the
front of the manometer with a clean rag and the back with compressed air (the device can
be removed from the plumbing panel and wiped clean). Follow recommendations on the
manometer instruction plate for further cleaning directions.
Open the manometer ports 1.5 turns counterclockwise from closed position. Make sure that
the manometer lines are connected and the manometer is level. Check the fluid level and, if
necessary, add fluid by removing the screw on the left side. The manometer is zeroed when
the oil meniscus and the reflected image at zero are aligned, and the fluid-level plunger
(zeroing control) can travel between 1/4” and 1/2” inward.
Note: When shipping, disconnect the manometer lines and close the manometer ports by
turning clockwise. If the manometer unit ever becomes inverted (as may happen during
shipping), be sure the floating check valves, located under the manometer ports, return to
their normal position before use.

2.1.6 Pitot Tube Lines

Check the Pitot tube line quick connects for obstructions by blowing gently, the Pitot tube
gauge should respond.

2.1.7 Null Switch

With all electrical switches turned off, plug the power cord into a 115-volt outlet. Turn the
power switch to the “ON” position. Power up is indicated when the digital temperature
controllers show a readout or, if analog temperature controllers are used on your system,

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 2. MAINTENANCE

the temperature readout displays. Turn on the “NULL” switch; the solenoids should make an
audible “click”. If the clicking sound does not occur, check the power source, power cable,
power connections, and solenoid valve.
The “NULL” switch on the front panel of the console operates the solenoid valve assembly
for obtaining a zero reading during a test without interrupting sample collection. The normal
position is “OFF” while reading ∆H. In the “on” position the orifice lines are blocked to the
manometer.
Turn off all switches except the power and pump switches. Carefully adjust the Main-
(Coarse) and Fine-Adjust valves. The manometer should respond to valve controls. If no
movement is observed, check the solenoid valves or the orifice gauge system.

2.1.8 Timer

The timer is located next to the pump switch on the console electrical panel so that the
operator can easily turn on the timer along with the pump to measure elapsed time.

2.1.9 Temperature Controllers

There are two types of solid-state temperature controllers available for probe and filter heat
regulation. Your system will have either two analog (dial type) controllers or two
programmable digital controllers. Each style of temperature controller employs an indicator
light to show when the controller is powering its 10 Amp solid-state relay, indicating heating
to setpoint. When setpoint is reached, the controller will cycle off and repeat the on-off cycle
in response to thermocouple feedback.
The analog controllers are operated by turning the knob to the desired setpoint. Setting or
resetting the temperature for the programmable, digital controller is outlined below. For
more details on the operation of the digital controller please refer to the manual included
with your console. NOTE: If your console is equipped with digital controllers, the switchable
temperature readouts for the probe and filter are disabled, so that the temperatures can be
read directly from the readout on the digital controller.
RESETTING THE TEMPERATURE CONTROLLER (FUJI)
1. Press “SV” gently to observe the temperature setpoint.
2. Press the “^” key of the digit to be set: 100 digit (left), 10 digit (middle), unit digit
(right). Repeatedly press each key until the desired digit is obtained.
3. When the desired temperature setpoint is keyed in properly, press the “ENT”
key to accept the setpoint. The flashing will stop.
4. Press “PV” to observe the current temperature.
EXAMPLE: Set Temperature to 250°°F
1. Press the 10 digit “^” key (middle) five times. Press the 100 digit “^” key (left) two
times.
2. Press ”ENT” to accept the 250°F setpoint. Press “SV” to check the setpoint
value. Press “PV” for the current temperature.

2.1.10 Vacuum System

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C-5000 Source Sampling System Operating Manual

Insert a plugged 1/2" male quick connect into the sample inlet port on the front of the
console. Turn the Pump switch “ON”, the Coarse-Adjust valve “ON” and close the Fine-
Adjust valve. The vacuum gauge should read about 25 inches of mercury when ambient
barometric pressure is 30 inches of mercury. Check the leakage rate using the reading on
the dry gas meter and a watch.
Regulations require a leak rate in the train less than .02 cfm, however the pump and
console should not be taken to the field with a leak rate greater than .01 cfm. If this rate is
exceeded: 1) close the coarse valve and check again; 2) check the oiler and inlet filter jars
for tightness, broken threads, or bad gaskets; and 3) check fittings. Continued leaking is
indication of the need for repair or replacement.

2.2 SAMPLE CASE

2.2.1 Heated Filter Compartment

Connect the umbilical between the

console and sample case and plug the
console into a 115 VAC power source.

Turn on the Filter Heater Control on the

C-5000 Console electrical panel. Check
its operation by watching the
temperature on the controller as it heats.
The usual setting is 250°F.
Check the Probe Heater Control in the
same manner.
For recording purposes a sample case
checklist should be employed to record
results of component checking
procedures. Each sample case should be numbered. At least two sample cases, including
the glassware for each, should be on hand for a stack test. The availability of extra sets
increases efficiency during the test since the sample train can be cleaned while the second
run is being made.

2.2.2 Impinger (Cold) Box

Fill the impinger box with water and check for leaks. Leaks may be repaired with fiberglass
and epoxy resin or filled with silicone rubber.

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 2. MAINTENANCE

2.2.3 Impinger Glassware

The illustration at left shows the relative position of all

glassware during a particulate sample test. It is
essential that glassware be clean to insure accurate
sampling results. Glass cleaning solution may be used
for light cleaning and dichromate sulfuric acid solution
for heavy cleaning. Avoid contact of acid cleaning
solution with sealing rings or plastic screw caps.
Glassware should be rinsed with distilled, deionized
water, and then acetone and allowed to air dry with openings covered to avoid
contamination.

2.2.4 Filter Assembly Pressure Drop Check

Connect the filter holder assembly directly to the umbilical adapter and run the umbilical
cable to the console for a pressure-drop check. Turn the pump on and adjust flow on the
orifice gauge to a reading of 5.0 inches Hg. If the vacuum gauge on the console reads
higher than two inches of mercury, the frit needs cleaning and rechecking.

2.3 PROBE ASSEMBLY

The probe nozzle is sealed with a front and rear ferrule and a union nut to the union body
that fastens to a permanently welded union nut on the sample entry end of the probe
sheath. The sample entry end of the probe liner inserts into this union body and is secured
with an inverted rear ferrule and Viton O-ring. The end of the probe liner should be
positioned flush with the front end of the welded union nut when inserting in the union body.
Detach the union assembly from the probe sheath welded nut before attempting to
remove the probe liner. Finger tightening is sufficient to reattach the union body assembly
(with inverted ferrule and Viton O-ring) to the welded nut. Do not use a wrench for this
procedure. However the probe nozzle-to-union body attachment requires two wrenches for
proper tightening. We suggest using mineral fiber string as an alternative to the Viton O-ring
when stack temperatures over 500°F are expected.

2.3.1 The Probe Sheath and Probe Liner

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C-5000 Source Sampling System Operating Manual

The liner must be removed from the probe sheath to inspect the heating mantle or replace
the liner. Remove the nozzle and union from the welded nut and gently slide the liner out of
the sheath. To reassemble, slide the probe liner inside the probe sheath and guide the end
of the liner through the hole of the welded union nut until it extends flush to the end of the
nut.

2.3.2 Probe Test

Examine the electrical components of the probe for any visible damage prior to following
test procedures.
1. Plug the probe into the sample case and set the probe heat controller to 250°. The
probe should become warm to the touch over its entire length in a few minutes. If the
probe does not heat, check the probe heat control for loose connections, the umbilical
cord and the sample case.
2. Use an ohmmeter to measure the resistance between leads and also to ground.
Deviations from proper value indicate faulty wiring.

2.3.3 Probe Cleaning

Clean the probe liner internally by brushing, first using tap water, then distilled, deionized
water, and finally using acetone. Perform a final rinse with acetone and allow to air dry.
Inspect visually for cleanliness and repeat the procedure if necessary.
Clean the stainless steel union, nut ferrules, Viton O-ring, and nozzle by scrubbing. Rinse
with distilled, deionized water, and then with acetone and allow to air dry with all open ends
of probes and nozzles covered with serum caps or saran wrap to prevent contamination.

2.3.4 S-Type Pitot Tube Maintenance

Remove the quick connects from the Pitot tube and wipe them clean. A drop of penetrating
oil helps keep them in good working condition.
Use compressed air to blow out the Pitot tube. Both the Pitot tube and sheath should be
wiped or washed clean with water and air-dried. Inspect the Pitot tube openings for damage
and misalignment, and, if necessary, repair and recalibrate the tube.

2.3.5 Nozzle

Inspect the knife-edge of the nozzle for damage. If damaged, repair and recalibrate the
nozzle (see recalibration section). Clean the nozzle by scrubbing, then rinse with distilled,
deionized water, and finally with acetone. Allow to air dry with the open ends covered with
serum caps to avoid contamination or damage to the knife-edge.
Ideally there should be a selection of nozzles ranging from 1/8” to 1/2” in diameter in 1/16”
increments with two or three sets of each size. A number reflecting the exact diameter in
1/32” increments should be etched near the inlet end of each of the nozzles (e.g. #8
indicates a 1/4” nozzle, #9 indicates a 9/32” nozzle).

2.4 UMBILICAL CORD AND ADAPTER

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 2. MAINTENANCE

The umbilical cord consists of one 1/2” sample (vacuum) line, two 3/8” Pitot lines, one 1/4”
orsat line, one power line with Amphenol connectors, and five thermocouple lines. Lines of
like dimension and purpose are numbered at each end to avoid cross connections and
assist in proper hookup of the umbilical couplings.

2.4.1 Quick Connects

Wipe the vacuum line and Pitot tube quick connects and apply a drop of penetrating oil on
each to keep them in good working condition.

2.4.2 Umbilical Adapter Thermocouple Check

Check the impinger temperature thermocouple (“DRYER” connections and settings on the
console) on the umbilical adapter against a mercury-in-glass thermometer.

2.4.3 Umbilical Adapter Check Valve

Disconnect the joint at the check valve and add a drop of lubricating oil on the valve.

2.4.4 Sample and Pitot Lines

Test the sample line for leaks by placing a plugged male quick connect into the inlet,
connecting the line to the console and checking for leakage as before. If there is leakage, all
connections should first be checked, and then the tubing. If the leak is not evident by
inspection, slightly pressurize the line and check for leaks using soapy water.
Connect one end of the Pitot tube line to a 36-inch U-tube mercury manometer or a similar
device. Pull a vacuum of at least ten inches, seal the tubing at the pump end, and check for
leaks by noting the mercury manometer. Do the same for the other side. If there is leakage,
check the tubing by following the same procedure as for the vacuum line.

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3. CALIBRATION & OPERATION

3.1 CONTROL CONSOLE

All units are calibrated before shipping. If desired, the dry gas meter and the orifice meter
can be recalibrated according to the procedure below.
Connect a wet test meter (1-cubic-foot-per-revolution meter with ± 1% accuracy) to the
umbilical cord running from the control console. Run the pump for about 15 minutes with the
orifice gauge set at about 0.5 inches of water to warm up the pump and dampen the interior
surface of the wet test meter. Record the information requested on the Suggested Orifice
and Dry Gas Meter Calibration and Calculation Form (appendix). Calculate γ, the ratio of
accuracy of the wet test meter to the dry test meter, and ∆H@. If an average γ of 1.0 ± 0.01
is not obtained, adjust the dry gas meter by removing the plate on top of the dry gas meter
and adjusting the linkages until γ meets the specification.
A value of 1.84 inches ±0.25 inches of water is acceptable. If the achieved value is not in
this range, the orifice opening should be cleaned, adjusted, or replaced. ∆H@ should not
vary by more than 0.15 over the range of operation from 0.5 to 8 inches of water. If the ∆H@
is satisfactory, record ∆H@ on the front of the monitor unit.

3.2 PITOT TUBE CALIBRATION

Measure the velocity pressure, ∆P, at the same point within a cross section of a straight run
of ductwork (8 diameters downstream and 2 diameters upstream from any point of
disturbance) with a standard Pitot tube and the S-type Pitot tube for the desired range of
gas velocities. The S-type Pitot should be calibrated twice, reversing the direction of the legs
during the second calibration. Make at least three determinations for each direction.
Determine the Pitot tube coefficient (Cp(s)) of each direction as:

∆P( s tan dard )

Cp(s) = 0.99
∆P( s )

Pitot tube acceptability is in the range of Cp = 0.85 ± 0.03 in both directions, since the
nomograph used with the sampling train is designed for this number. If the Cp is not in this
range, the Pitot tube was probably not calibrated properly. Be sure that the Pitot tube is
square with the duct and pointing directly into the gas stream. A special nomograph is
available to correct for variations in Cp. (catalog # M5-SRN)

3.3 NOZZLE CALIBRATION

Using a micrometer, measure the inside diameter of the nozzle to the nearest 0.001 inch.
Make ten separate measurements using different diameters each time and obtain the
average of the measurements. The largest deviation from the average should not exceed
0.002 inch. If the variation is more than 0.002 inch, repair the nozzle with a tapered plumb
bob (for inside damage) or emery paper (for outside damage). If the nozzle is satisfactory,
polish off the old inscribed value, or, if new, etch the value of the inside diameter on the
outside of the nozzle.

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 3. CALIBRATION & OPERATION

3.4 FIELD OPERATION

3.4.1 Site Selection

It is important to take your sample data from a site that fits the following criteria. Existing
sample sites are often chosen based on inadequate information. If necessary, relocate the
sampling site to acquire acceptable data.
A sampling site should be chosen with a minimum of at least two diameters downstream
and 0.5 diameters upstream from any expansion, contraction, bend, obstruction, visible
flame, or exit, and requiring 48 sampling points within the duct. The optimum sampling
location is at least eight diameters downstream and two upstream, requiring only 12
sampling points. For rectangular cross sections the equivalent diameter is determined by
using the following equation:

equivalent diameter =2
(length)(width )
length + width

The chart below is provided to assist in determining the number of sampling points required
for a sampling site. First measure the distance from the chosen sampling location to the
nearest upstream and downstream disturbances. Using the upstream and downstream
scales, two numbers will be indicated. Select the higher of the two numbers. Then round off
the number for a round stack to the nearest multiple of four. For a square or rectangle stack,
divide the cross section into as many equal rectangular areas as sample points, such that
the ratio of the length to width of each elemental area is between one and two.

Number of Duct Diameters Upstream*

(Distance A)
0.5 1.0 1.5 2.0 2.5
50
Disturbance
40
A
Sampling
30
Site
20
* From point of any type of disturbance B
10 (bend, expansion, contraction, etc.)
Disturbance

0
2 3 4 5 6 7 8 9 10
Number of Duct Diameters Downstream*
(Distance B)

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C-5000 Source Sampling System Operating Manual

For circular stacks, locate the sampling points on at least two diameters according to the
diagram below. Make sure that the traverse axes divide the stack into equal parts. For
rectangular stacks, locate the points at the centroid of each equal area as shown below.

Another factor to be considered in selecting the sampling site is that the distance from the
probe to the bottom of the sample case is about 13 inches. Although the equipment was
designed to fit into 2 1/2-inch holes, it has been found that 3-inch holes allow easier
entrance and removal without nicking the nozzle or picking up deposited dust.

3.5 VERTICAL AND HORIZONTAL TRAVERSING

Sampling should always be done traversing perpendicular to the flow of the stack gases. A
vertical stack of duct requires a horizontal traverse. A horizontal stack may be traversed
horizontally or vertically. For stacks or ducts at offset angles, horizontal traversing is
recommended. However, for round stacks this will not always be practical. The sampling
site must meet the requirements of least flow disturbance and also accessibility of the
sampling equipment. In general, the following will hold true for most sampling projects:
1. Horizontal traversing is the least complicated, requires only standard supporting
apparatus, i.e. the support rail, and allows the easiest access to the probe and sample
case.
2. Vertical down traversing is preferable to vertical up as bottom side ports may emit
accumulated particulate.
3. Support of the sample case and probe during a vertical traverse is best accomplished
by a custom built frame for each sampling site. The design of such an apparatus is left
to the project engineer.
The lightweight ESC Compact Filter Box (M5-CFB) is ideal for vertical traversing or sampling
in constrained areas.

3.6 SAMPLE CASE SUPPORT

Support of the sample case is a primary consideration in any stack sampling application.
The need for a traversing platform equal in length to at least 1/2 the stack diameter has
brought about the development of several sample case support systems. The support rail is
used primarily on circular stacks of any material that can safely support the weight of the rail
and equipment. The stacks can range from three to fifteen feet in diameter. Since two
traverses, perpendicular to each other, are required per stack, it is convenient to have two
support rails.
Square or rectangular ducts, or any vertical sampling, do not readily lend themselves to the
use of the support rail. In such cases, scaffolding or other platform structures are

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 3. CALIBRATION & OPERATION

recommended. Each sampling site's requirements must be analyzed by the project

engineer. Such factors as safety, availability of structural material, permanency, rigidity of
the ductwork, etc., must all be considered. For quality results, no short cuts should be taken.
The well-planned, firmly structured sampling platform will pay for itself in convenience and
security for the sampling engineer.
If the sampling site lends itself to the use of the support rail, great care should be taken in its
installation. The support rail is shown below, fastened to an angle iron permanently affixed
to the stack. A support chain supports the outer end of the support rail in a level position.
Permanent welding of the support rail is the most secure installation. On a masonry stack,
mechanical anchors (molly
bolts or lead shields) prove to
work satisfactorily. In any
case, firm support of the rail
is mandatory.
It is assumed that the
sampling engineer is
stationed in the immediate
area of the stack, and has no
access to the outer extremity
of the support rail. The probe
must, on occasion, be
inserted in the sampling port
first, before being mounted in
the sample case. This allows
ease of assembly and
eliminates awkward handling
of the equipment. All
precautions should be taken
not to contaminate the probe
liner. A cap should be left on
the nozzle tip until actual
sampling has begun. While
using the support rail, the sample case can be moved by pushing or pulling on the probe.

3.6.1 ESC Suspension Rail System

The ESC Sample Case is designed for use with most any monorail system. The ESC
Suspension Rail System is both lightweight and flexible and permits rapid attachment of the
sample case to the suspension rail trolley by use of snap hooks. After hanging the sample
case on the suspension rail it may be freely rotated so that the probe can be attached by
the operator while standing on a platform very close to the stack. The sample case is then
pushed out to its farthest position by holding the probe prior to insertion into the stack port.

3.6.2 Slide Box

A slide box is probably the simplest support system of all. However it can only be used
conveniently when sampling very near the rooftop. A typical arrangement would be a
plywood table supported by any suitable weight bearing legs (cinder blocks or laterally

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C-5000 Source Sampling System Operating Manual

braced 2x4 assemblies) that will elevate the sample case and probe to be aligned with the
sample port. Many variations are possible depending on the operator and materials
available.

3.7 PRESAMPLING CALCULATIONS

All sampling results are dependent upon the correct isokinetic sampling rate and proper
calculation of data obtained there from. Presampling calculations must be performed
accurately and without assumptions.
A stack calculating slide rule, calculator or nomograph should be used to find both the
proper nozzle size and the isokinetic sampling rate. The stack calculating slide rule has two
sides, one for nozzle size determination for all sampling trains with an orifice meter and the
other side for K factor determination. When the calculation is complete, the ∆P and ∆H
scales are properly aligned for isokinetic sampling and the slide can be locked in place.
Stack calculating slide rules are designed to handle any sampling situation that might be
encountered. Please refer to the instruction manual included with your stack calculating
slide rule for calculation procedures.

3.8 SAMPLE COLLECTION ASSEMBLY

3.8.1 Sample Case Assembly

Once the sampling site has been prepared to accommodate all necessary apparatus, the
sample train can be assembled. The sample case should be properly fitted with the
impingers and glass connectors. Fill two of the impingers with 100 ml of distilled water and
one with 175 grams of silica gel. Place tarred filter in the filter holder and record the filter
weight on the data sheet. Environmental Supply Company supplies type "A" fiberglass
filters packaged for this purpose.
Tighten the phenolic screw joint around the filter holder to prevent leakage around the frit
gasket and position the assembly in the heated compartment of the sample case. Position
the umbilical adapter onto the last impinger arm while sliding the umbilical adapter bracket
into the support block mounted on the side of the impinger box. Tighten the thumbscrew to
hold the adapter firmly in place. The sample case can now be moved to the sample site.

3.8.2 Probe Assembly

After selecting a suitable probe length and nozzle size, insert the probe liner carefully into
the sheath and connect the nozzle using the union connections. Cover the nozzle and
probe liner with serum caps or saran wrap. Mark the probe with heat-resistant tape or by
some other method to denote the proper distance into the stack or duct for each sampling
point. Move the probe to the sampling site.

3.9 MOUNTING THE PROBE

For Horizontal Traverse--Swing open the probe support bracket clamping mechanism.
Insert the probe end (opposite from nozzle end) through the front hole of the sample case

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 3. CALIBRATION & OPERATION

and align with glassware inlet (cyclone bypass). Tighten the 1/4 - 20 wing nut to secure the
probe to the support bracket. For ball joint probe and glassware, clamp the probe liner ball
to the socket on the inlet glassware. For screw joint probe liner and glassware tighten the
screw cap with ring seal to the inlet glassware. Fit the filter inlet arm to the cyclone bypass
and secure.
For Vertical Up or Down Traverses--For these applications it is recommended that a
vertical probe support adapter (ESC catalog # M5-VPS) be used to hold the probe in proper
position. The assembly is the same as above except that an additional elbow must be
secured between the probe liner exit end and the glassware inlet. The ESC Compact Filter
Box (catalog # M5-CFB) may be used as an alternative to the vertical probe support
adapter. This lightweight heated filter box is designed to operate in any position and/or in
tightly constrained areas.

3.10 LEAK TEST

Connect the umbilical cord to the sample case and control console. The sample train should
now be completely assembled. Plug the probe nozzle with a suitable stopper. Turn the
Coarse-Adjust valve on the Monitor Unit to the ON position and fully open the Fine-Adjust
valve. Turn on the Pump switch. Partially close the Fine-Adjust valve until the vacuum
gauge reads 10 inches of mercury; then check the dry gas meter flow. If the flow through
the dry gas meter exceeds 0.02 cubic feet per minute at 10 inches of mercury gauge
pressure, the leak or leaks must be found and corrected. If the union assembly has been
sealed with asbestos string, it should be checked first if any leaks do exist.
When the check is complete, first remove the stopper from the probe nozzle inlet, and then
turn off the vacuum pump. This prevents water from being forced backward through the
impingers into the filter and cyclone.

3.11 WARM-UP PROCEDURE

Make all necessary electrical and gas line connections. Turn on the Filter Heat Control and
the Probe Heat Control. Allow the sample case and probe to heat for at least 15 minutes
before starting the test and make periodic checks and adjustments to assure the desired
sample case temperature.
Fill the impinger section of the sample case with ice and a little water. Add ice periodically
during testing to maintain the temperature of the gas leaving the last impinger at less than
80°F.

3.12 SAMPLE RUN

Record all necessary initial data such as that shown at the top of the Sample Data Sheet
(appendix), including the initial dry gas meter reading. Turn off the Main (coarse adjust)
valve on the console and fully open the Fine-Adjust valve. Remove the cover from the
nozzle tip and place the probe at the first sampling point. Record the clock time, read ∆P on
the Pitot tube gauge, and determine ∆H as described previously. Turn the pump on and set
∆H on the orifice gauge by adjusting the Main (coarse adjust) valve and the Fine valve.

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C-5000 Source Sampling System Operating Manual

The sample run plan should consider the number of traverse points and the sampling time
at each point. A good rule of thumb to follow is to collect a weight of particulate matter equal
to about 20 percent of the filter weight. The upper limit is usually set by the pressure drop
across the filter and the amount of condensate the impingers can hold. Generally the length
of sampling time at each traverse point is 2 to 10 minutes.
During the sample traverse, the probe is moved from point to point without turning the pump
off except when changing to a different sampling port. The ∆P should be monitored and
adjustments made on the orifice gauge with the aid of the stack calculation slide rule.
Besides the regular time interval recordings, a set of readings should be recorded when the
∆P changes by more than 20 percent.

3.13 SHUTDOWN
When testing has been completed, close the sample valve, remove the probe from the
stack, and take a final set of readings. It is possible to turn off the pump rather than close
the sample valve. However, using this procedure may occasionally cause the contents of
the first impinger to back up into the filter unless a check valve is installed in the umbilical
adapter (such as ESC Model M5-UA). Turn off the Filter Heat and Probe Heat Controls and
remove the probe from the sampling port. Cover the nozzle tip as soon as possible to avoid
contamination or loss of sample. Disconnect the probe from the sample case support
bracket and cyclone bypass inlet glassware. Cover both the end of the probe and the
glassware inlet (cyclone bypass). Disconnect the umbilical cord from the sample case. The
probe and sample case are then ready for clean up and analysis.

3.14 SAMPLE CLEAN-UP

For each sample taken at any source, there should be a sample transport kit consisting of
the following items:
1. One: 32 ounce, wide mouth glass jar with a Teflon lined lid.
2. Two: 16 ounce, wide mouth glass jars with a Teflon lined lid.
3. One: 8 ounce, polyethylene or Nalgene bottle with an airtight lid.
These four clean-up containers will accommodate most sources. However, occasionally it
will be necessary to have extra containers of equal specifications. The ESC Sample Caddy
(catalog no. M5-STC) contains 3- 32 oz jars, 6- 16 oz jars, 4- 8 oz Nalgene bottles and 6-4”
Petri dishes (for filter paper storage) in a foam-lined aluminum case suitable for shipping.
The tools required for a sample cleanup are as follows:
1. Three laboratory quality, bristle, or nylon brushes with galvanized wire
handles. One brush of proper shape and size to clean the filter holder, glass
connectors and probe nozzles; another suited to cleaning the impingers; and
a third for probe liner cleaning with an extendable rigid handle.
2. Two glass funnels and one polyethylene funnel large enough in diameter to
set in the mouth of the sample transport containers mentioned above.
3. Two polyethylene or glass wash bottles at least 500 ml capacity.
4. A small spatula for collecting loose particulate matter, a pair of tweezers for
filter paper handling, and labels for marking transport containers.

(Cleanup kit, Model M5-CK contains each of the above in a steel carrying case.)

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 3. CALIBRATION & OPERATION

When the shutdown process has been completed, move the collection train from the test
site to the sample recovery area to minimize the loss of collected sample or gain of
extraneous particulate matter. Set aside a portion of the acetone used in the sample
recovery as a blank for analysis. Place the samples in container as follows:
Container #1: Place the water contents from the first three impingers in this
container and seal.
Container #2: Remove the filter from its holder, place in this container, and seal.
Container #3: In this container, place loose particulate matter and acetone
washings from the filter half of the filter holder, cyclone and flask,
probe liner, and probe nozzle. (This is commonly referred to as
the front half.) Cleanup is best accomplished with a simultaneous
acetone-wash bottle rinse and brushing into the glass funnel
seated in the mouth of the container. A good reagent grade of
acetone with less than .001 percent residue, stored in glass
containers, gives excellent results. Each piece should be cleaned
thoroughly until all glassware is clear. The probe nozzle should be
removed from the union body, both openings covered, and set
aside. The probe liner should now be acetone-wash bottle rinsed
and brushed until all particulate matter is removed. The nozzle is
now ready for cleaning. Smaller nozzle sizes may present a
difficult clean-up task. Each nozzle cleaned should at least rinse
clear and some attempt should be made to brush the inner nozzle
walls.
Container #4: Transfer the silica gel from the fourth impinger to the plastic bottle
and seal. Use a rubber policeman as an aid in removing silica gel
from the impinger.
NOTE: At no time should the clean-up procedure be undertaken with soiled hands, or with a
dirt film on any glassware or the probe. If needed, clean all exterior surfaces before the
clean-up procedure is followed.

3.15 ANALYSIS
Record the data required on a data sheet. Handle each sample container as follows:
Container #1: Measure the volume of water. If an analysis of the back half, i.e.
back half of the filter holder contents of the impingers and the
glass connectors is required, refer to the state laws that govern
the clean-up of the back half for various sources. If no back half
extraction is required, discard the water after measuring the
volume.
Container #2: Transfer the filter and any loose particulate matter from the
sample container to a tarred glass-weighing dish, desiccate, and
dry to a constant weight. Report results to the nearest 0.5 mg.
Container #3: Transfer the acetone washings to a tarred beaker and evaporate
to dryness at ambient temperature and pressure. Desiccate and
dry to a constant weight. Report results to the nearest 0.5 mg.
Container #4: Weigh the spent silica gel and report to the nearest gram.

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C-5000 Source Sampling System Operating Manual

3.16 CALCULATIONS

3.16.1 Average Dry Gas Meter Temperature

Average dry gas meter temperature and average orifice pressure drop. See data sheet
(appendix).

3.16.2 Dry Gas Volume

Correct the sample volume measured by the dry gas meter to standard conditions (70°F,
29.92 inches Hg) by using the equation below:
∆H ∆H
Pbar + Pbar +
 Tstd 
Vmstd =Vm 13.6 =17.65 oR Vm 13.6
  
 Tm  Pstd  in.Hg  Tm

Where:
Vmstd = Volume of gas sample through the dry gas meter at standard conditions,
cu. ft.
Vm = Volume of gas sample through the dry gas meter (meter conditions), cu.
ft.
Tstd = Absolute temperature at standard conditions 530°R.
Tm = Absolute temperature at meter (°F + 460), °R.
Pbar = Barometric pressure at the orifice meter, in. Hg
∆H = Average pressure drop across the orifice meter, in. H2O
13.6 = Specific gravity of mercury
Pstd = Absolute pressure at standard conditions, 29.92 inches Hg
3.16.3 Volume of Water Vapor
 ρH 2O  RTstd   cu. ft. 
Vwstd =V 1c    =0.0472 V 1c
 MH 2O  Pstd   ml 

Where:
Vwstd = Volume of water vapor in the gas sample (standard conditions), cu. ft.
V1c = Total volume of liquid collected in impingers and silica gel
ρH2O = Density of water, 1g/ml
MH2O = Molecular weight of water, 18 lb./lb.-mole
R = Ideal gas constant, 21.83 in. Hg-cu. ft./lb.-mole-°R
Tstd = Absolute temperature at standard conditions, 530°R
Pstd = Absolute pressure at standard conditions, 29.92 in. Hg
3.16.4 Moisture Content
Vwstd
Bwo =
Vmstd +Vwstd

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 3. CALIBRATION & OPERATION

Where:
Bwo = Proportion by volume of water vapor in the gas stream, dimensionless
Vwstd = Volume of water in gas sample (standard conditions), cu. ft.
Vmstd = Volume of gas sample through the dry gas meter (standard conditions),
cu. ft.
3.16.5 Stack Gas Velocity
 (Ts )avg .  1 / 2
(Vs )avg .=KpCp ( ∆p avg.
 PsMs 

Where:
(Vs) avg. = Stack gas velocity, feet per second (f.p.s.)
1/ 2
 lb. 
Kp = 85.48ft. /sec. 
 lb. mole−° R 
Cp = Pitot tube coefficient, dimensionless
(Ts) avg. = Average absolute stack gas temperature, °R
( ∆p ) avg. = Average velocity head of stack gas, in. H2O
Ps = Absolute stack gas pressure, in. Hg
Ms = Molecular weight of stack gas (wet basis), lb./lb.-mole
Md = Dry molecular weight of stack gas, (28.8 for air)
Bwo = Proportion by volume of water vapor in the gas stream
3.16.6 Volumetric Flow Rate
 Tstd   Ps 
Qs=60(1− Bwo )VsA  
 (Ts )avg.   Pstd 

Where:
Qs = Volumetric flow rate, dry basis, standard conditions, ft3/min.
A = Cross-sectional area of stack, ft2
Tstd = Absolute temperature at standard conditions, 530°R
Pstd = Absolute pressure at standard conditions, 29.92 in. Hg
3.16.7 Total Particulate Weight

Determine the total particulate catch from the sum of the weights from the analysis.
3.16.8 Concentration in gr./s.c.f.
C’s = 0.0154

gr.  Mn 
mg.Vmstd 

Where:
C’s = Concentration of particulate matter in stack gas, gr./s.c.f., dry basis
Ms = Total amount of particulate matter collected, mg.

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C-5000 Source Sampling System Operating Manual

Vmstd = Volume of gas sample through dry gas meter (standard conditions), cu.
ft.
3.16.9 Emission Rate in Pounds/Hour
 lbs.   min . 
G=0.000143 60 C ' sQs
 gr .   hr. 

Where:
G = Stack emission rate, lbs./min.
C’s = Concentration of particulate matter in stack gas, gr./s.c.f., dry basis
Qs = Volumetric flow rate, dry basis, standard conditions, ft3/min.
3.16.10 Percent Isokinetic

V1c(ρH 2O)R Vm ∆H  min . in.Hg − cu. ft.  Vm ∆H 

Ts + Pbar+ 1.667  0.00267 V1c+  Pbar+  Ts
 MH 2O Tm 
13.6  sec.  ml. − °R  Tm 13.6 
I= 100=
eVsPs An eVsPs An

Where:
I = Percent of isokinetic sampling
V1c = Total volume of liquid collected in impingers and silica gel, ml.
ρH2O = Density of water, 1g. /ml.
Mh2O = Molecular weight of water, 18 lb./lb.-mole.
Vm = Volume of gas sample through the dry gas meter (meter conditions), cu.
ft.
Tm = Absolute average dry gas meter temperature, °R
Pbar = Barometric pressure at sampling site, in. Hg
∆H = Average pressure drop across the orifice, in. H2O
Ts = Absolute average stack gas temperature, °R
Q = Total sampling time, min.
Vs = Stack gas velocity calculated by ft./sec.
Ps = Absolute stack gas pressure, in. Hg
An = Cross-sectional area of nozzle, ft2
3.16.11 Acceptable Isokinetic Sampling Results
If 90% ≤ I ≤ 110%, the results are acceptable; otherwise, reject the results and repeat the
test.
3.17 ORSAT SAMPLE SYSTEM (OPTION -O)
Remove stack moisture using a chiller or dryer located at the sampling site (on the stack).
Connect the 1/4” quick-connect from the umbilical cable to the 1/4” orsat line quick-connect
located on the probe sheath. Connect the other end of the umbilical orsat line to the 1/4”
quick-connect labeled “ORSAT IN” on the front panel of the console. The “ORSAT IN” port
is immediately next to the 3/8” “PITOT +” quick-connect. Connect a length of 1/4” tygon
tubing and a 1/4” quick connect (not included in orsat option) to the “ORSAT OUT” port and
prepare to connect the tygon tubing to a Tedlar bag. Activate the orsat pump using the

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 3. CALIBRATION & OPERATION

“ORSAT ON” switch on the front electrical panel. Close the orsat control valve on the orsat
flow meter located on the front panel prior to attempting to capture a sample.
After the probe assembly is inserted in the gas stream, let the system purge for 2 to 3
minutes before connecting the tygon tube to the Tedlar bag valve. Be sure that the bag is
evacuated before use. After purging, adjust the flowrate control valve to a rate of 1.0 to 1.5
scfh (0.50 - 0.71 lpm). Shut off the valve each time the probe is removed from the gas
stream.

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 4. PLUMBING and ELECTRICAL

C-5000 PLUMBING ASSEMBLY DIAGRAM

REAR VIEW

3 3
SOL. SOL.
1 2 ∆P ∆H ∆P ∆H
1 2
TC
TC

GAS METER
(shown here in outline only)

ORIFICE FINE FILTER/

ROTAMETER MUFFLER
FLOW
CONTROL

TO
IN
EXHAUST MA VACUUM
HOSE GAUGE

ORSAT
OUT IN OUT IN

ORSAT
PUMP PUMP
SAMPLE PITOT PRESSURE VAC
INLET
PRESSURE LINE
GAS LINE
THERMOCOUPLE

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Environmental Supply Company, Inc

LED TEMP DISPLAY

ELAPSED TIMER

MANOMETER ORSAT PUMP

“NULL” SOLENOIDS “OPTIONAL”

Enable Reset Start/Stop

+ -

To T/C Switch
“TC READOUT”

ORSAT

+ EMI FILTER

- NULL

3 4 5 6 3 4 5 6
FILTER PROBE
TEMP TEMP
CONTROLLER CONTROLLER
1 8 7 POWER
To T/C SWITCH 2 1 8 7 2 5 AMP
“TC READOUT” FILTER
To T/C -
“FILTER” +

AC
To T/C -
FILTER
“PROBE” + 10 AMP

PROBE
10 AMP POWER
PROBE
ON/OFF
1/L1 2/T1 1/L1 2/T1
FILTER PROBE
SS RELAY SS RELAY
25 AMP 25 AMP
AUX /PUMP
D A 15 AMP
4/-A2 3/A1+ 4/-A2 3/A1+

3. CALIBRATION & OPERATION

C B PUMP

4-PIN
AMPHENOL
TC READOUT
11 - 21
STACK - - +
DGM OUT PUMP AUX
12 - 22
- - + 18 - 28
- - +
+ + + + +
PROBE DGM IN - - - - -
13 - 23 17 - 27
- - + - - +

FILTER AUX
14 - 24 16 - 26
- - + - - +
Page 27

DRYER
15 - 25
- - +
T/C SWITCH To T/C SWITCH To T/CSWITCH To T/C SWITCH To T/C SWITCH To T/C SWITCH
7-STATION “AUX” “DRYER” “FILTER” “PROBE” “STACK” C-5000 ELECTRICAL DIAGRAM