vvEPA
           United States
           Environmental Protection
           Agency
           Office of Air Quality
           Planning and Standards
           Research Triangle Park NC 27711
EPA-340/1-84-017
September 1984
           Air
Guidelines on
Preferred Location
And Design of
Measurement Ports
For Air Pollution
Control Systems

-------

-------
                                    EPA-340/1-84-017
Guidelines on Preferred Location and
Design of  Measurement Ports for Air
        Pollution Control Systems
                      Prepared by:

                    Richards Engineering
                   2605 Tanglewood Road
                 Durham, North Carolina 27705

                        and

                    JACA Corporation
                    550 Pinetown Road
               Fort Washington, Pennsylvania 19034
                 EPA Project Officer: John Busik
                 EPA Task Manager: Kirk Foster
                  Contract No. 68-01-3962
                      Prepared for:

               Stationary Source Compliance Division
             Office of Air Quality Planning and Standards
               U.S. Environmental Protection Agency
                  Washington, D.C. 20460

                     September 1984

-------
                                  DISCLAIMER

     This report is furnished to the U.S. Environmental Protection Agency
by JACA Corporation of Fort Washington, Pennsylvania and Richards Engineering
of Durham, North Carolina.  The opinions, findings and conclusions are those
of the authors and not necessarily those of the U.S. Environmental Protection
Agency.  Any mention of products does not constitute endorsement by Richards
Engineering, JACA Corporation, or the U.S. Environmental Protection Agency.
Parts and fittings equivalent to those listed in measurement port drawings are
available from a number of suppliers.

-------
                                ACKNOWLEDGEMENTS          I


     JAGA Corporation and Richards Engineering would like to thank Mr. Kirk
Foster of the U.S. Environmental Protection Agency for his assistance during
this project.  The assistance of Mr. R. Stroup and Mr. S Schleisser of Nutech
Corporation in providing details concerning the replaceable tip S-type pitot
tube is also gratefully acknowledged.

     Mr. R.C. Richards, P.E. of Richards Technical Services and Mr. J. Richards,
P.E. of Richards Engineering prepared the measurement port:designs.  Final
drawings were prepared by Ms. Kathy Butz.of Graphic Associates and by Mr  R C
Richards.  Mr. Uday Patankar, P.E. of JACA Corporation served as the Proiect
Director.

-------

-------
                               TABLE  OF CONTENTS
 1.0  Introduction
     1.1  Background
     1.2  Scope

 2.0  Measurement Requirements and Problems
     2.1  Static Pressure
     2.2  Gas Temperature Measurement
     2.3  Gas Stream Oxygen and Carbon Dioxide Concentrations
     2.4  Gas Flow Measurement

3.0  Port Design and Location
     3.1  Limitations of Existing Ports
     3.2  Recommended Port Design Characteristics
     3.3  Port Designs                                     !
     3.4  Port Locations

References

-------
                               TABLE OF FIGURES
Number             Title

2-1         Aspiration Effect
2-1         Use of Sanding Disk to Seal Ports
3-1         Port Located Near Burn Hazard
3-2         Clean-out Port for D/P Transmitter
3-3         1/4 Inch Diameter Measurement Ports
3-4         1/4 Inch Diameter Measurement Port with Extension Tube
3-5         Modified S-Type Pitot Tube
3-6         Pitot Tube Port and Sleeve
3-7         Pitot Differential Pressure Gauge Shelter
3-8         Modified Stack Sampling Ports
3-9         S-Type Pitot Tube with Replaceable Tip Shown
            with Alignment Sleeve
3-10        Modified Stack Sampling Port and S-Type Pitot Tube
3-11        Pitot Tube Mounting Bracket
3-12        Location of Ports on Outlet Duct of Fabric Filter
3-13        Instrument Port Location for Pulse Jet
            and Plenum Pulse Baghouses
3-14        Location of Ports on Reverse Air Fabric Filter,
            (Outside-to-Inside Flow)
3-15        Location of Ports on Reverse Air and Shaker
            Fabric Filters
3-16        Location of Ports on a Spray Tower Scrubber
3-17        Location of Ports on Packed Bed, Moving Bed
            and Tray Type Scrubbers
3-18        Location of Ports on Gas-Atomized Scrubbers
3-19        Location of Ports on Inlet Duct to Gas-Atomized
            Scrubbers
3-24

3-25

3-26
3-28

3-30
3-31

3-32

-------
                              1.0 INTRODUCTION
     Portable instrumentation is useful in evaluating the performance of air
pollution control systems during both regulatory agency compliance inspections
and source operator routine maintenance checks. However, the use of instrumen-
tation, such as static pressure gauges, thermocouples, oxygen analyzers and
pitot tubes, has been limited by the lack of adequate measurement ports on the
existing control systems.  This report examines the data requirements and
provides recommendations on measurement port design and location.
1.1  BACKGROUND                                            I

     The U.S Environmental Protection Agency has been actively involved in the
development of new and more detailed equipment inspection procedures.  These
are intended to provide regulatory agencies with the capability of identifying
emerging problems before there is serious community impact and before the
equipment deterioration demands expensive repair.  Equally important is the need
to have complete technical information when negotiating compliance programs
with sources experiencing chronic compliance problems.  While these new pro-
cedures are being developed primarily to aid regulatory agencies, they will
also aid sources operators.

     The use of portable instruments such as static pressure gauges, thermo-
couples, gas analyzers, and pitot tubes, is often necessary when evaluating the
performance of air pollution control systems.  Unfortunately, many existing
systems have been installed without any measurement ports or with ports in
improper locations.  This has limited both the regulatory agency inspector and
the equipment operator.

     As regulatory agencies adopt these new inspection procedures, there will
be a need, to reach agreement with source operators concerning the types of
ports to be installed and concerning the most favorable locations for these
ports on specific units.  The recommendations presented in this report are
intended to serve as a starting point for agency and source personnel in
discussing port requirements.  Specific designs are proposed which should
minimize common measurement errors. Potential safety factors which must be
taken into account are also discussed.                     !

1.2  SCOPE                                                 i

     The specific types of control equipment addressed include fabric filters,
wet scrubbers, mechanical collectors, absorbers, and electrostatic precipita-
tors.  The types of measurements necessary to evaluate performance of each of
these types of collectors are briefly summarized, and more detailed information
is provided in References 1, 2 and 3.   The instrumentation required for each
measurement is introduced primarily to illustrate the type ;of probe required
and the necessary access to the port area.  Common problems which can occur
while attempting to use existing ports are also covered.  These problems can
seriously affect the accuracy of the measurement and can also lengthen the time
required to make reasonable measurements,.

                                      1-1

-------
     Specific port designs are proposed in this report.  Drawings and general
specifications are provided to facilitate the location and installation of the
ports on the types of control devices listed above.  They have been designed
in a manner to minimize measurement problems while using commonly available
parts and materials.  It is possible to install these ports economically.   The
specifications have been prepared to include some flexibility.  However, it
is easy to modify these designs to satisfy site specific conditions.

     Most of the measurement port designs presented in this report are too
small for the EPA Reference Method test equipment.  The optimum locations  for
emission testing are usually different than the optimum locations for control
system performance diagnosis.   Also, the stack sampling ports are too large
for the types of probes used with the portable inspection instruments.  It
must be understood that both stack sampling ports AND inspection ports are
necessary in most cases.

    There can be a number of serious safety problems associated with improper-
ly located measurement ports.  The most obvious of these are falls due to
ports situated in precarious locations.  Other common problems include pollu-
tant accumulation in poorly ventilated areas in the vicinity of the ports,  hot
surfaces adjacent to the ports, and static charge accumulation on the probes.
Static charge accumulation is very common downstream of electrostatic precipi-
tators, but can also occur in any gas stream in which the relative humidity is
low and the particulate concentration is high.  These safety issues are
discussed at various locations in the manual.  Readers are advised to consult
standard industrial hygiene and safety texts and applicable company/agency
safety procedures manuals before attempting any measurements or conducting any
field activities.
                                     1-

-------
                  2.0  MEASUREMENT REQUIREMENTS AND PROBLEMS
     The instruments used to analyze the performance of a.ir pollution control
equipment measure basic parameters such as gas static pressures, gas tempera-
tures and gas flow rates.   None of the instruments are exotic and all have
been in common use for a number of years.  Only their use by regulatory agen-
cies is relatively new.  All of the,instruments are small and easily carried.

     Despite the familar nature of the instruments, there has been very little
written about measurement techniques and common measurement errors.  The
following section addresses the data which is necessary for system evaluation
and some of the common measurement problems which have been encountered with
existing ports.  This section provides the basis for later discussions
concerning specific port configurations and locations.   ;

2.1  STATIC PRESSURE

      The static pressure of a gas stream is simply the pressure exerted in
all directions by the fluid, measured in a direction normal to the flow.  It
is similar to the barometric pressure which is the pressure exerted by the
atmosphere on the surface of the earth.   When the static: pressure is greater
than the barometric pressure, it is called "positive" pressure, and when it is
lower it is called "negative" pressure.  Both positive and negative pressures
are common in air pollution control systems.  The measurement problems and
potential safety hazards, however, are quite different for each.

2.1.1  Reasons for Measuring Static Pressure             ;
                                                         I
     The gas stream static pressure drop while going through an air pollution
control system is a measure of the amount of energy removed from the gas
stream.  This parameter can be used in a number of ways to identify control
system problems as indicated in the brief summary provided b'elow:
     Particulate Wet Scrubbers  -
     Fabric Filters
Static pressure drop can be indirectly
related to the particulate removal
efficiencies for most common .types of
scrubbers.  Demister pluggage and severe
air infiltration can also be identified.

The pressure drop across each compartment
provides useful information concerning
the dust layer on the bags and the gas flow
through the compartment.  If the static
pressure drop is higher than normal,
cleaning system problems or fabric
blinding are probable.

The static pressure drop across a fabric
filter compartment which has been isolated
for cleaning provides an indication
of the damper operation and condition.
                                      2-1

-------
      Mechanical  Collectors
      Electrostatic
      Precipitators

      Absorbers
The static pressure drop provides an
indication of any problems which change
the gas flow resistance.  Most such
problems lead to increased emissions.

Static pressure drop is not a meaning-
ful operating parameter.

Static pressure drop changes provide
indications of gas flow rate changes,
liquor flow rate changes, and poor gas-
liquor distribution.  The data can also
be used to identify demister pluggage
and severe air infiltration.
     There is  a static pressure decrease whenever gas is accelerated in a hood
from essentially zero velocity to the duct transport velocity.  This is due to
the conversion of potential energy to kinetic energy in the duct and due to
frictional energy losses.  This hood static pressure drop is proportional to
the gas flow rate, thereby making this a useful qualitative indication of total
hood capture effectiveness.  A decrease in the hood static pressure often
indicates severe air infiltration in the downstream ductwork or a change in the
fan operating  conditions.

     There is  also a static pressure decrease whenever gas is passing through
a duct.  This  is due primarily to the conversion from potential energy to
frictional heat.  The changes are normally too small to be of diagnostic use.
However, the inlet static pressure to the control device can be used as an
approximation  of the hood static pressure.  If the absolute value of this
static pressure has decreased, the gas flow rate to the collector has probably
decreased.
2.1.2  Instruments Used to Measure Static Pressure

     Instruments used to measure static pressure are listed in Table 2-1 along
with the generally accepted meter operating ranges.  The inclined manometer is
used primarily for pitot traverse velocity pressure measurements due to its
limited range.  This instrument has the best resolution of any of the gauges
and does not need to be calibrated.  The slack tube could theoretically be
used for any range.  However, practical considerations limit the normal range
to about 36 inches of water.  The diaphragm gauge can be used over a very wide
range.  These gauges must be regularly calibrated against a slack tube or
inclined manometer.

     There is no gas flow through any of these instruments.  Therefore, no
pumps or power supplies are necessary to operate the gauges.  Most of the
instruments are easily carried.

     The static pressure measurements can be made in several locations: (1) the
interior surface of the duct or collector, (2) the middle of duct, and (3)
several locations along a traverse of the duct.  Interior surface measurement

                                      2-2

-------
is the only option for collectors due to the presence of internal components.
These surface measurements are also appropriate for ducts in which the gas
velocity is low.  However, errors are possible at normal duct velocities with
this style of port.

           Table 2-1.  INSTRUMENTS USED TO MEASURE STATIC PRESSURE
      Instrument
Operating Range
Inches of Water
 Resolution
Inches of Water
Accuracy
      Inclined Manometer     0 to  +5
      Slack Tube Manometer   0 to  ±36
      Diaphragm Gauges       0 to +150
                          0.05
                          0.20
                          1.00
                    1-2%
                    1-3%
                    3-5%
    In ducts, the surface irregularities around the port and flow patterns
within the duct can lead to some variation between surface static pressures and
the true static pressure within the gas stream.  It is sometimes desirable to
move away from the inner surface of the duct and into the main flow stream.  To
do this, the gauge can be connected to a section of 1/4 inch O.D. tubing.  The
instruments can also be connected to the downstream side of an S-type pitot
tube.  With either the copper tube or the S-Type pitot tube, it is possible to
traverse the entire duct and average the static pressure measurements.
However, it should be noted that both the S-Type pitot tube and the copper tube
do not provide measurements as accurate as those obtained using a standard
pitot tube.  Unfortunately, the standard pitot tubes can rarely be used on the
upstream side of the control device since the small ports are prone to
pltiggage.  The standard pitot tubes are also more difficult to use when the
ports are small.                                 .         '

2.1.3  Possible Errors in the Measurement of Static Pressure

      One of the major errors involved in static pressure measurement is the
aspiration effect in negative pressure ducts and vessels (Reference 2).  If the
port is not entirely sealed around the probe there can be high velocity gas
"jets" through the open areas.  If these pass by the opening of. the probe as
shown in Figure 2-1, the jets can induce negative static pressures.  The mea-
sured value is then the true negative static pressure plus the aspiration
induced negative static pressure.  While this is usually insignificant below 10
inches of water, it is definitely important at -20 inches of water and above
(higher negative pressures).  For example, it is possible to measure a -25
inches in a duct where the true static pressure is actually -20 inches.  At the
very high negative pressure of -100 inches, it is possible to induce additional
suction to yield measured values as high as -150 inches W.C,

     One common way of sealing a port is to use a cloth or glove around the
probe.  This is done at the risk of losing the material into the duct where
it could damage downstream equipment such as fans ,and air pollution control
devices.  To illustrate the forces across the port, the data in Table 2-2
contains the calculated static pressures in pounds force across the area of
the port.                                                 !
                                      2-3

-------
NEGATIVE
PRESSURE
OUCT
                                  COPPER PROBE

                               BBER STOPPER
          Figure 2-1.  Aspiration Effect
                                  SANDING DISK
                                             COPPER TUBE
                            1      V
                                       RUBBER STOPPER
                     -DUCT WALL
  Figure  2-2.  Use of  Sanding Disk  to Seal Ports

                         2-4

-------
                Table 2-2.  FORCES ACROSS OPEN MEASUREMENT PORTS
              Port Diameter
                Inches

                  1
                  1
                  1

                  4
                  4
                  4
Static Pressure
Inches of Water

     10
     25
    100

     10
     25
    100
Total Pressure
   Pounds

    0.31
    0.78
    3.10

    4.58
   11.45
   45.82
                     Basis:  Open Area of  1  Inch Port equals 0.864 square inches
                            Open Area of  4  inch port equals 12.73 square inches
                            (Assuming Schedule 40 IPS Pipe)

     It  is obvious  from the  data in Table 2-2 that the slightest moment of
 inattention  will allow the  cloth or  glove  to be sucked into the duct or vessel
 being tested.   One way to eliminate  this problem is to use a flat rubber
 sanding disk (available from most hardware stores) which has a diameter of at
 least one inch  greater than the port being used.  This is shown in Figure 2-2.

     Another approach  is to use a large  rubber stopper, drilled to allow move-
 ment of the  port.  Both this and the rubber sanding disk provide a seal against
 infiltration around  the probe.   Also, the  seal inherently Isolates the probe
 from the  duct.  Therefore,  the  dissipation of static charges which develop on
 the probe is inhibited.

 2.2  GAS  TEMPERATURE MEASUREMENT                          i

 2.2.1   Reasons for Measuring _the_ Gas Temperatures          '

     Gas  temperature data is often essential in the evaluation of air pollu-
 tion control system  performance.  In some cases,  the performance of the con-
 trol device is directly  related  to the gas temperatures existing at the inlet
 of the  collector.  On control devices operating at elevated temperatures,  the
 change  in the gas temperature from inlet to outlet provides one indication of
 air infiltration, which is one of the insults which can gradually harm the
 physical condition of control equipment.   Closely associated with air infiltra-
 tion is the localized condensation of acidic vapors and water,  both of which
attack system components.  The temperature data is also necessary to determine
if high temperature excursions have probably damaged temperature sensitive com-
ponents of the control system.   A brief summary of the  most common uses of gas
temperature measurements is provided in the list  below  for  each major type of
control system:

     Particulate Wet Scrubbers - Measured to determine  if the gas  stream
                                 is saturated after the scrubber and to
                                 determine if changes in the  inlet  gas
                                 temperature have  changed the quantity  of
                                 condensed  particles.
                                      2-5

-------
     Fabric Filters
     Mechanical Collectors
     Electrostatic
     Precipitators
    Absorbers
Measured to determine if high temperature
limits of the fabric are being exceeded.   The
outlet temperature is measured to determine
if air infiltration is significant or if
there is some potential for acid vapor
condensation.

Measured to determine if air infiltration
is significant or if there is some potential
for acid vapor condensation.  It is also
measured to correct the static pressure
drop for gas density changes since the
baseline period.

Measured to determine if resistivity changes
or severe resistivity differences have been
caused by temperature changes.  It is also
measured to determine if the start-up periods
are excessive.

Measured to determine if there have been
major changes in the equilibrium curve.
2.2.2  Instruments Used to Measure Gas Temperature

      The equipment generally available for temperature measurement includes:
(1) dial-type thermometers, (2) fixed position thermocouples,  and (3)  portable
thermocouples.  Both the dial-type thermometers and fixed position thermo-
couples can indicate lower than actual temperatures since they must be mounted
close to the duct wall.  Some ducts can have a substantial difference  between
the gas temperature close to the duct wall and that in the center of the duct.

     In addition to the limited reach of the dial-type thermometer, the
inherent design renders the unit susceptible to a bias to lower than actual
temperatures.  Heat can be conducted up the metallic stem to the large
circular face plate outside of the gas stream.  This serves as a very
effective heat exchanger.
     The probe portion of the dial-type thermometer is the bimetallic coil
sealed in the end of the stem.  Commercial units are generally 1/4 inch in
diameter.  The probes for the thermocouples can be a variety of sizes ranging
from the bare bead to several sizes of thermowells.  The bare bead type
thermocouple probe has a diameter of approximately 1/8 inch.
2.2.3  Measurement Problems

      If the distribution of temperatures is large enough, errors in operation
of the control system are possible.  For example, if a fixed position thermo-
couple on a baghouse inlet indicates 500 °F, the actual gas stream temperature
in the duct center could be 525 °F.  The higher temperature exceeds the

                                       2-6

-------
 normally accepted  limit  of  500  °F.   For  this reason, it is sometimes necessary
 to traverse the gas  stream  to determine  both the average temperature and the
 temperature distribution.   This can  only be done using a portable thermocouple.
 Since  a  flexible thermocouple probe  is the easiest to transport around a con-
 trol device,  there must  be  ways to fix the probe at the desired position in the
 duct.  For  small ducts,  the probe can be threaded through 1/4 inch O.D. copper
 tubing as long  as  the wall  thickness of  the tubing does not exceed 1/16 of an
 inch.  This is  adequate  as  long as the duct is small or a complete traverse is
 not necessary.   For  for  more demanding situations, the probe can be wired or
 taped  (depending on  temperature) to  an S-type pitot tube.

     By  placing the  thermocouple probe well inside the duct or by performing a
 complete traverse  of the duct,  it is possible to avoid the errors due to air
 infiltration  through the port.  Note that the 1/4" tube can be bent slightly
 near its end  so that when close to the duct wall, it is out of the path of cold
 ambient  air leaking  through the port.  The complete traverse is useful when
 accuracy i,s very important  and  a significant temperature variation is expected.

     Another  common  problem is  the impaction of water droplets.  If the gas
 stream is not saturated, this will cause rapid fluctuations between the dry
 bulb and wet  bulb  temperatures.  It  is very difficult to accurately measure the
 dry bulb temperature under  these conditions.                 i

 2.3  GAS STREAM OXYGEN AND  CARBON DIOXIDE CONCENTRATIONS     \

     These  measurements are valuable when inspecting air pollution control
 systems  serving  stoker fired coal boilers, oil-fired boilers and other fuel
 combustion  sources.                                          :

 2.3.1  Reasons  for Measuring the Oxygen and Carbon Dioxide Concentrations

     The control device inlet conditions help to determine if the combustion
 conditions  have  deteriorated to the point that excess emission conditions are
 possible.   The difference between the oxygen levels measured before and after
 the collector clearly shows the extent of air infiltration into the collector.
 With such information, the inspector can evaluate whether corrective actions
 proposed  by the operator have a reasonable chance of succeeding.

 2.3.2  Instruments in General Use

     Instruments generally used for this purpose include:  (1); Orsat Analyzers
 (2) Specific Gas Absorbers,  and (3) Electroconductivity Analyzers.   The
 first two are similar in that the gas sample is mixed with chemicals which
absorb one component of the gas sample.   The change in the height of a column
 of liquid is proportional to the concentration of the absorbed gas.   The Orsat
 instrument measures oxygen,  carbon dioxide and  carbon monoxide from a single
 gas sample.   The specific gas absorbers  measure either the carbon dioxide or
oxygen concentration.  Both the Orsat and Specific Gas Absorbers are manually
operated, wet chemical analyzers.   The electroconductivity inistrument is a
standard line powered unit which senses  the oxygen concentration in a contin-
uously extracted gas sample. The electroconductivity unit  is  generally consid-
ered as accurate as the Orsat and less time consuming.   The specific gas
absorbers are very portable and simple to use,  but are slightly less accurate

                                      2-7

-------
than the other two approaches.  The common element of all three approaches  is
that the sample can be easily acquired through a 1/4 inch O.D.  tube inserted
into the gas stream.  Again, if there is a need to traverse a large duct, the
pitot tube can serve as a sampling tube.

2.3.3  Possible Errors in the Measurement of Oxygen and Carbon Dioxide

     The major error possible in the measurement of oxygen and carbon dioxide
concentrations is the inadvertent inclusion of inleaking ambient  air with the
sample.  This is avoided by placing the sampling probe upstream from the port
or by extending the probe well into the duct.  This is identical  to the steps
taken to minimize air infiltration related static pressure and gas temperature
measurements errors.  Other problems with can affect the oxygen and carbon
dioxide concentration measurements include the use of spent absorbing
solutions, the use of absorbing solutions which are very hot or very cold,  and
stratification of gases within the duct.

2.4  GAS FLOW MEASUREMENT

     Gas flow data is measured less frequently than the data discussed
previously.  The gas flow data is measured only when other data obtained during
the inspection indicates possible control equipment operating problems.

2.4.1  Reasons for Measuring Gas Flow Rate_

     For all pollution control systems, the measurement of gas flow rate at the
inlet of the unit demonstrates whether the proper gas flow rate from the
process equipment is being delivered. A drop in the flow rate could be  due  to  a
change in fan operation or severe air infiltration into the ductwork downstream
from the sampling point.  The difference in the gas flow rates before and after
the collector provides an estimate of the air infiltration rate (after  correct-
ion for gas density changes.)

2.4.2  Instruments Used to Measure Gag^ Flow; jfetg_

     The standard instrument for measuring the gas flow rate is the pitot
tube.  The Standard pitot tube does not need to be calibrated. However, the
small static pressure ports are vulnerable to pluggage when used  on the inlet
side of many particulate control devices.  For this reason, the S-type pitot
tube is used most often by inspectors.  Standard pitot tubes may  also require  a
larger measurement port.

     The dimensions of the S-Type pitot tube are partially fixed  by EPA Refer-
ence Method 2 and by customer specifications.  The width of the sensor portion
of the tube must not exceed 1 and 1/2 inches.  The diameter of the tubes is
generally 3/8 inches and the tubes are tack welded together at several spots.
A thermocouple well may also be included along the pneumatic tubes.

2.4.3  Measurement Problems

      Port air infiltration is as much of a problem with this measurement as
it was with the previously discussed instruments.  It is necessary to seal  the
port adequately to prevent erroneous measurements at the traverse points close
to the port.
                                       2-8

-------
     Orientation of the probe is important.   If it is allowed to dip  or  float
in the gas stream, a lower than actual velocity pressure is indicated.   This
type of error is especially difficult to avoid when the probe is extended well
into the gas stream and the operator has only limited leverage.   The  second
orientation error is simply a matter of carelessness.  If the tube is twisted
in the gas stream, significant positive or negative errors are possible. Such
errors are not common on stack sampling tests since the probe is rigidly
mounted on the main sampling tube which is securly hung.  However, in the case
of the field inspector, the individual is generally working with only a  pitot
tube and at a location where the pitot must be hand held.  The inspector is
also working either alone or with plant personnel who are not familiar with the
techniques.

     Prior to each flow measurement it is important to confirm that cyclonic
flow does not exist at the measurement site.  Also, the calibration of the
S-Type pitot tube and the attachment of a thermocouple to the pitot tube should
be done in accordance with the procedures of EPA Reference Method 2.
                                     2-9

-------

-------
                                 3.0  PORT  DESIGN


       This  section  examines  some of the major limitations and potential safety
  hazards  of existing ports.  Its purpose is to compile a list of criteria that
  define an  acceptable inspection/measurement port for air pollution control
  systems.   Port designs have been developed during this project based on these
  criteria.   They could be installed on many systems with little or no modifica-
  tions.   In other cases, these designs will serve as a useful starting point in
  developing the necessary ports.  Siting recommendations for major categories of
  control  systems have also been  proposed.
 3.1 LIMITATIONS OF EXISTING PORTS

      Because of the relatively limited use of portable instruments on air
 pollution control systems, little effort has been spent previously on the
 design and location of ports.  Some of these are located in completely in-
 accessible locations, and some have been placed in unrepresentative locations
 along the ductwork.  A variety of safety hazards may be present in the
 immediate vicinity of the ports.               ......

 3.1.1  Port Pluggage

       Pluggage is a very common problem which plagues measurement  ports of
 practically all sizes and descriptions.   The recesses which are inherent  to the
 port provide an ideal location for the accumulation  of sludge and  solids.

      While pluggage can not be avoided entirely,  common sense should be used
 on port location.   Ports should be located  in an  area protected from the
 natural drainage of water and sludge.   They should also be  placed  in portions
 of the duct or collector which are usually  free of dust accumulation   The
 ports should not be on the lower  sides of ducts.

      Due to plugging  tendencies,  access to  the port area is necessary so that
 the deposits can be rodded out  prior to the measurement.  Long  tubing runs
 ^°m.thf port to an accessible  location should be avoided since it is sometimes
 difficult  to clear  the deposits using  compressed air.
                                                            i
 3.1.2   Oversized Port  Fumigation

      Large  4 inch diameter ports are common since these are large enough for
 standard stack sampling probes.  With positive pressure conditions, however
 there can be  substantial gas flow out of the port into the immediate vicinity
 ot  the inspector.  Inhalation hazards can be created if the'persons involved  do
not have the appropriate respirators or if ventilation is poor,,   Chemical
and physical asphyxiants can also accumulate within the breathing zone.

     The pollutant concentrations can exceed the capability of most cartridge
and canister type respirators.  In some cases, combinations of pollutants  would
pose a threat even at lower concentrations since each type cf respirator is

                                      3-1

-------
effective only for a single pollutant.  Therefore,  it is important  to avoid use
of an open positive pressure port.

     Large ports are not desirable for inspection measurements since all of
the probes discussed in the previous section are relatively small.  The
largest probe used is the pitot tube which has a width of less than 1 and  1/2
inches (with the exception of the model with the replaceable tip).  In some
cases, all measurements necessary can be made through 1/4 inch diameter ports.
There is no advantage to the large ports and there  can be significant safety
problems involved when the pressures are even slightly positive because of
fumigation.

3.1.3  Ports in Partially Confined Areas^

      Inhalation hazards similar to those possible with large positive pres-
sure ports occur when the ports are located in portions of the collector with
inherently poor ventilation.  This is most common in large multi-compartment
fabric filters where the measurement ports and instrumentation are  mounted in
the walkways between rows of compartments.  Gas leakage from access hatches,
weld gaps, and ductwork expansion joints can accumulate to high concentrations
during periods of low ambient wind speed.  Partially confined areas are also
common on wet scrubber systems since they are often inside to minimize freezing
conditions during off-line periods.  The ports on these scrubbers are often
located in areas with very little natural ventilation.  Partially confined
areas are common to all types of air pollution control systems.

3.1.4  Static Charge Accumulation

      Particles striking a probe within a gas stream result in some static
charge on the probe.  If this is not dissipated, it is conceivable that  the
electrical charge will accumulate to a sufficient voltage to arc over to a
grounded portion of the duct wall.  This could initiate an explosion within the
duct due to the presence of either suspended particulate matter in the gas
stream or small deposits of dust at the bottom of the duct.  While a search of
the literature and numerous contacts with instrument manufacturers have failed
to uncover any published reports of static accumulation, unpublished data com-
piled by the authors of this report indicate that such charges do accumulate
under certain conditions.

     Considering the explosive nature of many common dusts such as metallic
dusts, grain and flour dusts and  coal dust, a cautious approach is necessary
with regard to static electricity.  All probes should be electrically bonded to
a grounded component of the control system to dissipate the electrical charge
as it develops.

3.1.5  Burn Hazards

      Many gas streams treated in air pollution  control systems are very hot.
The ductwork surfaces and measurement ports are  often more than 500 °F.  There-
fore, direct contact can quickly  lead to  a painful burn.  The  port shown in
Figure 3-1, is located between the  side wall and a large flange.  A painful
burn  could occur while opening the  port since  both the  side wall and the  flange
are above  400  °F.  Unfortunately, many  ports are located in such a manner that

                                      3-2

-------
 a burn is likely  while working with portable instrumentation.  The port should
 be located away from hot  surfaces.  A short extension nipple moves the
 inspector away from the hot  surface of the duct itself and also moves activity'
 away from hot  adjacent surfaces.  A layer of insulation on the duct reduces the
 chances of direct contact while also reducing the radiant,energy from the duct.
                  Figure 3-1.  Port Located Near Burn Hazards
                                                          I
3.1.6  Transducers

      The ports must not be mounted along with differential pressure (D/P)
transducers.  Figure 3-2 illustrates a D/P transducer with a 1 inch line
leading to the port and a 2 inch pipe welded to the side of the wet scrubber.
While the 2 inch plug on the front side of the tee looks like a useable port,
opening it would affect the pressure sensed by the transducer.  It is quite
possible that the low pressure signal generated by the transducer could be
interpreted as a major upset by the automated process control system which
would then trip off the system components.  Actually, the 2 inch plug is not
intended as an inspection measurement port but rather as a means for routine
cleaning of the port deposits,,  The inspection port should be located away from
the transducer port so that false static pressure signals are not transmitted.
                Figure  3-2.   Clean-out  Port  for  D/P Transmitter

                                     3-3

-------
3.1.7  Stuck Port Caps

      The most difficult part of any sampling or measurement exercise  is often
the removal of the large 4 inch pipe caps often used to close off the  port.   It
may be necessary to remove a cap by heating with a torch or by use of  a large
pipe wrench with a several foot pipe extender.  The latter approach is taken at
the risk of accidentally ripping off the entire port nipple.


3.2  RECOMMENDED PORT DESIGN CHARACTERISTICS

     Port design and siting criteria have been compiled which should minimize
the measurement problems and safety hazards of many existing ports. These
criteria should be satisfied to the extent possible on all new systems and on
existing collectors where ports are being installed.  The recommended  port
designs presented later in this section satisfy these criteria.


3.2.1  Criteria of Good Inspection Measurement Ports

      The general criteria for good measurement ports are described here.  Due
to the different types of measurements required at different locations in an
air pollution control system, it is necessary to list somewhat different
criteria for ports mounted on the walls of the collector and ports mounted on
ducts upstream and downstream of the collector.

3.2.1.1  Ductwork Ports - These ports must accomodate a pitot tube which is
used not only for gas flow measurement but also: (1) as a thermocouple support
when traversing the duct, (2) as a static pressure probe when traversing the
duct, and (3) as a sampling tube when analyzing gas stream oxygen, carbon
dioxide and carbon monoxide levels.  The general guidelines regarding  ductwork
ports are discussed below.
      1,  Accessibility - Access platforms and ladders should meet
           OSHA requirements.

      2,  Port Locations - The ports should be located at least 2 duct
          diameters downstream and at least 1/2 duct diameter upstream from
          any flow disturbances.  The ports should be as far from the flow
          disturbances as conveniently and economically possible to minimize
          the number of sampling points necessary to characterize flow and
          composition.

      3.  Port Spacing on Rectangular Ducts - The number of ports necessary
          on a rectangular duct depends on the distances from the upstream and
          downstream disturbances.  EPA Reference Method 1 requirements should
          be satisfied.

      4,  Port Diameter - The ports should not have an internal diameter
          exceeding 2 inches.  All probes can fit through a port of this size.
          Larger ports have greater air infiltration (negative static pressure)
          or greater potential for pollutant exposure (positive pressure).

                                      3-4

-------
        5.
       6.
       7.
       8.
       9.
      Partially Confined Areas - The ports should not be located in
      areas which are prone to pollutant accumulation due to poor natural
      ventilation.
                                                "
      Large Rectangular Ducts - Ports are needed on each vertical side
      which exceeds 6 feet.  The maximum .extension distance  of pitot
      tubes in common use is 6 feet.

      Round Pucts -  Two ports spaced 90° apart  should be located on
      round ducts.  If the ducts exceed  a diameter of six feet,  then four
      ports spaced equally around the duct are necessary due to  pitot tube
      reach limits.   Each port must be accessible.

      Exposed  Locations - The  ports should  not be  located above  plant
      equipment or vents which could  suddenly release either steam or
      pollutant laden gases which could engulf the  sampling  area.  The
      ports should not be in the immediate  vicinity of  components  of the
      ductwork prone  to leakage,  such as  expansion  joints.,

      Hot Surfaces -  Hot surfaces  in  the  vicinity of  the  port should be
      insulated to reduce the  radiation rate and chance of direct  contact.
      10.   Port Caps - Easily  removed  port  caps  should be used,

      11.   Static  Electricity  Bonding  - The port must be designed to inher-
           ently provide a bonding path for current flow from the probe to the
           duct.   There must also be provisions  for the use pf a grounding and
           bonding cable.

           Pluggage  - The port should  be located in areas which are not
           prone to  pluggage.  Orientation  of the port should minimize build-up
           of material.

           Port Sealing - There must be effective ways to minimize gas flow
           out of  positive pressure ports during the use of the portable
           instruments.  There must be effective ways to minimize air
           infiltration into negative pressure ports.       i

3.2.1.2  Collector Wall Ports -  The ports used on the walls of the air
pollution  control device are quite different since there is rarely a need to
traverse the internal space.   All of the measurements done on fabric filters
mechanical collectors, and wet scrubbers can be done using only a 1/4 inch  '
diameter probe.  The criteria for these ports are presented below-
12.
13.
      1.
      2.
     Accessibility  - There must be safe and convenient access
     to  the  port location on the collector wall so that: it is possible
     to  rod  out the port prior to the measurement.  All ladders and
     platforms should meet OSHA requirements.

     Connecting Tubing - There should be no permanently mounted
     connecting tubing from the port to a "convenient" measurement
     location.  It  is impossible to obtain representative temperature
     data after the gas passes through the long tubing.
                                     3-5

-------
     3.  Differential Pressure Transducers •- The port  should not be
         directly connected to a differential pressure transducer.   Opening
         the port to make the measurement could result in a false signal to
         the process control equipment.

     4.  Extension Tubing - When extension tubing inside the unit is
         necessary to connect a port to  an internal area of the collector,
         this tube should be straight so that it can be rodded out prior
         to the measurement.

     5.  Size - The port should have an  internal diameter between 1/4 inch
         and 1 inch.  It should be only  as large as necessary to accept the
         specific probes to be used.

     6.  Partially Confined Areas - To the extent possible, the ports
         should be located in well-ventilated areas, where accumulation of
         pollutants is unlikely.

     7.  Pluggage - The ports should not be located in areas prone to
         pluggage.  Orientation of the port should minimize the accumulation
         of materials in the port recess.

     8.  Moving Equipment - The ports should not be located near moving
         equipment such as shaker assemblies and fan sheaves.

     9.  Air Infiltration - To the extent possible, the ports should be
         located away from common sites  of air infiltration such as  large
         access hatches.

    10.  Hot Surfaces - To the extent possible, the port should extend
         outward away from hot collector wall surfaces to minimize the risk
         of direct contact.
3.3  PORT DESIGNS

     Ports which satisfy the criteria presented earlier are discussed in this
section.  Several relatively large ports are proposed for areas where a
complete traverse of a gas stream is necessary.  A simple 1/4 inch diameter
port is proposed for collector walls and other areas where measurements close
to the interior surface are sufficient.  A special port which has interior
extension tubing is also proposed for certain types of fabric filter systems.
This is presented since this design would permit the installation of ports in
safe locations without the need for additional ladders and platforms, both of
which can be expensive.

3.3.1  Small Ports

     These ports are intended for static pressure, gas temperature, and
oxygen/carbon dioxide measurements at various positions on the control systems
listed in Table 3-1.
                                      3-6

-------
                      Table 3-1.  Locations

               Application

     1.  Pulse jet fabric filters

     2.  Mechanical collectors
         (multi-cyclone designs)

     3.  Particulate wet scrubbers
     4.  Reverse air fabric filters
         (cylindrical shell, outside-
         to-inside flow designs)

     5.  Hoods
     6.   Ductwork
for Small Ports

      Location of Ports

   Above and below tube sheet

   Above and below clean side
   tube sheet

   Before and after trays,
   beds, and restricted throats

   Before and after demisters

   Above and below tube sheet
   Immediately after
   converging section.

   Various locations
      A sketch of the recommended  port  configuration for these applications is
 presented in Figure 3-3a.   This is  constructed of a stainless steel Swagelok
 pipe weld connector. A 3/16 inch  weld  around  the circumference provides a gas
 tight seal and holds the port  fitting  to the  collector wall.  The compression
 of the 0-ring against the  probe and against the fittings prevents any leakage
 of gas out of the port.  Air infiltration in  negative pressure situations is
 also negligible.

      For  areas where sludge or liquids occasionally accumulate on the inner
 surface of the duct,  the port can be inclined to facilitate drainage.  This is
 illustrated on the upper right side of Figure 3-3b.  A port cap, as shown
 in the lower  right of Figure 3-3c,  can be used to seal the 1/4 inch port.
 This prevents material accumulation in the port recess when the port is closed
 and it also prevents air infiltration  (negative pressure situations) into the
 collector.  In the case of  fabric filters, this localized air infiltration
 could  cause some  corrosion  and some acid condensation related bag damage.

 3.3.2   Small  Ports with Extension Tubes                   !

     There  are  several common types of fabric filters for which it is very
 difficult to  arrange  the measurement ports.   In the large,  multi-compartment
 reverse air (inside-to-outside flow) and shaker collectors,;  the tube sheet
 separating  the  "clean" from the "dirty" side is mounted directly above the
 hoppers.  The walkways are almost always above the elevation of the tube sheet.
 Therefore,  the  ports must supposedly be below the walkway.   There is often an
 elbow fitting below the walkway which connects the port to a tube leading above
 the walkway area.  This does not satisfy one of the main port siting criteria
in that the port is not accessible.   Since this part of the  hopper area is also
prone to solids accumulation, this failing is especially troublesome.
                                      3-7

-------
r
                          SWAGELOK PLUG # SS-600-P
                 PARKER O-RING
                 SIZE 2-202

                 -SWAGELOK NUT
                 *SS-602-I
       SWAGELOK MALE CONNECTOR
       SS-600-1-8MPW
Figure 3-3b. 1/4" Port With
           Standard Plug
               OUTSIDE
               TNS!DE
SWAGELOK
          SS FLAT HEAD RIVET
          1/4" X 1 3/4"
       * SS-602-
             SWAGELOK TO MALE
             PIPE WELD CONNECTOR
             *SS-600-!-8MPW
Figure 3-3a.  1/4"  Port With
            Seal  Nut Clamp
      SWAGELOK MALE CONNECTOR
      SS-600-1-8MPW

Figure 3-3c.  1/4" Port With
Stem Type Cap
               Figure 3-9.  1/4" Measurement Port

                            3-8

-------
       The recommended means  for installing the port for these types of collect-
  ors  is  shown in  Figure 3-4.   In this case, the port is mounted on a section of
  3/8  inch IPS Schedule 40 pipe which extends inside the fabric filter from below
  the  tube sheet to a position  outside the collector shell,,  The pipe terminates
  at a position above the walkway so that there is good accessibility for rodding
  out  the extension pipe.  The  extension pipe must be positioned so that it
  passes  between the bag thimble or snap ring connections on the tube sheet.  The
  60°  angle minimizes the length of pipe needed and ensures that the port will-
  not  extend very  far out into  the walking area.           '

       The  pipe must be welded  completely around the circumference on the lower
  side of the  tube sheet.  Failure to do this will result in dust leakage through
  the  gap and  may invite crevice corrosion.  The pipe must ,also be welded on the
  outside of the collector wall.  A mounting plate has been provided at this
  position  to  facilitate the welding.  The remainder of the fittings and the cap
  are identical to that described earlier for standard small ports.  The 0-ring
  seal provides the necessary protection against positive pressure gas leakage.

      The  "clean" side port for the compartment should be mounted horizontally
  in the same general vicinity of the "dirty" side port shown in Figure 3-4.
 This is a standard small port without any extension pipe.

      A port similar to  that  described in Figure 3-4 can be used for top access
 type, pulse jet fabric  filters.  With these collectors,  the tube sheet which
 separates the "clean" side from the "dirty" side is mounted close to the top of
 the baghouse.  There is  good accessibility  to  the top of fhe unit due
 to the need to routinely service the  diaphragm valves and to replace bags.
 However, there is rarely any access to  the  side of the collector where the
 ports should logically be placed.   Nevertheless,  some ports have been installed
 along the side, usually  in a spot  that  can  not be reached through the ladder
 cage.

      An  alternative  design for these  ports  is  shown  in Figure 3-4.   In  this
 case, both of the ports are  located on  the  roof  of the pulse jet baghouse.   The
  dirty  side  port has an extension pipe which  passes  through the roof of  the
 collector, down through the  clean air plenum,  and  through the tube sheet.  The
 tube  is  welded entirely around the circumference  of  the tube sheet to prevent
 gas leakage.   The cap with an  0-ring seal is identical to that described  in
 Figure 3-3.    The "dirty" side port is located directly above a  portion of the
 tube  sheet which  is equidistant from the bags  and bag  clamps.  By placing the
 port  between  the  access hatches, the port should not present a trip hazard.
 The "clean" side  port is located close to the  "dirty" side port.  It consists
 of a  fitting  identical to that shown in Figure 3-3.  The main disadvantages of
 this  arrangment include burn hazards on the access hatch and potential errors
 due to air infiltration.  These are outweighed by the improved accessiblity
 at this  location.


 3-3.3  Standard Large Inspection Measurement Ports

      These ports accept pitot tubes either for gas flow neasurement or for
 traverse checks of static pressure, gas temperature or gas composition.  They
would be ,used on all ducts greater than 2 feet diameter.
                                      3-9

-------
                                                         0)
                                                         ^3

                                                         H

                                                         (3
                                                         O
                                                         •H
                                                         w
                                                         C
                                                         
-------
       i      o7^S?nS,°r *""" "civxug ti  wxutn  oetween  i and 1 and 1/2 inches   Tf
      The oort
          oT
       The pztot alignment sleeve and port are shown in Figure 3-6

  5 140 inthes'TL04 I/H" 1/4Kln? M Plpe hayl"8 a
  welded To a i/4 ijh rt •  v       * ^f "a11 °" °°e end"   The oth«
  outer flanL ^h   i    f ,Tntlv8 flange'   ^ pitot is ™PPorted in an
         3 6            "   3/8 inch hole through the center.   As  shown  in

    M,             Pit0t tUbe C°llar maintain the pitot tube in a level oosition
    that pxtch error is negligible even when the pitot tube is fully extended
 The score marks on the collar also help the inspector to avoid anyylw errors
n-i^   f          be Sealed during Perl°ds of nonuse with
and
                                                                       inch
                                                             i

     While the measurement is being made, the entire port recess is filled
  etolh06.-^6 rSSlbility °f UnUSUal fl°W P-tterns'close to the pfS aL
due to the disturbance caused by the discontinuous inner surface of the duct
                        1GSS             Disturbance than typSllta'k dUCt'
                                      ;, thereby freeing the inspector's hands

or low ran8e-diaph-ra^ l^U^^^T^^^l^T^ll

                                      3-11                   :  •

-------
         -BULKHEAD
          (WELD GAS
           TIGHT)
    NOTE: 3/16 a i 5/ie SLEEVES
    ADD 1 LB/FT OF LGTH
                                  'APPROX.
      SS TUBE 3/16" O.D. X .035" WALL-
SS TUBE 1.315" O.D. X .065" WALL-
                                             8 TK
     VIEW I-I
SECTION IT-IE
BULKHEAD DETAIL
            MODIFICATION OF 3/8" STANDARD S-TYPE PITOT TUBE


NOTE: 3/ie" a i s/ie" O.D. SLEEVES ADD LESS THAN i #/FT OF PITOT
       TUBE LENGTH


                   Figure 3-5. Modified S-Type Pitot Tube-
                                  3-12

-------
0-RING  1  11/16 O.D. X 1  5/16"I.D. X 3/16"D!A.
 \

    's/sssssssssssssssssssssssssssssssjm a
1/4"-20 THUMB SCREW X 1
                      to?


1  5/16" PROBE SHELL
                                                           LG
                      I
             SPOT WEL'D
                               SCORE COLLAR
          SS PIPE-1 1/4" IPS X
                    .140  WALL
(2) 3/8 HEX HD BOLT X l" LG
   WITH HEX NUT
\
1
li
i!
1-


^
s/ss/j//'SS'Sf/f£i£Zf//////SSJ/^>fJ!>
-------
          SHELTER (16 GA SHEET)
                 -MANOMETER
1/4" SQ. HD. BOLT 8 WING NUT
                                                     SPOT WELD
                  HANDHELD DIGITAL THERMOMETER
•TO PITOTTUBE\   PROVIDE HOOK OR BASKET FOR SUPPORT

     THERMOCOUPLE CABLE
        Figure 3-7. Pitot Differential Pressure Gauge Shelter
                            3-14

-------
  for  leveling  the  inclined manometer.  This shelter is an optional feature
  which  is helpful  when frequent pitot traverses are anticipated.

      It should be noted that all commercially available pitot tubes could be
  used in these ports, with or without the mounting collar and sleeve.  The
  advantages of the modifications shown are a substantial reduction in pitch and
  yaw  errors, facilitation of checks for cyclonic flow, and protection from toxic
•  pollutants under  positive pressure conditions.  These modifications to typical
  pitot  tubes would increase the cost slightly due to more difficult fabrication
  steps.  The total additional weight would be less than 1 pound per foot.
  Therefore, the portability of the pitot tube is not affected.  The permanent
  parts  included in each of the ports can be easily constructed out of commer-
  cially available  fittings and materials.  While more costly than the simple 4
  inch IPS pipe nipples in common use, this port design provides for more accur-
  ate measurement and safer working conditions.

  3.3.4  Modified Stack Sampling Ports

     In some plants,  existing stack sampling ports are at some of the locations
 useful for evaluation of system conditions.  It is also possible that plants
 will want the flexibility to conduct EPA Reference Method stack tests at the
 locations chosen for inspection measurement ports.   It is also possible that
 the plants will want the capability of  using pitot tubes with replaceable
 tips.  This section  presents recommendations for ports which satisfy most of
 the design criteria  discussed earlier, while allowing the use of large stack
 sampling probes and/or replaceable  tip S-type  pitot tubes.   i

      The port  design is  illustrated in Figures 3-8 a,b,  and c.   The  top sketch,
 Figure  3-8  a,  is the port which  would be  used  in a location where  there is no
 existing 4  inch port.  An 11  inch piece of  IPS Schedule  40  pipe  is welded to a
 flange  constructed of 1/2 inch plate.  A  4  inch diameter  hole is made  in this
 flange  and  the surface is hand ground to  be  flush  with the  inner surface of
 the pipe.   After burning or cutting  the necessary  hole in the collector or
 duct  wall,  the 4 inch IPS Schedule  40 pipe with flange is welded to  the
 exterior of the wall.  Both of the welds  should be 1/4 inch, gas tight welds.

      The pipe  flange includes two 1/2 inch - 13 NC x 2 inch long .square head
 bolts.  These  are  tack welded to the back side of  the pipe flange  so that
 they  do not have to  be removed when opening and closing the p'ort.

      When there are  existing 4 inch ports in the desired location, it is a
 simple  matter  to modify these to facilitate inspection measurements.  For
 those with a female  IPS pipe thread, 4 inch IPS Schedule 40 pipe with one end
 threaded can.be used.  This is illustrated in Figure 3-8b.  As before, a
 flange  is installed  on the other end to accept the pitot fittings discussed in
 later sketches.  Existing ports having a 4 inch male IPS fitting can be
 converted using a  4  inch standard pipe coupling, as shown in Figure 3-8c.
 Again it is necessary that the main body of the port be a 4 inch pipe with one
 end threaded.  The coupling should be allowed to seize or corrode since it will
not be  removed and since rotation is not desired.

     A  drawing of  the replaceable tip S-type pitot tube is provided in Figure
3-9.  It has two unions connecting the 3/8 inch O.D.  tubes.   This allows for

                                      3-15

-------
                               9/16" DRILL-2 HOLES
             10 5/8
FOR 7 1/2" STD S-TYPE PITOT TUBE TIP
     r
       4" IPS PIPE X .238 WALL
  4" DIA BURN-SHELL
!  HAND GRIND INSIDE SURFACE
h-FLUSH WITH SHELL I.D.--kvvv
        GAS TIGHT 1/4

      NEW PORT INSTALLATION
  r4" IPS FEMALE THREAD PIPE
    (EXISTING)
     4" IPS PIPE.SCHED40-
         G AS TIGHT 1/4 "
  ALTERATION OF EXISTING PORT
  4" IPS FEMALE THREADED PIPE


 r4" IPS MALE THREAD PIPE PORT
   (EXISTING)                  ,
    4" IPS PIPE ,SCHED 40-1
   ..-. .  	    »           »
      " STD PIPE COUPLING
         GAS TIGHT 1/4" V

  ALTERATION OF EXISTING PORT

    4" IPS MALE THREADED PIPE
                                                       1/2 -13 HEX NUT
                                                           BRASS
            l/2°-l3SQ.HDBOLT X 2"
                LONG

   L-SPOT WELD-OPPOSITE SIDES
     OF FLAT HEADS

          ENLARGED DETAIL
                                               (TYPICAL)
   NOTES IN TEXT:
     PL.FLANGE MUST BE SQUARE
      WITH AXIS OF PORT
     NEVER-SEEZ®BOLTS BEFORE
      LEAVING SITE
             Note:
Figure 3-8a is on  the  top left
Figure 3-8b is on  the  middle left
Figure 3-8c is on  the  lower left
        Figure 3-8.  Modified Stack Sampling Ports.

                             3-16

-------
                                                            o
                                                            PH
                                                           •H
                                                           E-i
                                                            CO
                                                            i 4->
                                                           H  -H
                                                           co
                                                            60
                                                           •H
3-17

-------
replacement of the tip in the event that it io damaged  during use  or shipment.
The distance from the tip to the end of the caps (which attach  to  the unions)
is approxiamately 7 and 1/2 inches.  The width of the pitot tube at the  unions
is approximately 2 and 1/8 inches.  It is this width which prevents use  of the
replaceable tip S-type pitot tubes in the port described in Figure 3-4.  The
long port bodies presented in Figure 3-8 were sized so  that the wide portion
of the pitot tube around the union fittings would fit within the port recess.
Alignment and support necessary to prevent measurement  errors are  now accom-
plished by an external mounting sleeve.

     The manner in which an S-Type pitot tube would be  mounted  in  the port is
shown in Figure 3-10.  A pitot mounting bracket is secured to the  port  flange
by means of the two 1/2 inch bolts.  This bracket includes a square  sleeve
which extends backward 5 inches.  This is designed to hold the  mounting sleeve
attached to the pitot tube.

     The pitot mounting bracket, shown in Figure 3-11,  is a piece  that  would be
brought by the inspector to the plant, assuming that the plant  is  using the
standard fittings and port design shown.  It consists of a 9 inch  diameter  1/4
inch thick plate with a hole of 2 and 1/4 inches cut through it.   A 5/8 inch
section of 3 and 1/2 inch IPS Schedule 40 pipe is welded to the back side of
the plate to serve as a guide as it is inserted into the pipe flange shown  in
Figure 3-9.  The front of the flange has a 5 and 1/2 inch long piece of 2 and
1/2 inch square tubing.  It is this square tubing which serves as  the holder
for the pitot tube sleeve.  The square tube is welded entirely around the
circumference while the 3 and 1/2 inch round pipe is simply tack welded at four
locations.

     The pitot sleeve is illustrated  in Figure 3-9.  This is simply a 5 and
5/16 inch long, 2 and 1/2 inch diameter square bar which has holes for the
pitot tube and thermocouple wire  tube.  This is placed around the pitot tube
and the two halves are tack welded  together.  The pitot tube should move
freely through this sleeve.  Gas  flow leakage through the gap will be minimal
under moderate positive pressure  conditions.

     The mounting flange includes the enlarged bolt holes so that it is
possible to rotate the probe slightly in  the  event of cyclonic flow.  There is
also a neoprene  gasket to  seal off any leakage around the mounting flange.

     There are two alternatives  for closing the  modified  stack sampling ports
when not  in use.  An  insert as  shown in Figure  3-10  can be  used to completely
fill the  recessed area.   This is simply a 4 inch IPS Schedule  pipe welded to a
blank  1/4 inch thick  plate.  This front plate has two  5/8 inch holes so that it
can be mounted on the protruding 1/2 inch bolts  welded  to  the  permanent port
body   At the end of  the  4 inch  port plug,  there is  a  3 and 5/8 inch diamter
 1/4 inch plate which blanks off  the end pointed toward  the duct.  In this way,
 there  is no recess  to allow the  build-up of solids and sludge.  To prevent
 corrosion of  this pipe insert,  an anti-seizing  compound should be applied,  tor
 severe corrosion conditions when gas temperatures are  below 500   F, the insert
 can be constructed  of teflon.

     The second  alternative is simply a 1/4 inch thick plate identical  to that
 shown  in Figure  3-10.  Instead  of being welded  to the  4 inch pipe insert, it

                                       3-18

-------
m

LJ
CO
en

o

_j
Q.
Q
Z
<
                                            O
                                            Q.
                                                              
-------
                                                  a)
                                                  oo
                                                 S
                                                  0)
                                                 •H
                                                 PH
                                                 CO

                                                  0)
                                                   ,
3-20

-------
 is attached directly to the port.  This provides an easily removed seal.  How-
 ever, it does not prevent materials from accumulating in the port recess.

      The parts chosen to seal the port during nonuse must be provided by the
 source.  The mounting bracket and mounting sleeve are brought by the inspector
 Therefore, relatively few of these must be made.  The total weight of the
 mounting bracket and mounting sleeve are estimated at 10 pounds.  While this
 assembly greatly reduces the errors involved in pitot traverse and simplifies
 traverses for other measurements, it does require a port which extends out from
 the wall a distance of 11 inches.  The is considerably greater than most
 present ports.  Whenever possible, the smaller port described in section 3.3.3
 should be used.

 3.4  PORT LOCATIONS                                       !

      This section illustrates the preferred locations for the various types of
 measurement ports presented in Section 3.3.  The control devices illustrated
 in the following drawings represent most of the common types of commercially
 available units.

 3.4.1  Duct Ports

      The pitot tube ports (see sections 3.3.2 and 3.3.3)  should be  placed  in
 locations as far as possible  from flow disturbances.   On circular ducts which
 are  equal to or less than 6 feet  in diameter  (inside  dimensions), there should
 be at least two pitot tube ports  spaced 90° apart.  On larger circular ducts,
 it is necessary to have  4 ports spaced 90°  apart so that  conventional pitot
 tubes can be used.   The  number and spacing  of pitot tube  ports on rectangular
 ducts should be consistent with the requirements of EPA Method 1.  Again,  it is
 necessary to include ports on  both sides of the  ducts  if  the  width exceeds 6
 feet.  All  pitot tube ports must  meet  the upstream and downstream distance
 requirements of  Method 1.

      A possible  location  for ports on  the outlet duct  of  a pulse jet baghouse
 is shown  in  Figure 3-12.   This has been located  close  to  the  ground to
 minimize  the cost of the ladder and  access  platform.   However, it must be far
 enough away  from the fan to avoid  flow disturbances caused by  the duct elbow
 and the inlet  damper of the fan.   In the plan view sketch on  the left side of
 Figure 3-12, it is apparent that there are  two pitot tube ports spaced 90°
 apart and^a small 1/4 inch port between these pitot tube ports.  The small port
 is to facilitate gas temperature,  static pressure, and oxygen concentration
 measurements.  Similar pitot tube  ports could be installed in the outlet
 ductwork of most other types of air pollution control systems.,

     The sketch on the right side of Figure 3-12 illustrates the arrangement
 of pitot tube ports in the stack.   These are located 45° degrees from the
 platform center line so that there is adequate clearance for both ports.
They should be located well upstream of the gas inlet to the stack.   However,
they should not be so high in the stack that downmixing is possible.

3.4.2  Port Locations for Fabric Filters                   ;

     The types of ports used on fabric filters include both the standard
1/4 inch port and the 1/4 inch port with the extended tube.    Good access
                                       3-21

-------
                 -BAG HOUSE
                             PITOT TUBE PORTS
EXHAUST FAN
                                   1/4" INSTRUMENT PORT
                                           STACK
                                                      PITOT
                                                      TUBE PORTS-/,
                  LOCATION OF PORTS
            FOR INDUCED DRAFT FAN SYSTEM
ALTERNATE PORT LOCATION
         Figure 3-12.  Location of Ports on Outlet Duct of Fabric Filter
                                   3-22

-------
to the port area is necessary so that it can be rodded out prior to the
measurement and so that accurate gas temperature measurements can be made.

3.4.2.1  Pulse Jet Fabric Filters - The locations for 1/4 inch instrument ports
for conventional top access pulse jet baghouses are illustrated in Figure 3-13.
There are two "clean" side ports which pass through the top shell of the
baghouse and terminate in the clean air plenum of the unit.  Between these  two
is another 1/4 inch port which extends down through the tube sheet.  This port
is for monitoring "dirty" side conditions.  There is convenient access to these
ports since it is necessary to perform all service work from the roof.  It  is
easy to rod out the "dirty" side port since the extension tube is straight.
They do not present a trip hazard and do not present an obstacle to bag
maintenance and replacement.  These ports must be located at a position which
is opposite to the direction which the hatches swing when opened.  This varies
from unit to unit.

     The only disadvantage of this location is the potential for burns on the
hand while removing the port caps on baghouses operating at elevated tempera-
tures.  This problem is easily avoided by wearing gloves.  Since gloves are
necessary for other inspection activities, this is not a burden for regulatory
agency personnel.

     For pulse jet baghouses having "dirty" side access only, there must be a
platform near the access hatch.  The standard 1/4 inch ports should be
installed above and below the tube sheet which is normally slightly above the
top of the access hatch.  In fact, this is the location selected by manu-
facturers of these baghouses.  The only disadvantage of this location is that
the inspectors must exercise restraint when rodding out the "dirty" side port
since it is possible to puncture a bag near the port.
3.4.2.2  Reverse Air (Outside-to-Inside Flow	
often have a rotating cleaning arm in the clean air plenum.
                                              Fabric Filters -  These units
                                                             This precludes the
use of the extender pipe shown in the pulse jet baghouse sketch.  The "dirty"
side port location must be below the elevation of the tube sheet, as shown in
Figure 3-14.  This means that a small platform must be provided in the area of
the port.  The "clean" side port can be cut through the top shell since this
will not interfere with the bag cleaning equipment.  Since bags hang in the
proximity of the "dirty" side port, it is again necessary to rod out this port
carefully.  It should be noted that the ladder to the top of the baghouse is
necessary for general maintenance.  Only the small lower platform must be
added.                                                   i

3.4.2.3  Shaker and Reverse Air (Inside-to-Outside Flow) Fabric Filters -
These fabric filters generally have a number of individual compartments.  The
small ports must be placed on each of these, as shown in Figure 3-15.  The
"clean" side port is the standard 1/4 inch fitting mounted on the exterior wall
above the tube sheet.  It should be placed at an elevation which is convenient
for using the portable instruments.  The "dirty" side port must include an
extension tube which passes through the clean gas plenum and terminates below
the tube sheet.  It must have a gas tight weld on the lower side of the tube
sheet to prevent gas sneakage through gaps.  A straight tube is used so that
it can be easily cleaned out before any measurement.   The entire assembly is
oriented on a 60° angle so that the port cap does not extend into the normal

                                      3-23               !

-------
         GAS INLET

         ACCESS HATCHES
1/4" INSTRUMENT PORTS
ACCESS HATCH
GAS OUTLET
GAS INLET-
                                                GAS OUTLET
                                     TUBE SHEET
                                                        " INSTRUMENT PORTS
                                                     -1/4" INSTRUMENT PORT WITH
                                                      CROSS PLENUM PIPE
HANDRAIL
1/4" INSTRUMENT PORT WITHl
CROSS PLENUM PIPE
    Figure 3-13.  Instrument Port Location for Pulse Jet (or Plenum Pulse)
                Baghouse
                                    3-24

-------
  REVERSE AIR
  BLOWER
HAND RAIL
                                         1/4" INSTRUMENT PORT
                                                1/4" INSTRUMENT PORT
                                       1/4" INSTRUMENT PORT
                                          CELL PLATE
                                          1/4" INSTRUMENT PORT
               FABRIC FILTER  DUST COLLECTOR
               REVERSE JET CLEANING TYPE
Figure 3-14.
Location of Ports on Reverse Air Fabrit Filter
    (Outside-to-Inside Flow)
                        3-25

-------
                                               GAS OUTLET
COMPARTMENT-
               1/4" INSTRUMENT PORT
                                          ELEVATION
                                SHAKER OR REVERSE AIR BAGHOUSE
                               •1/4"-60° INSTRUMENT PORT
                                                                   ACCESS
                                                                   DOORS
  ENLARGED  DETAIL
  Figure 3-15.  Location of Ports on Reverse Air and Shaker Fabric Filters
                               3-26

-------
  walking  area.   As  shown  in the side elevation view, these ports are located on
  each  of  the compartments in the unit.  Not shown here are the pitot tube ports
  which would be  necessary on the inlet ductwork to this collector.

  3.4.3 Ports for Electrostatic Precipitators
                                                           i-
       Ports should not be installed on or near the shells of electrostatic
  precipitators.  A high voltage arc to a probe could occur if the port were
  close to the energized portion of the precipitator.  Measurement ports can be
  located only in the inlet and outlet ductwork or in the stack.  All downstream
  ports should be.equipped with grounding taps and cables since the charged
  particles passing the probes can result in very high static charges on these
  probes.

       In the very large majority of cases, there are adequate stack sampling
 ports before the precipitator and in the stack.  These should be used, if
 possible.   The modified port design illustrated in Figures 3-8 to 3-11 will
 aid accurate pitot tube traverses and minimize the exposure to potentially
 toxic pollutants.

 3.4.4  Ports for Mechanical Collectors

      Small ports should be  installed above and below the  "clean" side  tube
 sheet of multi-cyclone collectors.   The  platforms  should  allow safe access to
 the ports.   It  is generally necessary  to include 6 inch extension pipes on the
 exterior of the unit to penetrate insulation around  the mechanical collector.
 The end  of the  pipe should  resemble  the  port shown in  Figure 3-3.

      Pitot  tube ports should be installed  upstream and downstream of the unit
 at locations where  there  is  safe access.   The  downstream  port should be
 before the induced  draft  fan,  if possible.  The upstream  port should be close
 to the multi-cyclone collector inlet so  that the measurements can  isolate
 air infiltration and gas  flow  resistance for only  the collector and not other
 common components such as economizers and  air preheaters.


 3.4.5  Ports for Wet  Scrubbers

       A  combination  of small  1/4 inch ports and pitot tube ports is used to
 evaluate wet scrubber performance.  The small ports are placed between all
 beds and stages  to measure static pressure changes across each.  These are
 also used before and after demisters to identify demister pluggage.  The pitot
 tube ports are located on the  ductwork before and after the scrubber vessel.
 They are used to measure  gas flow rates, to evaluate scrubber vessel air
 infiltration, and to conduct reentrainment tests.

 3.4.5.1  Spray Tower Scrubbers -  The inlet ductwork pitot tube ports should
 be situated upstream of any spray headers in order to minimize droplet impac-
 tion on the probes and to minimize pluggage of  the ports.   A parallel set of
 small  ports is provided along side the pitot tube ports so that some measure-
ments  can be made without opening the larger ports.  This  is particularly
important when the unit is under positive pressure.  The small ports do not
add any significant cost to  the small platform  assembly shown in Figure 3-16.

                                      3-27

-------
              LIQUOR  INLET
                  DEMISTER
1/4" INSTRUMENT PORT
    PITOTTUBE PORT
                                          1/4" INSTRUMENT PORT
                                             l/4"-30° INSTRUMENT
                                             PORT
                 CENTRIFUGAL CYCLONIC SCRUBBER
     Figure 3-16.  Location of Ports on a Spray Tower Scrubber
                            3-28

-------
      There is  another set  of small ports located immediately upstream and
 downstream of  the demister.  These provide a means of identifying demister
 pluggage  by measurement of the static pressure drop.  Obviously, only one of
 these ports would be needed on a unit which does not have a demister.

 3.4.5.2   Packed Bed, Moving Bed and Tray Tower Scrubbers - Preferred port
 locations for  this large group of scrubbers is illustrated in Figure 3-17.
 Small instrumentation ports are provided between each bed or tray and before
 and after the  demister.  All of these are inclined 30° to facilitate drainage
 from  the  port  (see Figure  3-3).  Pitot tube ports are present in the ductwork
 before and after the scrubber.  Due to the small scale of many systems,  a
 single port is normally adequate and this minimizes the cost of the top plat-
 form.  For large systems (> 24 inches diameter), two ports spaced 90° apart
 should be used.

 3.4.5.3 Gas-Atomized Scrubbers -  A typical venturi scrubber is shown in
 Figure 3-18.   The small measurement ports are installed immediately upstream
 of the point of liquor injection, on the horizontal duct leading to the
 cyclonic  chamber, and above the demister.  In this case, the static pressure
 drop can  be determined using the middle port and the port above the demister.
 The pressure drop across the throat can be estimated using the initial port
 and the middle port.

     It is  important that the middle port be in the middle or upper portion of
 the horizontal duct.  This is an area very prone to port pluggage due to the
 turbulent motion of the liquor droplets coming from the venturi throat.  There
 is also a layer of liquor floxtfing on the sloped bottom of this duct.

     Pitot  tube ports similar to those illustrated in Figure 3-4 should be
 installed in the ductwork upstream and downstream of the venturi scrubber
 vessel.  These should be located as far from flow disturbances as possible.
 The outlet  duct ports should be located before an induced draft fan.  However,
 if this is not possible, the stack ports can be used.

     Figure 3-19 illustrates the pitot tube ports which are appropriate for
most gas-atomized scrubbers.   There are two separate ports, spaced 90°  apart,
 each of which  is 45° off the center line of the platform. | This allows access
 to both ports with an economical platform.
                                      3-29

-------
I
                     PITOTTUBE PORT
                  1/4" INSTRUMENT PORT
                    PITOT TUBE PORT
         1/4"INSTRUMENT PORT
                                                           DEMISTER

                                                           1/4" INSTRUMENT
                                                           PORTS (3)
                                                           IMPINGEMENT TRAYS
                                                           { 3 STAGES SHOWN)

                                                           SPRAY MANIFOLD
                           IMPINGEMENT TRAY TYPE SCRUBBER
           Figure 3-17.
Location of Ports on Packed Bed, Moving Bed and Tray Type
Scrubbers
                                        3-30

-------
                  1/4" INSTRUMENT PORT    *
    1/4" INSTRUMENT PORT
VARIABLE VENTURI
     1/4" INSTRUMENT PORT
                                          : :xr^:V—DEMISTER
                       HIGH ENERGY VENTURI SCRUBBER
       Figure 3-18.  Location of Ports on Gas-Atomized Scrubbers
                              3-31

-------
                                                 rn
                                                 LJ
                                                1
1/4" INSTRUMENT PORT
                             r-PITOT TUBE PORTS (2)
                                                   r-DE MISTER
                                                  /  rl/4" INSTRUMENT PORT
                                                 fn
                         ORICLONE TYPE VENTURI SCRUBBER
      Figure 3-19.  Location of Ports on Inlet Duct to Gas-Atomized Scrubber
                                  3-32

-------
                                  REFERENCES
1.  Richards, J. and R. Segall.  Wet Scrubber Performance Evaluation.  EPA
    Publication No. 340/1-83-022.  September, 1983.

2.  Richards, J. and R. Segall.  Advanced Inspection Techniques Workshop,
    Student Manual (Draft).  Report to the U.S. Environmental Protection
    Agency under Contract No. 68-01-6312. May, 1984.

3.  Richards, J.  Chapter 8, Baseline Inspection Techniques.  In: Air
    Compliance Inspection Manual (Draft).  Report to U.S. Environmental
    Protection Agency under Contract No. 68-02-3960.  September; 1984.

-------

-------
                                    TECHNICAL REPORT DATA
                             (Please read Instructions on the reverse before completing)
 1. REPORT NO.
    EPA 340/1-84-017
2.
                              3. RECIPIENTS ACCESSION NO.
4. TITLE AND SUBTITLE

    Guidelines  on Preferred Location and Design of
    Measurement Ports for Air Pollution Control Systems
                              5. REPORT DATE
                                 September 1984
                              6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)

    John R. Richards
                              8. PERFORMING ORGANIZATION REPORT NO
9. PERFORMING ORGANIZATION NAME AND ADDRESS

    JACA Corporation
    550 Pinetown Rd.
    Fort Washington,  PA.   19034
                              10. PROGRAM ELEMENT NO.
                              11. CONTRACT/GRANT NO.
                                68-01-3962
 12. SPONSORING AGENCY NAME AND ADDRESS

    US Environmental  Protection Agencv
    Office of Air Quality Planning and Standards
    Washington, DC  20460
                              13. TYPE OF REPORT AND PERIOD COVERED
                              14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
                Of:eiceri
 Foster.  Stationary Source
                                                                             ™.
16. ABSTRACT


   Portable instrumentation is used in evaluating the performance of air pollution
   control systems by both regulatory agency compliance inspectors and source
   operators.  However,  the use of instrumentation, such as  static pressure gauges,
   thermocouples, oxygen analyzers and pitot tubes, has been limited by the lack
   of  adequate measurement ports on the existing control systems.  This report
   examines the parameter data requirements  and provides recommendations on
   measurement port design and location.
 7.
                                KEY WORDS AND DOCUMENT ANALYSIS
                  DESCRIPTORS
                                               b.lDENTIFIERS/OPEN ENDED TERMS  C.  COS AT I Field/Group
   Air Pollution
   Control Equipment
   Parameter Measurement
   Compliance  Inspection
 8. DISTRIBUTION STATEMENT
   Release unlimited
                                               19. SECURITY CLASS (ThisReport}
                                                Unclassified
                                                                           21. NO. OF PAGES
                20. SECURITY CLASS (Thispage)
                  Unclassified
                                                                          22. PRICE
EPA Form 2220-1 (Rev. 4-77)    PREVIOUS EDITION is OBSOLETE

-------

-------