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APTI
Introduction to Baseline
Source Inspection Techniques
Self-instructional
Guidebook
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APTI S
CORRESPONDENCE COURSE
BASELINE INSPECTION TECHNIQUE
FOR AIR POLLUTION
CONTROL EQUIPMENT PERFORMANCE EVALUATION
GUIDEBOOK
Prepared into a Correspondence Course by:
Robin R. Segall
Engi neeri ng-Sci ence
Durham, NC 27701
John R. Richards
Richards Engineering
Durham, NC 27705
Under Contract No.
68-01-6312 £
EPA Project Oficers
Kirk E. Foster
Charles Pratt
U.S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Research Triangle Park, NC 27711
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Notice
This is not an official policy and standards document. The opinions
and selections are those of the authors and not necessarily those of the
Environmental Protection Agency. Every attempt has been made to represent
the present state of the art as well as subject areas still under evalua-
tion. Any mention of products or organizations does not constitute endorse-
ment by the United States Environmental Protection Agency.
Availability
This document is issued by the Manpower and Technical Information
Branch, Control Programs Development Division, Office of Air Quality Plan-
ning and Standards, USEPA. It was developed for use in training courses
presented by the EPA Air Pollution Training Institute and others receiving
contractual or grant support from the Institute. Other organizations are
welcome to use the document.
This publication is available, free of charge, to schools or govern-
mental air pollution control agencies intending to conduct a training course
on the subject covered. Submit a written request to the Air Pollution
Training Institute, USEPA, MD 20, Research Triangle Park, NC 27711.
Others may obtain copies, for a fee, from the National Technical
Information Service (NTIS), 5825 Port Royal Road, Springfield, VA 22161.
ii
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TABLE OF CONTENTS
Page
COURSE INTRODUCTION 0-1
LESSON 1. PRINCIPLES OF THE BASELINE INSPECTION TECHNIQUE 1-1
Review Exercise 1-3
Review Exercise Answers and Reading Information 1-6
LESSON 2. USE OF PORTABLE INSTRUMENTATION 2-1
Review Exercise 2-4
Review Exercise Answers and Reading Information 2-10
LESSON 3. INSPECTION AND EVALUATION OF FABRIC FILTERS 3-1
Review Exercise 3-3
Review Exercise Answers and Reading Information 3-9
QUIZ 1. Questions Ql-1
Answers Ql-10
LESSON 4. INSPECTION AND EVALUATION OF ELECTROSTATIC PRECIPITATORS 4-1
Review Exercise 4-4
Review Exercise Answers and Reading Information 4-10
LESSON 5. INSPECTION AND EVALUATION OF MECHANICAL COLLECTORS 5-1
Review Exercise 5-6
Review Exercise Answers and Reading Information 5-11
LESSON 6. INSPECTION AND EVALUATION OF WET SCRUBBERS 6-1
Review Exercise 6-4
Review Exercise Answers and Reading Information 6-7
QUIZ 2. Questions Q2-1
Answers Q2-10
LESSON 7. INSPECTION AND EVALUATION OF CARBON BED ADSORBERS 7-1
Review Exercise 7-3
Review Exercise Answers and Reading Information 7-9
LESSON 8. INSPECTION SAFETY 8-1
Review Exercise 8-3
Review Exercise Answers and Reading Information 8-8
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Page
LESSON 9. VISIBLE EMISSION EVALUATION 9-1
Review Exercise 9-3
Review Exercise Answers and Reading Information 9-6
LESSON 10. ADMINISTRATIVE AND LEGAL ASPECTS OF PLANT INSPECTIONS 10-1
Review Exercise 10-3
Review Exercise Answers and Reading Information 10-6
IV
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COURSE INTRODUCTION
Course Description
This training course is an 88-hour correspondence course dealing with
inspection techniques for evaluating air pollution control equipment
performance. This course presents the general concept of the baseline
inspection technique, use and calibration of portable instrumentation,
general considerations during inspections such as safety procedures and
legal and administrative aspects, and specific evaluation procedures for
the types of air pollution control equipment listed below:
o fabric filters
o electrostatic precipitators
o wet scrubbers
o mechanical collectors
o carbon bed adsorbers
Course Goal
The goal of this course is to introduce air pollution inspection personnel
to the principles of the baseline inspection technique and to demonstrate
the application of the technique in evaluating the performance of specific
types of air pollution control equipment. It is also intended to present
general considerations for all facility inspections including use of por-
table instrumentation, safety procedures, and legal and administrative
aspects.
Course Objectives
Upon completion of this course, you should be able to:
1. Explain the baseline inspection technique and the principles upon
which it is based.
2. Utilize the baseline inspection technique in
evaluating air pollution control equipment performance.
3. List and explain the use of portable field inspection instrumentation
and equipment for evaluating air pollution control equipment.
4. Describe the administrative and legal considerations involved in
conducting a field inspection.
5. Recall safety considerations for field inspections.
0-1
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Sequence, Lesson Titles, and Trainee Involvement Time
Section Number Lesson Title
Lesson 1
Trainee Involvement
Time (hours)
Principles of the Baseline
Inspection Technique
Lesson 2
Lesson 3
Quiz 1
Lesson 4
Lesson 5
Lesson 6
Quiz 2
Lesson 7
Lesson 8
Lesson 9
Lesson 10
Final Exam
Use of Portable Instru- 8
mentation
Inspection and Evaluation 16
of Fabric Filters
Covering Lessons 1 through 3 2
Inspection and Evaluation 20
of Electrostatic Precipitators
Inspection and Evaluation 20
of Wet Scrubbers
Inspection and Evaluation 3
of Mechanical Collectors
Covering Lessons 4 through 6 2
Inspection and Evaluation
of Carbon Bed Adsorbers 3
Inspection Safety 4
Visible Emission Evaluation 2
Administrative and Legal Aspects 3
of Plant Inspections
Covering Lessons 1 through 10 3
Requirements for Successful Completion of this Course
In order to receive Continuing Education Units (CEUs) and a certificate
of course completion you must:
o take two self-graded quizzes and a supervised final examination.
o achieve a final course grade of at least 70% (out of 100%) on
the final examination.
0-2
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Reading Materials
o APTI Correspondence Course Baseline Inspection Technique for
Air Pollution Control Equipment Performance Evaluation EPA 450/ .
o Baseline Techniques for Air Pollution Control Equipment Performance
Evaluation, report prepared by Engineering-Science for the U.S.
Environmental Protection Agency under Contract No. 68-01-6312, Work
Assignment No. 30, February 1983, (referred to as the Baseline Man-
ual ).
o Field Inspection Notebook, report prepared by Engineering-Science for
the U.S. Environmental Protection Agency under Contract No. 68-01-6312,
Work Assignment Nos. 62 and 99, Revised Draft October 1983, (referred
to as the Field Inspection Notebook).
o The use of Portable Instruments for Evaluation of Air Pollution Con-
trol Systems, draft report prepared by Engineering-Science for
the U.S. Environmental Work Assignment 60, June 1982, (referred to as
the Portable Instruments Paper).
o EPA 340/1-83-011. September 1983. Wet Scrubber Performance Evalua-
tion, (referred to as the Wet Scrubber Manual).
Additional Suggested Readings
The following publications are not included with the course materials and
are not necessary for successful completion of this course. However, they
are informative and are, therefore, recommended supplemental readings. You
should obtain a copy from your State or local air pollution agency files.
Should these materials not be available through your agency, contact the
Air Pollution Training Institute for assistance.
o Control Techniques for Particulate Emissions from Stationary
Sources Volume I, U.S. Environmental Protection Agency Publication
EPA-450/3-81-005a, September 1982.
o Industrial Ventilation, Sixteenth Edition. Published by the
American Conference of Governmental Industrial Hygienists,
Lansing Michigan. 1980.
o Calvert, S., J. Goldschmid, D., Leith, and D. Mehta. Wet Scrubber
System Study, Volume I: Scrubber Handbook. U.S. Environmental
Protection Agency; Research Triangle Park, N.C. Publication EPA-
R2-72-118a, August 1972.
o Mappes, T. E., and R. D. Terns. PEDCo Environmental. An Investiga-
tion of Corrosion in Particulate Control Equipment. U.S. Environ-
mental Protection Agency Publication EPA-340/1-81-002, February 1981.
o Yung, S., Calvert and H. F. Barbarika. A.P.T. Inc. Venturi Scrubber
Performance Model. U.S. Environmental Protection Agency Publication
No. EPA-600/2-77-172, August 177.
0-3
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o Katz, J. The Art of Electrostatic Precipitation, S&S Printing Company,
Pittsburgh, Pennsylvania, 1979.
o White, H. Electrostatic Precipitation of Fly Ash, APCA Reprint
Series, Air Pollution Control Association, 1977.
o McDonald, J. R., and Dean, A. H., Southern Research Institute. A
Manual for the Use of Electrostatic Precipitators to Collect Fly Ash
Particles. U.S. Environmental Protection Agency Publication EPA-
600/8-80-025, May 1980.
Use of the Guidebook
This guidebook directs your progress through the course. This section
introduces the rest of the course material and how to use it. The in-
structional sections, Lessons 1 through 10, are self-paced and guide
you through the reading materials. Each contain the following subsec-
tions:
o reading assignment
o reading assignment topics
o learning goal and objectives
o reading guidance
o review exercise
o review exercise answers and reading information
If supplementary reading material is available, it will be recommended in
the appropriate lesson, but this material is not required for successful
completion of the course.
It is suggested that after reading the assigned materials and reading
guidance, the student complete each review exercise by noting the answers
to the multiple choice questions on a separate sheet of paper. (Note:
Review questions may have more than one correct answer.) A listing of
answers and reading information for each question follows the review
exercise. When you are unsure about a question or answer, review the
lesson section preceding the exercise. The guidebook includes two addi-
tional sections containing two quizzes, Quiz 1 and Quiz 2. They are each
located in the guidebook at the appropriate place in the course and should
be taken at that time. These quizzes are self-graded with the answers
following each quiz. Both are indicative of the type of question that
will appear on the final.
Instructions for Completing the Final Examination
o You should have received, along with this guidebook, a separate
sealed envelope containing a final examination.
o You must arrange to have someone serve as your test supervisor.
o You must give the sealed envelope containing the final examination
to your test supervisor.
0-4
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o At the end of the course, under the supervision of your test super'
visor, complete the final exam.
o After you have completed the final exam, your test supervisor must
sign a statement on the exam answer sheet certifying that it was
administered in accordance with the specified test instructions.
o After signing the exam answer sheet, your test supervisor must
mail the exam and its answer sheet to the following address:
Air Pollution Training Institute
Environmental Research Center
MD-20
Research Triangle Park, NC 27711
o Exam and course grade results will be mailed to you.
If you have questions, contact:
Air Pollution Training Institute
Environmental Research Center
MD-20
Research Triangle Park, NC 27711
Telephone numbers:
Commercial: (919) 541-2401
FTS: 629-2401
0-5
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LESSON 1
Principles of the Baseline Inspection Technique
Reading Assignments
Baseline Manual, Chapter 1.
Field Inspection Notebook, page 1.
Reading Assignment Topics
o Need for comparison of present air pollution control device
operating parameters with site-specific baseline data.
o Steps and procedures in the "counterflow" manner of the baseline
inspection technique.
o Underlying principles of the baseline inspection technique.
Learning Goal and Objectives
Learning Goal
To familiarize you with the concept of the baseline inspection technique
and to explain its underlying principles.
Learning Objectives
When you have completed this lesson, you should be able to:
1. Describe the baseline inspection technique.
2. Explain what the "counterflow" method of inspection is and what the
advantages of using it are.
3. List and describe the five underlying principles of the baseline
inspection technique.
Reading Guidance
o When you have finished the reading assignment, complete the
review exercise for Lesson 1. It begins on the following page.
o After you have answered the review exercise questions, check
your answers. The correct answers are listed on the page
immediately following the review exercise. Note that many of
the questions have more than one correct answer.
1-1
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For any review exercise questions that you answered incorrectly,
review the page of the reading assignment indicated on the
answers page.
After you have reviewed your incorrect answers (if any), proceed
to Lesson 2 of this guidebook.
1-2
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Review Exercise
1. The baseline inspection technique provides
a. an accurate and complete compliance determination
b. a general evaluation of control system performance
c. a detailed evaluation of plant maintenance practices
d. al1 of the above
2. The baseline technique is the
a. is the official inspection technique of the U.S. EPA
b. is the official inspection technique of Regions III and V
of the U.S. EPA
c. is the official inspection technique adopted by the
States of North Carolina and Pennsylvania
d. none of the above
3. Approaching a control system from the stack through to the process
("counterflow" method) is usually advantageous because
a. it avoids unnecessary handling of process oriented
confidential data
b. it may be done without the operator becoming aware
c. it avoids time consuming process equipment inspection
which is often unnecessary
d. operating data of the control system is easier to
obtain and to evaluate
e. most air pollution regulations apply directly to
stack emissions and control system operation
f. all of the above
4. The use of portable inspection instruments is often recommended be-
cause .
a. many on-site permanent monitors are inoperative a significant
portion of the time
b. many control systems do not have the necessary instruments
c. highly complex analyses must be performed and it is usually
not possible to complete these without additional data
d. many operators set on-site instruments to give an incorrect
indication of control system performance
5. The baseline inspection technique involves detailed internal inspections
of the control systems.
a. true
b. false
6. Control systems designed by the same manufacturer and operated under
similar conditions can be assumed to operate in a similar manner.
a. true
b. false
1-3
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7. The baseline inspection technique utilizes
a. one key operating parameter
b. a set of symptoms of performance
c. comparison of operating parameters at a given site against
similar units at plants known to be in compliance
d. none of the above
8. A symptom used in baseline analyses means
a. a significant difference between an operating parameter at a
given plant as compared against industry norms
b. a significant difference between an operating parameter measured
during the inspection as compared against the value during the
baseline period
c. neither
9. As part of the baseline inspection, an inspector should conduct sur-
veillance around the plant at least an hour prior to announcing his
or her presence.
a. true
b. false
10. A baseline inspection should be terminated or altered whenever .
a. the inspector does not have the proper safety equipment
b. it is apparent that the control system is probably in compliance
c. it is apparent that the control system is not operating
d. conditions make it potentially unsafe to continue
e. none of the above
f. all of the above
11. The baseline inspection technique can prove particularly advantageous
to regulatory agency personnel because .
a. it yields data which is often very consistent with state and
local regulations
b. it often allows the inspector to abbreviate inspections when
compliance is highly probable
c. it stresses a thorough inspection of the process equipment
d. al1 of the above
12. Portable instrumentation is sometimes used to confirm the operational
status of the onsite gauges.
a. true
b. false
13. In the baseline technique as much readily obtainable information as
possible is used to evaluate performance.
a. true
b. false
1-4
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14. The baseline inspection technique uses detailed checklists of
informations which must be obtained at every source.
a. true
b. false
1-5
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Review Exercise Answers and Reading Information
Question Page(s) in
Number and Baseline
Answer Manual
1. b 1-1
2. d 1-1
3. a,c,d,e 1-2, 1-3
4. a,b 1-4
5. b 1-4
6. b 1-3, 1-4
7. b 1-4
8. b 1-3 to 1-5
9. b 1-2, 1-3
10. a,b,d 1-3, 1-5
11. a,b 1-3
12. a 1-4
13. a 1-3, 1-4
14. b 1-1 to 1-5
1-6
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LESSON 2
Use of Portable Instrumentation
Reading Assignments
Portable Instruments Paper, pages 1-36.
Field Inspection Notebook, pages 65-76.
Reading Assignment Topics
o Selection of appropriate measurement ports.
o Instrument calibration procedures.
o Instrument selection.
o Measurement port sealing techniques.
o Identifying measurement errors.
o Instrument static grounding procedures.
o Safety procedures for using instruments.
o Legal and policy restraints in use of instrumentation.
Learning Goal and Objectives
Learning Goal
To familiarize you with the common portable field instruments used to
evaluate the performance of air pollution control equipment. This
includes knowing when to use the instrumentation, when to accept data
from on-site gauges, and how to use the instrumentation safely.
Learning Objectives
When you have completed this lesson, you should:
1. Understand the calibration procedures for portable instruments
such as differential pressure gauges, thermocouples, 03 and C02
analyzers, pH meters and other instruments.
2. Understand how to use the instrument so that an accurate
measurement can be obtained without any errors induced by an
incompletely sealed measurement port.
3. Understand to use the proper probe assembly so that there is no risk
of loss of the probe or port seal into the duct.
2-1
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4. Recognize ports which should not be used due to potential for fumiga-
tion from pollutants, due to improper access, or due to potential
hazards.
Reading Guidance
o The introduction to the Portable Instruments Paper is very important.
This section describes some of the important limitations of the use
of the portable instruments. It is also important to read the gen-
eral guidelines stated on page 65 of the Field Inspection Notebook.
o For more information on the hood static pressure method of making
a qualitative estimate of the total gas flow rate, see the Indus-
trial Ventilation Manual (see Supplemental Reference Number 2).
o It is important to fully understand the concept of positive and
negative pressure. Before opening a measurement port or even
approaching a control device the inspector must know whether the
pollutant laden gas stream will tend to escape into the air immedi-
ately around the equipment or whether ambient air will leak into
the collector. Pages 3-5 of the Portable Instruments Paper address
the algebraic sign of the static pressure reading.
o Sealing up the measurement port is an important step in all types
of measurements. A useful means to seal a large (greater than
2 inch diameter) port is shown on page 4-11 of the Wet Scrubber
Manual (see Supplemental Reference Number 1).
o It is important to ground any metallic probe prior to the start
of the measurement. One means to ground the probe is illustrated
on page 68 of the Field Inspection Notebook.
o The material concerning the pitot traverses has been excerpted from
EPA Methods 1 and 2. However, the equation shown on page 72 of the
Field Inspection Notebook is strictly for air or for gas streams
having a molecular weight very close to air. Actually this is a
very common situation since most combustion gases have a molecular
weight very similar to air. The equation shown on page 72 is usually
adequate for field inspectors. The full equation is shown on page 20
of the Portable Instruments Paper.
o The information concerning single point gas flow measurements is
intended only for situations where an approximate gas flow rate is
acceptable. This should not be used for compliance tests. The
material is presented since a single point measurement can be made
in much less time than a full traverse and the field inspector often
needs to know only whether there has been a major increase or decrease
in the flow rate since the last inspection or test.
o Information is presented concerning fan speed measurements on pages
31 through 32 of the Portable Instruments Paper. It should be noted
that it is rarely necessary to make this measurement. Also, an in-
spector should understand and respect all potential safety hazards
in the vicinity of the fan.
2-2
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o When you have finished the reading assignment, complete the review
exercise for Lesson 2. It begins on the following page.
o After you have answered the review exercise questions, check your
answers. The correct answers are listed on the page immediately
following the review exercise. Note that many of the questions
have more than one correct answer.
o For any review exercise questions that you answered incorrectly, re-
view the page of the reading assignment indicated on the answers page.
o After you have reviewed your incorrect answers (if any), proceed
to Lesson 3 of this guidebook.
Supplemental References
1. Richards, J. and R. Segall. Wet Scrubber Performance Evaluation.
U.S. Environmental Protection Agency Publication EPA-340/1-83-022,
September 1982.
2. Industrial Ventilation, Sixteenth Edition. Published by the American
Conference of Governmental Industrial Hygienists, Lansing Michigan.
1980.
2-3
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Review Exercise
1. If the necessary access ports are not available, the inspector
should
a. demand that these be installed immediately
b. conclude that the plant is not performing adequate
maintenance and prepare a notice of violation
c. request that these be installed the next time the
system is down for maintenance
d. offer to drill a 1/4" hole to facilitate the present
inspection, and request a permanent port for future
inspection
2. Static electricity is especially likely following
a. a wet scrubber with a high static pressure drop
b. an electrostatic precipitator
c. a fabric filter handling high resistivity dust
d. none of the above
3. When calibrating the Fyrite® analyzer, the ambient oxygen
concentration is usually
a. 21.9% in the winter, 21.5% in the summer
b. 20.9% in the winter, 20.9% in the summer
c. 19.9% throughout the Northeast
d. 19.9% everywhere, all the time
4. The static pressure drop across a control system is best measured
by .
a. connecting both sides of a differential pressure gauge to
taps before and after the collector
b. measuring the static pressures at both taps separately and
then substracting the outlet from the inlet
5. The best type of Pitot tube to use during an inspection is a
a. type S tube
b. type B tube
c. type F (modified) tube
d. standard tube
6. Failure to saturate the gas stream prior to calibrating the Fyrite"
02 meter will cause ,
a. measured values 1 to 2% 02 greater than actual
b. measured values 1 to 2% 02 less than actual
c. only minor errors
2-4
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7. Prior to measuring the static pressure, an inspector should
a. clean out the tap
b. ground the probe, if necessary
c. evaluate potential gas fumigation
d. calibrate the gauges
e. check for pressure transducers
f. adjust the gauge zero
g. evaluate potential safety conditions
h. al1 of the above
8. Water impaction on a thermocouple in an unsaturated gas stream
should tend to give .
a. a higher than actual reading due to the exchange of the
heat of vaporization
b. a lower than actual reading
c. a wet bulb reading
d. none of the above
9. As a general guidelines, measurement ports on systems with positive
pressure should not have a diameter exceeding .
a. 1/4 inch
b. 1/2 inch
c. 1 inch
d. 2 inches
e. 4 inches
f. none of the above
10. The major problem resulting from the use of incompletely sealed
positive pressure measurement ports is .
a. aspiration effect
b. sample dilution
c. instrument instability
d. exposure to pollutants
e. al 1 of the above
f. none of the above
11. During an evaluation of a coal-fired boiler, the inspector measures
an oxygen concentration of 9% and a carbon dioxide concentration of
15%. Are the measurements acceptable?
a. yes
b. no
c. there is not enough information
2-5
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12. There is a 4 Inch measurement port on a duct at negative 5
inches of water pressure. What could be used to seal the port
during measurements of static pressure, gas temperature and gas
02/C02 concentrations?
a. a hand
b. a glove
c. a piece of cloth
d. a rubber stopper having a maximum diameter greater than
4 inches
e. a sanding disk having a maximum diameter greater than 4
inches
f. nothing is necessary
13. If, during a calibration of a Minihelic® or Magnehelic® gauge, it is
noticed that the gauge is no longer giving a linear response and
in part of the operating range the gauge is more than 10% in
error. The following should be done:
a. the meter should be disassembled and recalibrated
b. the meter should be stomped into the dirt
c. the degree to which the meter floats in a quiet
lake should be evaluated
d. the meter should be used in the next Softball pratice
e. the meter should be properly discarded
f. the inspector should wring hands and gnash teeth
g. the inspector should get a new meter
14. Prior to using the Fyrite® analyzer, the following should be done:
a. a properly sized port in a safe location should be selected
b. the port should be rodded out
c. the probe assembly should be leak tested
d. the probe should be grounded
e. all of the above
f. none of the above
15. Some of the problems associated with the use of a slack tube
manometer for the measurement static pressure include the following:
a. it is difficult to measure static pressures greater than
40 inches of water
b. the liquid may leak out while going to the measurement site
c. the liquid may freeze in very cold weather
d. the instrument is bulky
e. the instrument must be regularly calibrated against a
Magnahelic* differential pressure gauge
f. al1 of the above
2-6
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16. pH paper has an accuracy which is usually
a.
b.
c.
d.
Pi
Pi
Pi
Pi
us
us
us
us
or
or
or
or
mi
mi
mi
mi
nus
nus
nus
nus
0
0
1
5
.1
.5
.0
.0
pH
pH
pH
pH
uni
uni
uni
uni
ts
ts
ts
ts
17. pH paper is usually adequate for evaluation of particulate scrubber
liquor except under these conditions:
a. the liquor contains some strong oxidizing agents which will
attack the dyes on the pH paper
b. the liquor contains some strong alkalies
c. the liquor is highly colored
d. the liquor contains a lot of colloidal material
18. During a measurement of the effluent gas from a #6 oil fired
burner, the 02 value was 7% and C02 value was 11.5%. Should these
measurements be rejected as being obviously in error?
a. yes
b. no
c. there is not sufficient information
19. One simple way to calibrate the Fyrite® C02 Analyzer is to _
a. use ambient air which has an ambient concentration of 360 ppm
b. use a baking soda solution to generate a C02 stream
c. use an automobile exhaust
d. use your breath
e. the instrument is a Primary Standard which does not need to
be calibrated
f. al1 of the above
20. An air pollution control system consists of a hood, 125 feet of
carbon steel ductwork which leads to the fabric filter, a 15 foot
section of ductwork leading to a fan, and a 23 foot stack. During
the inspection the following static pressures are measured: Fan
intake +9 inches, filter inlet +3.5 inches, hood exit +0.5 inches,
filter outlet +8.5 inches. Is there enough information to calcu-
late the pressure drop across the fabric filter?
a. yes
b. no, the measurements were taken at the wrong locations
c. no, the measurements are obviously incorrect
d. no, velocity pressure measurements are also necessary
2-7
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21. A thermocouple should be calibrated using
a. a precision dial-type thermometer
b. a Wheatstone bridge
c. an NBS traceable thermocouple
d. an ice bath and a boiling solution
e. a mercury thermometer
22. A thermister is usually limited to a maximum temperature of
a. 1000°F
b. 500°F
c. 400°F
d. 350°F
e. 300°F
f. 250°F
g. 200°F
h. 150°F
i. 100°F
j. 50°F
k. 0°F
1. none of the above
23. A dial type thermometer usually reads low relative to a
thermocouple in measurement of air pollutant laded gas streams
because .
a. the dial type can often not reach a representative location
b. heat transfer to the dial type thermometer stem is too slow
c. heat transfer up the stem to the outer gauge
d. none of the above
e. all of the above
24. What should be done prior to making a pitot traverse of a duct?
a. make sure that it is necessary to know the gas flow rate
b. make sure that the measurement port is safe
c. make sure that the measurement port can be opened
d. ground the pitot tube
e. make sure that there is no turbulent flow
f. make sure that there is no cyclonic flow
g. make sure that the gas velocity is less than 3200 feet per
minute
2-8
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25. Prior to making a complete pitot traverse using EPA Reference
Method 2, the inspector should
a. determine if a centerpoint value could be used to determine
the average velocity pressure
b. perform fan calculations to get an estimate of the flow
rate
c. select the appropriate nozzle for the pitot tube
d. calibrate an inclined manometer
e. wring hands and gnash teeth
2-9
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Review Exercise Answers and Reading Information
Question
Number and
Answer
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
c
b,c
b
b
a
b
h
b,c
c
d
b
d,e
e,9
e
a,b,c,d
c
a,c,d
b
d
c
Page(s) in
Portable
Instruments
Paper
1-2
2
14
3-4
18
14
1-9
17
9
9
9
7
1-2, 13
6-9
33
34
14
3 & 5
Page(s) in
Field Page(s) in
Inspection Supplemental
Notebook References
65
68
74
#1 4-12
72
65-68 #1 4-7 to 4-13
68
66-67 #1 4-9 to 4-11
75
65-68 #1 4-9 to 4-11
65-66, 74
75-76
74
2-10
-------
Question
Number and
Answer
21. c
22. e
23. a, c
24. a,b,c,d,f
25. a
Page(s) in
Portable
Instruments
Paper
16-17
16
16
1-2, 18-19
24
Page(s) in
Field
Inspection
Notebook
Page(s) in
Supplementa
References
65-72
2-11
-------
LESSON 3
Inspection and Evaluation of Fabric Filters
Reading Assignments
Baseline Manual, Chapter 3.
Field Inspection Notebook, pages 1-20.
Reading Assignment Topics
o Components of fabric filter systems.
o The major categories of fabric filters.
o Inspection points and operating parameters of interest for
each category of fabric filter.
o Common operating problems for each type of fabric filter.
o Application of the baseline inspection technique to fabric filters
o General fabric characteristics and capabilities.
o Qualitative field test to determine fabric integrity.
o Diagnostic procedures which can be used if there are symptoms of
operating problems.
Learning Goal and Objectives
Learning Goal
The primary goal of this lesson is to illustrate that each of the cate-
gories of fabric filters is subject to different operating problems and
is inspected in a different manner. You should become familiar with the
inspection points which are most important for each type of system.
Learning Objectives
When you have completed this lesson, you should be able to:
1. Recognize the two basic types of pulse jet collector; namely the
top clean side access design and the side access design.
2. Understand how a pulse jet bag is cleaned and the typical ranges
in the compressed air pressures and cleaning frequency.
3. Understand commonly observed problems with the pulse jet cleaning
system components.
3-1
-------
4. Understand the factors which can influence the pressure drop in
pulse jet type, reverse air type, and shaker type fabric filters.
5. Understand the operating problems which can lead to dust seepage and
to fabric holes and tears.
6. Understand how a reverse air type bag is cleaned and the typical
operation of the cleaning system.
7. Understand how a shaker type bag is cleaned and the typical operation
of the cleaning system.
8. Understand the importance of tension in both reverse air and shaker
type fabric filters.
9. Understand ways to evaluate air infiltration in all types of fabric
fi Iters.
10. Understand the usefulness of charting bag failure location and frequency.
Reading Guidance
o It is important to recognize that there are four major types of
fabric filters. They each have different operating characteristics,
modes of failure, and inspection procedures.
o Although not discussed explicitly in the Field Inspection Notebook,
a reverse air (outside-to-inside flow) type fabric filter is inspected
in a manner similar to the pulse jet fabric filter. The major dif-
ference is that the reverse air (outside-to-inside) unit has a re-
verse air fan and air delivery system instead of the pulse jet's
compressed air supply and delivery system.
o When you have finished the reading assignment, complete the review
exercise for Lesson 3. It begins on the following page.
o After you have answered the review exercise questions, check your
answers. The correct answers are listed on the page immediately
following the review exercise. Note that many of the questions have
more than one correct answer.
o For any review exercise questions that you answered incorrectly, re-
view the page of the reading assignment indicated on the answers page.
o After you have reviewed your incorrect answers (if any), proceed to
Quiz 1 and then Lesson 4 of this guidebook.
3-2
-------
Review Exercise
1. The type of fabric generally used in a pulse jet fabric filter is
a. woven fabric
b. felted fabric
2. Pulse jet bags are normally mounted in the following manner inside
a baghouse:
a. hung from "J" hooks
b. mounted to the tube sheet using snap rings sewn into the bags
c. mounted on anti-collaspe rings
d. mounted on cages which hang from the tube sheet
3. The dust cake forms on the surface of the pulse jet bag.
a. inside
b. outside
4. The typical air-to-cloth ratio for a pulse jet fabric filter is
a. 0 to 4
b. 4 to 8
c. 8 to 12
d. 12 to 16
e. 16 to 20
5. The typical compressed air pressures used on pulse jet collectors
is .
a. 10 to 50 inches of water
b. 100 to 200 inches of water
c. 10 to 60 psig
d. 60 to 120 psig
e. 10 to 70 kilopascals
f. 70 to 140 kilopascals
6. The components of the pulse jet cleaning system include the
following .
a. the diaphragm valve
b. the rotary discharge valve
c. the solenoid (or "pilot") valve
d. the blow tube
e. the compressed air header
f. all of the above
3-3
-------
7. The proper units of the Air-to-Cloth Ratio are:
a. Ft/Min
b. (Ft/Min)/Ft2
c. (Ft3/Min)/Ft2
d. (M2/Min)
e. (M3/Min)/M2
8. Short term puffs from a pulse jet collector are normally indicative
of .
a. fabric blinding
b. seepage due to overcleaning
c. normal operation
d. none of the above
9. High pressure drop in a pulse jet collector is often due to the
following:
a. holes and tears
b. high gas flow rates
c. inadequate cleaning intensity or frequency
d. cage mi sali gnment
e. partial blinding of the fabric
f. excessive cleaning intensity or frequency
g. cage abrasion
10. Cleaning in a pulse jet collector is done .
a. bag by bag
b. row by row
c. compartment by compartment
d. none of the above
11. If the diaphragm valves are not working on a pulse jet collector,
the following conditions will develop shortly:
a. the bags will balloon outward away from the support cage
b. a substantial dust cake will build up on the bags not being
cleaned
c. the opacity will increase
d. the gas flow rate to the collector will decrease
e. the pressure drop across the collector will increase
f. there will be fugitive emissions from the process hood
12. If the compresed air pressure is too high,
a. there will be momentary seepage of dust immediately
following cleaning of each row
b. the diaphragm will not operate
c. the cage will become deformed
d. the efficiency of the collector will improve
e. no adverse effects will occur
3-4
-------
13. Leakage of compressed air from the header or the valve may cause
the following conditions:
a. inadequate cleaning
b. inoperative solenoid valves
c. inoperative rotary discharge valves
14. The static pressure drop across a pulse jet collector is a sensitive
indicator of holes and tears.
a. true
b. false
15. A blast plate is sometimes used to .
a. reduce the risk of dust explosions
b. reduce erosion of bags near the inlet ducts
c. reduce the necessary pressure drop
d. prevent solids discharge problems
e. al1 of the above
16. An access hatch may be opened when
a. it is necessary to observe the clean side deposits and/or the
baghouse components
b. the static pressure inside exceeds 5 inches
c. there is no differential pressure across the hatch
d. there is no differential pressure across the hatch and the
operator has completed all lockout procedures
e. there is no differential pressure across the hatch, the
operator has completed all lockout procedures, and there are
at least two individuals present
f. there is no differential pressure across the hatch, the
operator has completed all lockout procedures, there are at
least two individuals present both of whom have the appropri-
ate personal protective equipment
17. A snap ring assembly is usually used on a .
a. pulse jet collector
b. shaker col lector
c. compressed air dryer
d. reverse air collector
e. al1 of the above
18. The tube sheet in a pulse jet collector is normally
a. near the bottom of the baghouse
b. near the top of the baghouse
c. between compartments
d. not used
3-5
-------
19. Gas flow in a shaker type fabric filter is
a. from the outside to the inside of the bag
b. from the inside to the outside of the bag
20. Bag tension in a reverse air (inside to outside filtering) type
collector is .
a. critical
b. mildly important
c. unimportant
21. Bags in a reverse air (inside to outside filtering) are cleaned
in the following manner:
a. bag by bag basi s
b. row by row
c. compartment by compartment
22. The static pressure drop across the compartment of a shaker type bag-
house during cleaning should be in the following range:
a. -2 to -4 inches
b. 0 to -2 inches
c. 0
d. 0 to 2 inches
e. 2 to 4 inches
23. The static pressure drop across a compartment of a reverse air
(inside to outside filtering) should be zero.
a. true
b. false
24. The maximum rated temperature for a fiberglass fabric is .
a. 300°F
b. 400°F
c. 500°F
d. 600°F
e. 1000°F
25. Operation on a continuous basis should be at approximately
below the maximum rated temperature.
a. 10°F
b. 25°F
c. 50°F
d. 75°F
e. 100°F
f. 0°F
3-6
-------
26. The typical air-to-cloth ratios for shaker type and reverse air
fabric filters is .
a. 60 to 180 feet per minute
b. 0.25 to 1.0 meters per minute
c. 1 to 3 feet squared per minute
d. 4 to 8 feet squared per minute
e. 8 to 12 feet per minute squared
f. 1 to 3 feet per minute
g. 4 to 8 feet per minute
h. none of the above
27. The clean side deposits in shaker type and reverse air fabric
filters should not be .
a. more than a trace
b. > 1/4"
c. > 1"
d. > 3"
e. > 6"
f. >12"
g. >24"
28. If one failed bag which was recently removed from the collector could
not be ripped easily, even near the location of the hole, the most
probable cause of the hole includes the following:
a. high temperature excursions
b. chemical attack
c. abrasion
d. flex failure
e. installation damage
f. embers
g. all of the above
29. Useful means to evaluate air infiltration include the following:
a. inlet and outlet gas stream temperatures
b. inlet and outlet 0? and CO? measurements
c. listening for the audible sound of air infiltration
d. checking for obvious holes in ductwork or the collector
e. checking for missing solids discharge valves
f. all of the above
30. Problems with baghouses are often indicated when the stack opacity is
in the followi ng range:
a. 1 to 10%
b. 10 to 20%
c. 20 to 40%
d. 40 to 60%
3-7
-------
3l. The maximum recommended operating temperature of Nomex fabric is
F.
a. 100°
b. 200°
c. 300°
d. 400°
e. 500°
32. Fabrics which are generally considered flex and abrasion resistant
include the following:
a. cotton
b. nylon
c. polypropylene
d. polyester
e. fiberglass
3-8
-------
Review Exercise Answers and Reading Information
Question
Number and
Answer
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
b
d
b
b
d
a,c,d,e
a,c,e
a,b
b,c,e
b
b.d.e.f
a,d
a
b
b
a,f
b,d
b
b
a
c
c
b
Page(s) in
Baseli ne
Manual
3-3
3-1
3-1
3-3
3-6
3-1 to 3-3
3-6
3-6
3-3
3-5
3-5
3-8
3-7
3-4,3-9
3-5
3-5
3-4
Page(s) in
Field
Inspection
Notebook
3
2 to
3
4
3
2 to
4
7
8
3
6 to
7
7
4
3
8
13
2
13
13
13
18
18
3
3
7
3-9
-------
Page(s) in
Question Page(s) in Field
Number and Baseline Inspection
Answer Manual Notebook
24. c 15
25. c 14
26. b,f 3-5 14
27. a 3-9 19
28. c,d,e,f 20
29. f 3-6,3-8 18
30. a 5j17
31. d 15
32. b,c,d 15
3-10
-------
QUIZ 1
This self-administered and self-graded quiz covers the material
presented in Lessons 1 through 3. It introduces the type of questions
and problems which will appear on the final and is open book. The final,
however, will only allow use of the Field Inspection Notebook. Access to
a calculator for both the quiz and final will be helpful.
The quiz consists of 25 multiple choice questions and problems.
There may be more than one correct answer for each question. You should
use a separate sheet of paper to record your answers and scratch paper to
work the problems. The answers can be found on the page following the
last question.
Ql-1
-------
1. A symptom used in baseline analyses means
a. a significant difference between an operating parameter at a
given plant as compared against industry norms
b. a significant difference between an operating parameter measured
during the inspection as compared against the value during the
baseline period
c. neither
2. During the measurement of the static pressure in a duct ahead of a
fabric filter it is suspected that there is some slight air leakage
around the probe and into the duct. If the observed static pressure
is -18 inches of water, the true static pressure would probably be
a. -15 inches of water
b. -20 inches of water
c. -25 inches of water
d. +18 inches of water
e. either b or c
3. A bonding wire is used for the following:
a. to prevent loss of the probe into the duct
b. to connect the probe to the instrument
c. for dissipation of static electricity
d. to prevent magnetic interference
4. Calculate the average stack gas velocity using the following pitot
traverse data and the equation:
vs - 2.9 Cp (vTp~ ) avg V(Ts) avg
•here: vs - average stack gas velocity (ft/sec),
cp pitot tube coefficient (dimensionless, usually
varies between 0.83 and 0.87),
AP velocity head (manometer reading) of stack
gas (in. HjO), and
Ts « absolute stack temperature (460° + stack gas
temp, in °F).
Traverse Velocity Stack
Point No. Head, Temperature,
Inches ° F
1 0.42 314
2 0.46 316
3 0.58 321
4 0.76 325
5 0.83 323
6 0.47 320
7 0.42 315
8 0.38 314
a. 31.4 feet per second
b. 31.8 feet per second
c. 49.2 feet per second
d. 49.7 feet per second
01-2
-------
5. It is necessary to make a static pressure measurement on the duct
ahead of the collector. The location shown in the photograph below
has safe and convenient access. How should the measurement be made?
a. by removing the 2 inch plug
b. by removing the 2 inch plug and using a port seal
c. by reading the signal off the D/P Transmitter
d. at another location which will not affect the D/P Transmitter
If the inside diameter of the duct is 30 inches and the measured aver-
age velocity is 56 feet per second, what is the gas flow rate in ACFM?
a. 16,493
b. 275
c. 3,299
d. 65,972
7. Portable inspection instruments are sometimes necessary because _
a. some on-site permanent monitors are inoperative a significant
portion of the time
b. many control systems do not have the necessary instruments
c. highly complex analyses must be performed and it is usually
not possible to complete these without additional data
d. many operators set on-site instruments to give an incorrect
indication of control system performance
Ql-3
-------
During the inspection of a reverse air collector (inside-to-outside
filtering) it is noted that there is a trace of dust (see photograph.
below) on the clean side of the tube sheet. What does this indicate?
a. a trace of dust is inevitable and the compartment appears to be
in good shape
b. the compartment contains a number of broken bags
c. some bleeding of dust may be occurring during the shake cycle
d. none of the above
9. While evaluating a fabric filter on a spreader stoker boiler, the
following measurements were made using the Fyrite analyzers: Inlet
to collector, 02=12.6% and C02=11.6%; Outlet of collector, 02=9.6%,
C02=11.2%. What can be concluded from these measurements?
a. the boiler is operating at undesirable excess air rates
b. there is substantial air infiltration into the fabric filter
c. the measurement made at the outlet port is incorrect
d. the measurement made at the inlet port is incorrect
e. more data is necessary to make any conclusions
10. On a square duct, the length is 50 inches and the width is 20 inches.
What is the equivalent diameter?
a. 35.0 inches
b. 28.6 inches
c. 40.1 inches
d. 18.6 inches
Ql-4
-------
11.
12.
13.
What should be done prior to conducting a point-by-point pitot
traverse to determine the average gas stream velocity?
a. attach the grounding/bonding line to the pitot tube if there is
even a remote possibility of static electricity build-up
b. check for cyclonic flow
c. determine the number of traverse points necessary
d. ensure that the measurement port area is structurally secure
e. ensure that toxic gases and/or steam accidentally released
from plant equipment cannot engulf the measurement port location
f. calibrate the inclined manometer
g. confirm that it is actually necesary to know the gas stream
velocity during the inspection
h. measure the diameter of the stack at the port location
i . al 1 of the above
Measurement ports on negative pressure ducts must be well sealed
during the measurements in order to prevent the following:
a.
b.
c.
d.
e.
f.
ambient air infiltration into the Fyrite* probe
the build-up of static electricity
fumigation of the inspector as pollutant laden gas flows out of
the measurement port
aspiration effect error
cooling of the temperature sensor
lower than actual 63 and C02 measurement
The preferred method for measuring the pressure drop across a collector
is shown in figure _ .
a. A
b. B
c. neither
Ql-5
-------
14. During the inspection of a fabric filter, it is noted that the pres-
sure drop has decreased substantially since the baseline period and
the opacity has dropped from 10% to almost 0%. There is some minor
corrosion on the collector shell and some very audible air infiltra-
tion across the top access hatches. The rotary valves and the screw
conveyors seem to be performing adequately. Is it necessary to con-
tinue the inspection or should the unit be considered in compliance?
a. stop the inspection, the unit is in compliance
b. continue the inspection because the data clearly indicates that
the bags are being overcleaned
c. continue the inspection because it is quite possible that there
are substantial fugitive emissions from the process hoods
d. stop the inspection because any problems which may exist are not
causing the unit to operate out of compliance
15. During the inspection, the operator of a fabric filter serving a cup-
ola states that the previous bag failure problem has been corrected
by using a new bag hanger design and by modifying the tube sheet
thimble. He suggests that you follow him into the fabric filter to
confirm that this has been done properly. What should the inspector do?
a. check all six compartments to ensure that the same modifications
were made in each
b. just check one or two compartments
c. limit the inspection to what can be seen from the access hatch with-
out going inside the compartments
d. review the drawings and do not waste time on the equipment inspec-
tion
16. A pulse jet fabric filter serving a lime unloading (truck) station
has an opacity of 0%. The pressure drop has increased from a baseline
value of 4 inches of water to a present value of 9 inches. What can
be concluded from this data?
a. since the baghouse opacity is 0%, the baghouse is in compliance
with visible emission regulations
b. since the pressure drop has increased, the collection efficiency
has probably increased since the baseline period
c. the cleaning system should be inspected carefully
d. the rotary valves and screw conveyor should be inspected carefully
e. the potential for fugitive emissions from the unloading shed
should be evaluated
17. The baseline inspection technique involves detailed internal inspections
of the control systems.
a. true
b. false
Ql-6
-------
18. The static pressure indicated on the slack tube manometer shown below
is .
a. 60 inches
b. 40 inches
c. 20 inches
d. 0 inches
19.
20.
21.
The temperature recorder on the outlet of a reverse air fabric filter
indicated that there was a temperature excursion to 485°F for a period
of 1 hour. What types of fabric would be able to tolerate this condi-
tion?
a.
b.
c.
d.
e.
cotton
Nomex
fiberglass with silicon-graphite coating
Ryton
Dacron
During the inspection of a shaker type fabric filter, it is noted that
the shake duration is 5 minutes and the frequency is approximately
4 cycles per second. What should the innspector be concerned about?
over-cleaning with premature bag failures
bag blinding conditions possibly accompanied by fugitive emissions
from the source
hopper overflow problems
nothing
Control systems designed by the same manufacturer and operated under
similar conditions can be assumed to operate in a similar manner.
a.
b.
c.
d.
a.
b.
true
false
Ql-7
-------
22.
Static pressure measurement data on a given air pollution control
system are shown in the figure below. What is the pressure drop
across the collector?
a. 6.8 inches
b. 1.0 inches
c. 5.8 inches
d. 6.1 inches
e. it cannot be determined
f. the measurements are obviously in error
P- -0.5"
STACK
23. Water and oil in the compressed air lines of pulse jet fabric filters
can lead to which of the following problems?
a. seepage
b. blinding
c. freezing of the diaphragm valves
d. freezing of thr rotary valves
e. fires in the bags
f. cage erosion
Ql-8
-------
24. The bag shown in the photograph below has recently been removed from
a fabric filter with a long history of operating problems. The
operator states that the problem occurred due to a temperature
excursion and that the cause has been corrected. What should the
inspector do?
a. accept this explanation and reschedule an inspection in six months
b. attempt a rip test in the vicinity of the hole to evaluate the
overall fabric strength
c. determine if there are any signs of flex failure and or mechanical
damage
d. determine if there are any signs of embers
25. The conditions shown in the photograph below were observed in the
clean side plenum of a fabric filter. The unit is presently off-
line, however, it normally operates with an opacity of zero and no
apparent fugitive emissions from the process. Is there a need to
continue the inspection of the unit?
a. no, the unit is probably in compliance
b. yes, the pressure drop should be measured when the unit is on-line
c. yes, the potential for air infiltration should be carefully checked
when the unit conies back on-line
Ql-9
-------
Ql-10
-------
LESSON 4
Inspection and Evaluation of Electrostatic Precipitators
Reading Assignments
Baseline Manual, Chapter 2.
Field Inspection Notebook, pages 21 to 31.
Reading Assignment Topics
o The functions of components of an electrostatic precipitator
control system.
o The importance of determining the layout of Transformer-Rectifier
sets on the precipitator prior to starting the data evaluation.
o Procedure for plotting the Transformer-Rectifier set electrical
data in order to determine whether the precipitator is presently
handling high, moderate, or low resistivity particulate matter.
o Procedure for evaluating the voltages and currents of each field.
o Procedure for estimating the power input for each chamber of the
precipitator when the resistivity is either moderate or high.
o Useful inspection points when used with the stack opacity or the
electrical data suggests that precipitator performance has decreased
since the baseline period.
Learning Goals and Objectives
Learning Goal
To familiarize you with the general operating principles of an electrostatic
precipitator and with the parameters of most use in evaluating precipitator
performance.
Learning Objectives
When you have completed this lesson, you should:
1. Understand how to plot the Transformer-Rectifier set data (voltages,
currents, and spark rates) in order to make a general assessment of
the particulate resistivity.
2. Understand how to review the electrical set data plots to determine
if there probably are internal problems in one or more fields.
3. Understand how to analyze the present opacity levels and electrical
set data to determine if there has been a significant shift since
the baseline period.
4-1
-------
4. Understand when it is useful to calculate the precipitator power
input and when this value can be misleading.
5. Understand some of the mechanical problems which can lead to low
voltages and high currents in specific fields, including but not
limited to: air infiltration, insulator tracking, electrode
warpage, internal clearance problems, electrode sway, and hopper
overflow. Understand what external symptoms can be checked to
narrow the list of potential problems so that the source opera-
tor's corrective action(s) can be reviewed.
6. Understand the most common modes of failure of electrostatic
precipitator systems.
7. Understand how the interaction of two or more failures at the same
time can lead to a confusing and sometimes very difficult to inter-
pret set of data.
Reading Guidance
o Prior to reading about the inspection procedures for electrostatic
precipitators, it is very important to develop a good understand-
ing of the precipitator components and the operating principles.
Useful information is presented in the Baseline Manual on pages
2-1 to 2-8 and in the Field Inspection Notebook on Pages 21 to 24.
These two references are meant to provide only a quick overview of
the salient operating principles. It is recommended that a supple-
mental reference also be read before continuing with this lesson.
Very good information is presented in Katz (see Supplemental Ref-
erences) on pages 6 to 52 and pages 60 to 70.
o One of the most important concepts in electrostatic precipitation is
the particle resistivity. The general range of the resistivity (low,
moderate, or high) must be identified during the inspection so that
the inspection can focus on the problems most likely to be causing
any emissions problems. More information on resistivity is presented
in the supplemental references: White, pages 38 to 61; Southern
Research Institute, pages 323 to 411; and Katz, pages 60 to 75.
o In both the Baseline Manual and the Field Inspection Notebook, the
term resistivity means the average resistivity of the particulate
entrained in the inlet gas stream. Actually, the resistivity
varies from side-to-side of the inlet and varies from the front to
the back of the precipitator. Also, most commercial precipitators
will have some temporal variation in the resistivity conditions. It
is important to recognize that the resistivity is not a constant.
o It is important to recognize that there often is a complex
interaction between some of the precipitator operating problems.
It is often difficult, for an inspector with limited time and
using only the opacity strip charts (and stack observation) and
the electrical set data, to diagnose the specific operating
problem. It is important to respect the complexity of the
device.
4-2
-------
o Typical secondary voltages, secondary currents, and spark rates
are plotted on page 28 of the Field Inspection Noteboook. In
many cases, the baseline data and operating data is not as linear
as shown. All three plots should be used together to attempt to
identify the general range of the resistivity. The plots shown
are typical of moderate resistivity. A low resistivity set of
plots would usually have very high secondary currents in all
fields and spark rates near to or at zero in all fields. The
secondary voltages in low resistivity would drop in all fields.
The secondary voltages in low resistivity would drop in all
fields relative to the baseline values. In high resistivity, the
secondary currents would be low in all fields and the spark rates
would usually be high in all the fields. The plots may look
different if the unit is undersized or is suffering from internal
problems in many of the fields. For these reasons, the plots
should not be considered as absolutely reliable for determining
the general resistivity range. There will be isolated cases
where they do not yield a clear picture of the precipitator
operating conditions.
o It is important to realize that the power input should only be
used to evaluate emissions if the resistivity is in the high
or moderate ranges. In these ranges, the particulate emissions
from the precipitator are roughly proportional to the power
input. In the low resistivity range, the emissions can increase
as the power input goes up.
o When you have finished the reading assignment, complete the review
exercise for Lesson 4. It begins on the following page.
o After you have answered the review exercise questions, check your
answers. The corect answers are listed on the page immediately
following the review exercise. Note that many of the questions
have more than one correct answer.
o For any review exercise questions that you answered incorrectly,
review the page of the reading assignment indicated on the answers
page.
o After you have reviewed your incorrect answers (if any), proceed
to Lesson 5 of this guidebook.
Supplemental Reference^
1. Katz, J. The Art of Electrostatic Precipitation, S&S Printing
Company, Pittsburgh, Pennsylvania, 1979.
2. White, H. Electrostatic Precipitation of Fly Ash, APCA Reprint
Series, Air Pollution Control Association, 1977.
3. McDonald J.R., and Dean, A.H., Southern Research Institute. A
Manual for the Use of Electrostatic Precipitators to Collect Fly
Ash Particles. U.S. Environmental Protection Agency Publication
EPA-600/8-80-025, May 1980.
4-3
-------
Review Exercise
1. The two most important types of data used to evaluate an
electrostatic precipitator are the following:
a. the gas flow rate and the stack opacity
b. the gas inlet temperature and the gas flow rate
c. the T-R set electrical data and the opacity
d. the rapper intensities and rapper frequencies
e. the T-R set electrical data and the gas flow rate
2. The typical electrostatic precipitator has the following layout
of T-R sets:
a. one or two fields in series
b. two to ten fields in series
c. three to fifteen fields in series
d. four to twenty fields in series
e. five to forty fields in series
f. fields are not oriented in series
3. During the charging and particle migration process, dust
accumulates on the following:
a. the collection plate only
b. the collection plate and the distribution screens only
c. the discharge electrodes only
d. the collection plate, discharge electrodes, and the distribution
screens
e. none of the above
4. The voltage on the discharge electrode is the .
a. primary voltage
b. secondary voltage
c. none of the above
5. The primary side of the Transformer-Rectifier set operates as
a. alternating current
b. direct current
c. none of the above
6. The secondary side of the Transformer-Rectifier set operates as
a. alternating current
b. direct current
c. none of the above
4-4
-------
7. The typical secondary voltages of electrostatic precipitators is
between .
a. 1,000 and 5,000 volts
b. 15 and 50 kilovolts
c. 5 and 10 kilovolts
d. 1,000 and 5,000 kilovolts
e. none of the above
8. If the participate resistivity is low, the secondary currents are
usually .
a. very low in all of the fields
b. very high in all of the fields
c. secondary current is set at the T-R set and is unaffected
by the resistivity
9. If the particulate resistivity is high, the secondary currents are
usually .
a. very low in all fields
b. very high in all fields
c. secondary current is set at the T-R set and is unaffected
by the resistivity
10. Corona power is calculated by .
a. multiplying the primary current times the primary voltage
b. multiplying the primary current times the primary voltage
times the load factor
c. multiplying the secondary current times the secondary
voltage
d. multiplying the secondary current times the secondary
voltage times the power factor
e. multiplying the primary voltage times the primary current
times the power factor
11. The corona power is a general indicator of performance only when
a. the resistivity is moderate or low
b. the resistivity is moderate or high
c. the resistivity is low or high
12. The primary voltage in an electrostatic precipitator is usually in
•f ho ranne r\f
the range of
a. 0 to 1000 volts, A.C.
b. 0 to 1000 volts, D.C.
c. 0 to 480 volts, A.C.
d. 0 to 480 kilovolts, D.C.
4-5
-------
13. The secondary voltage necessary to establish a corona discharge is
usually .
a. 1000 to 2000 volts
b. 1 to 3 kilovolts
c. 15,000 to 25,000 kilovolts
d. 10 to 20 kilovolts
14. The collection efficiency of an electrostatic precipitator is
•
a. strongly affected by the secondary voltage
b. not related to the secondary voltage, only to the primary
voltage
15. The gas velocity through an electrostatic precipitator is usually
a. 1 to 3 feet per second
b. 180 to 480 feet per minute
c. 10 to 25 feet per minute
d. 3.5 to 12 feet per minute
e. 3 to 8 feet per second
f. 30 to 50 feet per minute
g. 50 to 75 feet per second
16. While observing the stack of an electrostatic precipitator system, the
following information is useful in evaluating the present conditions:
a. the average opacity
b. the peak opacity during puffs
c. the duration and timing of the puffs
d. the presence or absence of detached plumes
e. all of the above
f. none of the above
17. Method(s) for evaluating the spark rates in the various fields are
a. divide the primary current by the primary voltage
b. count the fluctuations of the primary voltage meter
c. check the spark rate meter (if present) on each of the
electrical cabinets
d. it is not necessary to know the spark rate
18. If the unit has suffered frequent wire breakage, the inspector may
wish to do the following:
a. evaluate the wire failure location records
b. examine the wires to evaluate the general type of failure which has
occurred
c. evaluate the power input to each chamber to determine if the
loss of fields due to wire failure has in fact caused a
significant decrease in the chamber total power input
4-6
-------
19. The corona power levels should be evaluated
a. when the resistivity is in the low to moderate range
b. on a chamber by chamber basis
c. for the entire precipitator system by summing up all chambers
d. when the resistivity is in the moderate to high range
e. when the opacity is above baseline levels and the resistivity
is in the moderate to high range
f. when the opacity is above baseline levels and the resistivity
is in the moderate to low range
20. When the resistivity is in the moderate range, the spark rate
tends to from the inlet to the outlet field of a
given chamber.
a. increase
b. decrease
c. remain unchanged
21. If the particulate resistivity is low, the dust layer on the
collection plate is .
a. held strongly
b. he!d only weakly
22. Factors which can aggravate reentrainment emissions from a
precipitator collecting low resistivity dust can include the
followi ng:
a. excessive rapping intensity
b. poor gas distribution
c. insulator tracking
d. high gas velocities
e. excessive rapping frequencies
f. al1 of the above
23. At low temperatures, the dissipation of charge from collected
particles occurs by .
a. surface conduction
b. bulk conduction
c. magic
d. not at all
24. Surface conduction occurs due to the presence of the following:
a. elemental nitrogen
b. adsorbed water molecules
c. adsorbed sulfur trioxide molecules
d. elemental calcium
e. all of the above
4-7
-------
25. Each field removes % of the particulate matter entering
that field.
a. 0 to 25%
b. 25 to 40%
c. 40 to 70%
d. 70 to 85%
e. 85 to 95%
f. 95 to 99%
26. The secondary currents in electrostatic precipitator fields are
usually in the range of .
a. 0 to 400 amps, D.C
b. 0 to 1500 amps, A.C.
c. 0 to 100 amps, D.C
d. 0 to 1000 amps, A.C.
e. 0 to 2 amps, D.C.
f. 0 to 1 amps, A.C.
g. 0 to 2000 milliamps, D.C.
h. 0 to 1000 milliamps, A.C.
i. 0 to 5000 microamps, A.C.
27. The resistivity of the particulate matter is affected by
a. the gas temperature
b. the concentrations of water vapor and sulfur trioxide
c. the composition of the particulate matter
d. the secondary voltage
e. the secondary current
28. For a specific electrostatic precipitator, the particulate matter
resistivity is .
a. a constant
b. not constant
29. If only one field or several fields exhibit shifts from baseline
conditions, the most likely cause(s) of the failure would include
the following:
a. resistivity shifts
b. rapper failure
c. insulator leakage or failure
d. misalignment
e. hopper overflow
f. localized air inleakage
g. poor gas distribution
h. all of the above
4-8
-------
30. The electrical set data should be recorded in the following order:
a. the order is not important
b. in numerical order
c. starting with the inlet and proceeding to the outlet
d. in a counterflow direction, starting with the outlet field
and proceeding to the inlet
4-9
-------
Review Exercise Answers and Reading Information
Question
Number and
Answer
1. c
2. b
3. d
4. b
5. a
6. b
7. b
8. b
9. a
10. c,e
11. b
12. c
13. d
14. a
15. b,e
16. e
17. b,c
18. a,b,c
19. b,d,e
20. b
21. b
22. a,b,d,e
Page(s) in
Baseline
Manual
2-1
2-2
2-2 to 2-3
2-4
2-2, 2-9
2-2, 2-9
2-2
2-10
2-10
2-5 to 2-8
2-5 to 2-8
2-2
2-4 to 2-5.
2-4
2-1
2-8
2-5 to 2-8
2-10
Page(s) in
Field
Inspection
Notebook
25
21
25
25
28
29
29
31
30
25
25
21
25,26
25
31
26
26,28
23
23
Page(s) in
Supplemental
References
#1 32
#1 60 to 75
#1 34 to 36
#1 30 to 31
#2 19
#1 60 to 75
4-10
-------
Page(s) in
Question Baseline
Number and Inspection
Answer Manual
23.
24.
25.
26.
27.
28.
29.
30.
a
b,c
d
e,g 2-9
a,b,c
b
b,c,d,e,f 2-12
c 2-8 to 2-10
Page(s) in
Field
Inspection
Notebook
23-24
23-24
21
25,28
23
23-24
30
26
Page(s) in
Supplemental
References
#1 60-63, #2 39-61
#3 340-356
#1 60-63, #2 39-61
#1 60-63
#1 134
4-11
-------
LESSON 5
Inspection and Evaluation of Participate Wet Scrubbers,
Reading Assignments
Baseline Manual, Chapter 4.
Field Inspection Notebook, pages 40 to 64.
Wet Scrubber Manual, pages 1-1 to 1-2, 2-1 to 2-41, 3-1 to 3-8, and
4-1 to 4-19.
Reading Assignment Topics
o General types of wet scrubbers and the differing performance
capabilities of these types.
o Components of wet scrubber systems.
o The relationship between static pressure drop and the energy
utilization within the scrubber.
o The effect of surface tension on performance.
o The importance of scrubber liquor pH.
o The relationship between the liquid-to-gas ratio, the
pressure drop, and the scrubber efficiency.
o The importance of particle size on scrubber performance.
o The performance parameters used to evaluate scrubber
performance.
o The types of instruments often used to evaluate scrubber performance,
o The baseline evaluation technique as applied to wet scrubbers.
o The importance of process operating conditions on the
performance of a wet scrubber system.
5-1
-------
Learning Goal and Objectives
Learning Goal
To familiarize you with the important wet scrubber performance
parameters and with a general methodology for evaluating the present
operating condition of the overall wet scrubber system.
Learning Objectives
When you have completed this lesson, you should:
1. Understand the basic design features of the major classes of wet
scrubbers.
2. Understand the relationship between the pressure drop, the gas
density, and the scrubber efficiency.
3. Understand the factors which can affect scrubber performance without
causing any observable change in the pressure drop or the gas density.
4. Understand when the portable instruments should be used and when
they are not necessary or are undesirable.
5. Respect all potential safety hazards which can be encountered
during an inspection of a wet scrubber.
6. Understand the locations in a scrubber system where corrosion and
erosion are most common.
7. Understand the importance of demister performance in preventing
liquor reentrainment.
8. Understand the importance of site specific performance evaluations.
Reading Guidance
o If you do not understand the differences between static pressure,
velocity pressure, and total pressure, refer to the Industrial
Ventilation Manual published by the American Conference of
Governmental Industrial Hygienists (see Supplemental Reference
list).
o Pages 2-20 to 2-34 of the Wet Scrubber Manual should be read
very carefully, since this section presents information demon-
strating that performance correlations should be based on the
value of pressure drop divided by the gas density. Previously
published literature suggested that the correlation could be based
on the value of the pressure drop alone. This section presents
information demonstrating that pressure drop alone is not adequate.
5-2
-------
The importance of particle size is discussed in Section 2.2
of the Wet Scrubber Manual. The importance of particle size
cannot be overstated. Unfortunately, there is very little
particle size data for commercial units.
Section 2.2.3.2 of the Wet Scrubber Manual presents a brief
discussion of the evaporative release mechanism for release
of "new" aerosols into the gas stream. There is very little
published literature available on this topic, possibly because
many have failed to recognize the importance of this very
undesirable operating condition. A large number of equipment
operators have independently discovered that the use of rela-
tively clean liquor in the presaturators and quench towers has
a very beneficial impact on the overall scrubber performance.
Section 2.2.3.1 of the Wet Scrubber Manual presents a brief
discussion of the possible ways in which a change in the process
equipment operating conditions could effect the scrubber efficiency,
Additional information on this very important topic is presented
in Section 4.3 of the same manual. It is a subject area in which
much more needs to be known. The variability of particle size
between different scrubbers on apparently similar process units
is one of the major reasons that the site specific baseline
approach is so important.
In reviewing published manuals and articles concerning wet scrub-
bers, the reader will frequently encounter the terms "efficiency",
"penetration", and "transfer units". These three terms actually
refer to the same basic concept, namely the extent to which pollu-
tants entering a system are removed. Information to facilitate
converting from one term to another are presented in Appendix A
of the Wet Scrubber Manual .
The Field Inspection Notebook, pages 40 to 64 should be read
after completing all of the assigned readings in the Wet Scrubber
Manual. The notebook section serves as a concise review of the
material presented in the Scrubber Manual.
The effect of liquor surface tension on the performance of a wet
scrubber system has not been studied extensively. More work is
necessary, especially concerning the effect of the surface tension
on the distribution of droplets across the throat of a venturi
scrubber and concerning the effect of surface tension on the
collection efficiency for fine particles. Refer to Section 2.6
of the Wet Scrubber Manual.
5-3
-------
o One of the main tasks in the evaluation of any wet scrubber system
is measurement of the pressure drop. Section 4.1.5 of the Wet
Scrubber Manual presents some instructions for measuring the
pressure drop which are not available elsewhere. This section
should be reviewed several times, and the following topics should
be clearly understood:
a. The need for carefully sealing the measurement port to
prevent aspiration error.
b. The need to ensure that the measurement port remains
open during the measurement.
c. The need to use an electrical grounding cable on all
measurements at the inlet to wet scrubbers to prevent
static electrically initiated explosions .
d. The need to fully document the measurement port loca-
tions so that the implications of the pressure drop
value can be determined.
o Gas densities as a function of gas temperature and pressure are
shown in Figure C-l of Appendix C of the Wet Scrubber Manual. This
chart demonstrates that the static pressure has a significant im-
pact on the gas density, therefore, gas density will change sub-
stantially while passing through the scrubber, even if the temper-
ature remains constant.
o When you have finished the reading assignment, complete the review
exercise for Lesson 5. It begins on the page following the Supple-
mental Reference listing.
o After you have answered the review exercise questions, check your
answers. The correct answers are listed on the page immediately
following the review exercise. Note that many of the questions have
more than one correct answer.
o For any review exercise questions that you answered incorrectly,
review the page of the reading assignment indicated on the answers
page.
o After you have reviewed your incorrect answers (if any), proceed
to Lesson 6 of this guidebook.
5-4
-------
Supplemental References
1. Calvert, S., J. Goldschmid, D., Leith, and D. Mehta. Wet Scrubber
System Study, Volume I: Scrubber Handbook. U.S. Environmental
Protection Agency, Research Triangle Park, N.C. Publication EPA-
2-72-118a, August 1972.
2. Richards, J., and R. Segal 1. Engineering-Science. "The Use of
Portable Instruments for Evaluation of Air Pollution Control
Systems" Draft Report to the U.S. Environmental Protection Agency,
Contract 68-01-6312, June 1982.
3. Mappes, T.E., and R.D. Terns. PEDCo Environmental. An Investigation
of Corrosion in Particulate Control Equipment. U.S. Environmental
Protection Agency Publication EPA-340/1-81-002, February 1981.
4. Conkle, H.N., H.S. Rosenberg, and S.T. DiNovo. Battelle Columbus
Laboratories. Guidelines for the Design of Mist Eliminators for
Lime/Limestone Scrubbing Systems. Electric Power Research Institute
Publication EPRI FP-327, December 1976.
5. Emission Standards and Engineering Division, OAQPS, U.S. EPA.
Control Techniques for Particulate Emissions from Stationary Sources
- Volume I. U.S. Environmental Protection Agency Publication EPA-
450/3-81-005a, September 1982.
6. Yung. S., S. Calvert, and H.F. Barbarika. A.P.T. Inc. Venturi
Scrubber Performance Model. U.S. Environmental Protection Agency
Publication No. EPA-600/2-77-172, August 1977.
5-5
-------
Review Exercise
1. The particle range which is most difficult to collect in a wet
scrubber is .
a. 0.01 to 0.1 microns
b. 0.1 to 0.2 microns
c. 0.2 to 0.5 microns
d. 0.5 to 1.0 microns
e. 1.0 to 2.0 microns
2. The dominant collection mechanisms in wet scrubbers include
a. Brownian diffusion
b. electrostatic attraction
c. sieving
d. impact ion
3. Corrosion in wet scrubbers fabricated of carbon steel occurs
rapidly when the pH is in the range of .
a. 4 to 8
b. 0 to 6
c. 7 to 14
d. 14 to 28
4. The liquor flow rate in the recirculation line is usually measured
by the following portable gauges during an inspection:
a. inductance ammeter
b. thermocouples
c. pitot tube
d. none of the above
5. Demister pluggage is usually caused by
a. inadequate cleaning of the demister
b. excessive gas velocity through the demister
c. high suspended solids in the recirculation liquor
d. low pH
e. high pH
6. Typical gas velocities through a demister are
a. 1 to 5 feet per second
b. 5 to 20 feet per second
. OO ^ _ A <~\ f _ _ ^ _.__ _ _. .^ ^ ,_. ..
d
j tu tu ieet per seuunu
20 to 40 feet per second
greater than 40 feet per second
5-6
-------
7. Scaling in a wet scrubber is frequently caused by
a. rusting of the carbon steel shell
b. low pH
c. pH levels above 11
8. The compliance status of a wet scrubber can be determined based
on .
a. the opacity
b. the contact power level
c. the Method 5 mass emission rate
d. the pressure drop
e. all of the above
9. Evaporation of atomized liquor droplets in the inlet of a venturi
scrubber could lead to .
a. particle agglomeration
b. particle regeneration
c. increased mass emissions from the system
d. increased suspended solids levels in the recirculation
liquor
10. Pressure drop in a venturi scrubber occurs because
a. acceleration of the liquor injected into the throat
b. acceleration of the gas in the throat
c. wall friction
d. impaction of the particles into the droplets
11. Outlet static pressure of a venturi scrubber should be evaluated
at the .
a. a point directly downstream of the throat
b. a point approximately halfway down the diverging section
of the venturi
c. a point near the elbow leading to the cyclonic separator
d. a point following the demister
e. none of the above
12. A make-up stream is necessary to
a. replace water lost due to evaporation
b. replace liquor in the recirculation line
c. replace liquor used in the demister flush system
d. replace liquor lost in the purge stream
5-7
-------
13. The use of liquor with high levels of suspended and dissolved
solids in the presaturator could potentially lead to
a. particle agglomeration
b. scaling in the presaturator
c. particle regeneration
d. demister pluggage
14. Alkaline additives are used in wet scrubbers to
a. reduce scaling potential
b. increase the pH
c. reduce corrosion
d. none of the above
15. Nozzle pluggage in spray tower scrubbers is often due to
a. scale from corroded pipes
b. high suspended solids in the recirculation line
c. operation at low pH
d. none of the above
16. The collection efficiency of particles which form from the
condensation of vapors in the throat of a venturi scrubber is
usually .
a. low
b. high
17. The overall penetration through a scrubber with a collection
efficiency of 98% is .
a. 0.01
b. 0.02
c. 1
d. 2
e. 0.98
f. none of the above
18. Most venturi scrubbers for particulate control operate at a liquid-
to-gas ratio of .
a. 0 to 2 gallons per 1000 ACF
b. 2 to 5 gallons per 1000 ACF
c. 5 to 20 gallons per 1000 ACF
d. 20 to 50 gallons per 1000 ACF
5-8
-------
19. Packed tower scrubbers are used primarily for
20.
21,
23.
a. removal of particles in the 1 to 5 micron size range
b. absorption of gases
c. humidification
d. removal of particles in the 0.1 to 1.0 micron size range
The liquor recirculation rate can sometimes be qualitatively
evaluated by .
a. observing the length of the steam plume
b. observing the rate of discharge from the sump
to the recirculation tank
c. measuring the pump R.P.M.
d. none of the above
of a venturi
Most particle impaction occurs in
scrubber.
a. the converging section
b. the throat
c. the diverging section
d. the cyclonic separator
e. the demister
22. A flooded elbow in a venturi scrubber is used primarily to
a. minimize the potential of sump overflow
b. minimize erosion at the bottom of the venturi
c. improve particle collection efficiency in the
cyclonic separator
d. none of the above
Collection efficiency of a venturi scrubber can usually be
improved by .
a. increasing the liquid-to-gas ratio
b. increasing the length of the venturi throat
c. increasing the gas velocity through the venturi throat
d. al1 of the above
e. none of the above
24. Corrosion of scrubbers may be minimized by
a. using alkaline additives
b. maintaining the pH at low levels
c. use of protective liners
d. none of the above
5-9
-------
25. Corrosion of scrubbers is accelerated by
a. potassium in the scrubbing liquor
b. chlorides in the scrubbing liquor
c. sodium in the scrubbing liquor
d. iron in the scrubbing liquor
e. all of the above
5-10
-------
Review Exercise Answers and Reading Information
Question
Number and
Answer
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
c
a,d
b
d
a,c,e
b
c
a,c
b,c
a.b.c
d
a,d
c
b,c
a,b
a
b
c
b,c
d
Page(s) in Page(s) in
Wet Scrubber Baseline
Manual Manual
2-12 to 4-1
2-13
2-10 to 4-1
2-11
3-3 4-12
4-7 4-11,4-7
1-1
2-15 to 4-12
2-16
2-17
4-8
2-6
2-15 to 4-12
2-16
2-7
4-22
2-17
A-l to A-5
2-38
4-23 4-4
Page(s) in
Field Page(s) in
Inspection Supplemental
Notebook References
40 to 41 #1 Sections
4.3.3 and 5.3
41 to 41 #1 Sections
4.3.3 and 5.3
47 #3 7 to 40
43 to 46 #2 All
61 to 64
46,64 #4 xv to xix
#4 All
#5 4.5-37
#6 36 to 40
59
45,63
5-11
-------
Question
Number and
Answer
21.
22.
23.
24.
25.
b
b
b,c
a,c
b
Page(s) in Page(s) in
Wet Scrubber Baseline
Manual Manual
4-29 4-5
4-35
2-10 to 2-12
2-37 to 2-38
3-3 4_12
Page(s) in
Field Page(s) in
Inspection Supplemental
Notebook References
41 #6 61 to 110
#6 61 to 110
47,54,64 #3 34 to 39
#3 34
5-12
-------
LESSON 6
Inspection and Evaluation of Mechanical Collectors
Reading Assignments
Baseline Manual, Chapter 5.
Field Inspection Notebook, pages 32 to 39.
Reading Assignment Topics
o The components and operating principles of cyclones and
multiple cyclone collectors.
o The importance of particle size on the collection efficiency
of mechanical collectors.
o The importance of gas flow rate on the collection efficiency
of mechanical collectors.
o Technique for correcting measured pressure drop back to
standard conditions in order to evaluate shifts from baseline
operating conditions.
o Techniques for evaluating air infiltration into mechanical
col lectors.
o General inspection points for mechanical collectors.
Learning Goal and Objectives
Learning Goal
To familiarize you with the basic operating principles of cyclone and
of multiple cyclone type mechanical collectors, and to familiarize you
with an effective methodology for inspecting these devices.
Learning Objectives
When you have completed this lesson, you should:
1. Know what the inspection data is necessary to complete a detailed
evaluation of a mechanical collector.
2. Understand what portable instruments are needed and when they should
be used.
3. Understand how to correct the observed pressure drop for the
present gas density and gas flow rate.
6-1
-------
4. Understand how to recognize the common operating problems of mechanical
collectors.
5. Understand the major factors which influence the collection efficiency
of mechanical collectors.
Reading Guidance
o Only cyclones and multiple cyclone type collectors are addressed
in this lesson. For information concerning other types of mechanical
collectors refer to the Particulate Control Techniques Document,
Second Edition, Section 4.2 (see Supplemental References).
o The inspection procedures and the evaluation techniques rely on
measurements of the static pressures, gas temperatures, and gas
stream oxygen concentrations. A large number of existing units
do not have measurement ports which can be used to obtain this
data. Many also do not have an operating differential pressure
gauge. Without these measurement ports and instruments the in-
spection is limited simply to the stack opacity. This, unfortu-
nately, can be misleading since on many sources the mass emissions
may be high while the opacity is in the moderate to low range.
o Some mechanical collectors do have measurements ports before and
after the collector, however, they are located in areas where
there is poor access and a potential for burns. For example,
there are some mechanical collectors which are located just above
the steam drum area of a stoker fired boiler. In these dimly lit
and limited access areas, it is sometimes risky to attempt to
measure the collector operating parameters. Unless there is safe
and convenient access to the measurement ports, the measurements
should not be made.
o It is important to correct all static pressure drop measurements
back to a standard temperature and gas flow rate. The procedure
for making the necessary corrections should be read carefully.
o When you have finished the reading assignment, complete the review
exercise for Lesson 6. It begins on the page following the
Supplemental References.
o After you have answered the review exercise questions, check your
answers. The correct answers are listed on the page immediately
following the review exercise. Note that many of the questions
have more than one correct answer.
o For any review exercise questions that you answered incorrectly,
review the page of the reading assignment indicated on the answers
page.
o After you have reviewed your incorrect answers (if any), proceed
to Quiz 2 and then Lesson 7 of this guidebook.
6-2
-------
Supplemental References
1. Control Techniques for Participate Emissions from Stationary
Sources - Volume I, U.S. Environmental Protection Agency
Publication EPA-450/3-81-005a, September 1982.
2. Industrial Ventilation, Sixteenth Edition. Published by the
American Conference of Governmental Industrial Hygienists,
Lansing Michigan. 1980.
6-3
-------
Review Exercise
1. The principal mechanism used to separate particles from the gas
stream in a mechanical collector is .
a. Brownian diffusion
b. inertia
c. diffusiophoresis
d. thermophoresis
e. al1 of the above
2. The typical tube diameters of cyclone tubes in multi-cylcone collectors
ranges from to inches.
a. 1 to 12
b. 3 to 36
c. 3 to 12
d. 12 to 36
e. none of the above
3. As the gas flow rate decreases from design levels, the particulate
matter collection efficiency increases (assume all other factors
remain constant).
a. t ru e
b. false
4. In multiple cyclone type collectors the vortex in the individual
tubes is created by .
a. by the tangential inlets
b. by the axial inlets and spinner vanes
c. by the rotary discharge valve
5. When large diameter cyclones are operated at gas flow rates above
the design level, the collection efficiency usually .
a. usually decreases due to increased turbulence within the
cylindrical section of the cyclone tube
b. remains at approximately the same efficiency as when the gas
flow rate is at the design flow rate
c. usually increases due to enhanced inertial separation
6. Some of the operating problems common to multiple cyclone type collectors
include the following:
a. air infiltration
b. inlet vane pluggage
c. dust discharge tube pluggage
d. outlet tube pluggage
e. maldistribution of gas
f. hopper recirculation
g. corrosion
h. poppet valve failure
i. outlet tube erosion
j. all of the above
6-4
-------
7. The static pressure drop across a cyclone tube is proportional
to the of the gas flow rate.
a. cube
b. square
c. square root
d. log
e. none of the above
8. In order to evaluate the pressure drop across a multiple cyclone
type collector the following data is necessary:
a. the gas temperature
b. the gas stream 63 content
c. the inlet static pressure
d. the outlet static pressure
e. the gas flow rate
f. the inlet mass concentration
g. all of the above
9. Possible ways to estimate the present gas flow rate through a
mechanical collector serving a coal-fired boiler include the
following:
a. pitot tube
b. Fyrite® analyzer
c. estimate using the boiler steam rate
d. al1 of the above
10. If the corrected pressure drop value is higher than the corrected
baseline pressure drop, the following conditions are possible:
a. pluggage of the inlet vanes
b. erosion of the outlet tube extension
c. weld failure on the clean side tube sheet
d. pluggage of the outlet tube
e. pluggage of the solids discharge hole
f. air infiltration
11. Techniques to evaluate air infiltration on mechanical collectors
serving boilers includes the following:
a. listen for audible leaks
b. look for cracks or weld gaps in the shell
c. look for missing solids discharge valves
d. evaluate inlet and outlet 02 concentrations
6-5
-------
12. Opacity spikes at the exit of a mechanical collector usually
suggest the following:
a. excessive rapping intensities
b. vibration of the spinner vanes
c. intermittant process related conditions
d. all of the above
13. Deformation of the hopper walls on a multiple cyclone type
collector often suggests ,
a. solids discharge problems
b. previous hopper fires
c. aggressive maintenance personnel
d. frustrated maintenance personnel
e. al 1 of the above
14. Internal inspections of multiple cyclone collectors should be
done .
a. by inspectors whenever the corrected pressure drop suggests
pluggage problems
b. by inspectors whenever the 62 levels increase by more than
1% going from the inlet to the outlet
c. by operators whenever there are symptoms of major operating
problems and the proper lockout procedures have been
followed
d. by operators on at least an annual basis
6-6
-------
Review Exercise Answers and Reading Information
Question
Number and
Answer
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
b
c
b
b
a
a,b,c,d
e,f,g,i
b
a.c.d.e
a,c
a,d
a,b,c,d
c
e
c,d
Page(s) in
Baseline
Manual
5-1
5-3
5-2
5-3
5-2
5-3 to 5-4
5-4
5-4
5-4
5-5
Page(s) in
Field Page(s) i n
Inspection Supplemental
Notebook References
33 #1 Section 4.2.1
33
33 #1 4.2-25
32
37 to 39 #1 4.2-31 to 4.2-33
37 #2 6-14
37
37
39
37 to 38
36
38
38 to 39
6-7
-------
QUIZ 2
The self-administered and self-graded quiz covers the material
presented in Lessons 4 through 6. It introduces the type of questions
and problems which will appear on the final and is open book. The final,
however, will only allow use of the Field Inspection Notebook. Access to
a calculator for both the quiz and final will be helpful.
The quiz consists of 25 multiple choice questions and problems.
There may be more than one correct answer for each question. You should
use a separate sheet of paper to record your answers and scratch paper to
work the problems. The answers can be found on the page following the
last question.
Q2-1
-------
1. There is a two chamber electrostatic precipitator having four fields
in series. The Transformer-Rectifier set numbering system is shown on
the sketch provided below. In what order should the electrical data
be recorded on the inspection notes?
a. the way the cabinets are laid out in the control room or substation
b. SI, S2, S3, S4, Ml, N2, N3, N4
c. S4, S3, S2, SI, N4, N3, N2, Nl
d. Nl, SI, N2, S2, N3, S3, N4, S4
e. none of the above
N4
1
S4
N3
S3
N2
S2
Nl
si !
2. The following electrical data was recorded during an inspection. What
is the total power input to this one chamber unit? (Use a spark rate of
35 in each field, a power factor of 0.75, a gas temperature of 350°F,
gas stream flow rate of 250,000 ACFM, if necessary to complete the cal-
culations. )
a. 484 watts/1000 ACFM
b. 2417 watts/1000 ACFM
c. 2860 watts/1000 ACFM
d. 3813 watts/1000 ACFM
Field
1
2
3
Primary
Voltage,
Volts, A.C.
259
298
260
Primary
Current,
Amps, A.C.
128
228
232
Secondary
Current,
Mi 11iamps, D.C.
730
1370
1370
Q2-2
-------
3. The electrical data
been plotted below.
from a one chamber electrostatic precipitator has
What does the data suggest?
a.
b.
c.
d.
e.
the rappers are obviously not operating properly
the dust resistivity has increased since the baseline period
the boiler load has decreased
one or more fields has serious malalignment problems
the dust resistivity has decreased since the baseline period
c Condition*
Rappers are often used on which of the following components of an
electrostatic precipitator system?
a. collection plates
b. discharge electrodes
c. insulators
d. gas distribution plates
e. transformer-rectifier sets
The gas flow through an electrostatic precipitator is 275,000 ACFM
and the unit has the following dimensions: length 50 feet, height
36 feet and width 25 feet. What is the superficial veloci through
the treatment zone (velocity across the face of the ESP)?
a.
b.
c.
d.
e.
3.67 feet per second
5.09 feet per second
2.55 feet per second
none of the above
it cannot be calculated using only the data given
Q2-3
-------
One field of an electrostatic precipitator had the following operating
conditions: secondary voltage 43 KV, secondary current 520 milliamps,
spark rate 10 per minute. What is the power input from this one field?
(Use the following data if necessary to complete the calculations:
power factor 0.75, gas temperature 320°F.)
a. 16,770 watts
b. 16.8 kilowatts
c. 22,360 watts
d. 2.24 kilowatts
The power input is a useful parameter to evaluate the operating condi-
tions of the electrostatic precipitator only when the following are true:
a. the resistivity is in the low to moderate range
b. the resistivity is in the moderate to high range
c. the gas velocity is below 3 feet per second
d. the gas velocity is between 3 and 8 feet per second
e. the gas velocity is above 8 feet per second
During an inspection the electrical
pitator was plotted as shown below.
this data?
data from an electrostatic precv
What would be suspected from
a. the fuel sulfur content has decreased substantially
b. the dust resistivity has increased since the baseline period
c. the collection plate rappers are not working properly
d. the gas velocity has increased substantially
Hot.: A Fl.ld 1> lol.t,
D Plaid Is Outlet
Q2-4
-------
9. When the dust resistivity is low there is increased potential for the
fol1owi ng:
a. hopper overflow
b. rapping reentrainment
c. hopper boil over
d. reduced secondary currents
e. increased spark rate
10. The secondary voltage is the voltage on the .
11,
12.
is noticed
should the
a. collection plate
b. discharge electrode
c. rapper
d. linear reactor
During the inspection of an electrostatic precipitator, it
that there is a 40% opacity puff every five minutes. What
inspector check?
a. the rapping frequency
b. the rapping intensities
c. the general range of the dust resistivity
d. the purge air blowers for the insulators
e. air infiltration through the hopper hatches
The photograph below shows the bottom section of a hopper on an elec-
trostatic precipitator. This unit serves a municipal incinerator.
The fan for the system is downstream of the precipitator, therefore,
there is a slight negative pressure on the precipitator. There is no
dust discharge valve on the hopper and the screw conveyor. What prob-
lems, if any, could this cause?
a. increased dust resistivity in the part of the precipitator directly
above this hopper
b. dust discharge problems caused by the inrushing ambient air
c. corrosion of the collection plates and discharge electrodes due to
the condensation of vaporous material directly above this hopper
d. deposits on the high voltage insulators
e. corrosion of the Transformer-Rectifier sets
Q2-5
-------
13. During an inspection of an electrostatic precipitator, the following
plots of the electrical data were prepared. What is the most likely
explanation of the conditions shown?
a. an increase in the dust resistivity
b. a decrease in the dust resistivity
c. an internal problem in field 3
d. an advanced voltage controller in field 3
e. none of the above
Note: A flild Is Inltc
0 Field la Ouclct
14. An internal inspection of an electrostatic precipitator should be con-
ducted by an agency inspector when .
a. there are indications of misaligned plates and wires based on the
secondary voltages and currents
b. there are indications of poor gas distribution and the source is
making major modifications to the precipitator inlet
c. there are symptoms of rapping reentrainment
d. the operator has reported severe corrosion problems
e. when hell freezes over
Q2-6
-------
15. What would be the expected pressure drop during the inspection assum-
ing that the condition of the mechanical collector was identical to
that during the baseline stack test? (Assume a flue gas moisture
content of 0.1 pounds per pound of dry air.)
a. 1.45" of water
b. 2.40" of water
c. 3.80" of water
d. 4.00" of water
16. During the inspection of a mechanical collector serving a spreader
stoker type boiler, the following data is obtained: Inlet Static
Pressure -2.1 inches, Inlet 02 12.6%, Inlet C02 6.5%, Inlet Temperature
380°F, Outlet Static Pressure -5.6 inches, Outlet 02 13.2%, Outlet
C02 6.2%, Outlet Temperature 366°F. What should be the main focus of
the inspection based on this data?
a. the measurements should be repeated since the data is obviously in
error
b. checks should be made to locate where the ambient air is infiltrat-
ing into the mechanical collector
c. the boiler should be inspected to determine why the excess air
rate is so high
d. an internal inspectionn of the mechanical collector should be con-
ducted
17. Erosion of the outlet tube extensions on a multiple cyclone type col-
lector would cause which of the following problems:
a. increased static pressure drop
b. air infiltration
c. reduced static pressure drop
d. increased opacity
e. decreased opacity
18. A packed tower wet scrubber is generally used for .
a. collection of submicron particulate matter
b. collection of particulate matter in sources with high mass
concentrations
c. gas pollutant absorption
d. collection of sticky aerosols
19. The most useful parameter for correlating scrubber particulate removal
efficiency is the following:
a. pressure drop divided by the gas temperature (average of inlet
and outlet)
b. pressure drop
c. pressure drop divided by the gas density (average of inlet and out-
let)
d. pressure drop divided by the gas velocity (average of inlet and out
let)
e. relative motion of the stars and planets
Q2-7
-------
20.
21.
The primary physical mechanism used to collect particles in
scrubbers is the following:
wet
a. gravity settling
b. interception
c. impact ion
d. electrostatic attraction
e. diffusiophoresis
f. thermophoresis
During an inspection of a wet scrubber system, it is noticed that the
I.D. fan is vibrating severely. What should the inspector do?
a. first, evaluate conditions which could lead to build up of material
on the fan, such as poor demister operation
b. carefully measure the fan R.P.M. and motor current
c. check the outlet damper position
d. leave the area immediiately
e. leave the area immediately and notify a responsible plant
official of the fan condition
22. Specify the two conditions which must exist in order for there to be
regeneration of aerosols in a particulate wet scrubber.
a. low pressure drop and low liquor flows
b. erosion of the pump impeller and high pressure spray nozzles
c. high liquor total solids and evaporation of some droplets to dryness
d. precipitation of solids out of solution of a low pH
23. An inspection of a multiple cyclone type collector serving a coal-
fired boiler yielded the following data. The baseline data came from
a stack test conducted several years before the inspection. Based on
the data, what conclusions can be made without making any calculations
(assume gas flow rate is proportional to steam rate).
Inspection Data
Inlet Static Pressure:
Outlet Static Pressure:
Inlet Gas temperature:
Outlet Gas Temperature:
Inlet 02:
Outlet 02:
Inlet C02:
Outlet C02:
Boiler Steam Flow:
-2.8"
-6.6
412°F
403°F
7.4%
8.0%
12.3%
12.0%
60,000
Lbs/hr
Baseline Data
Pressure Drop:
Inlet Gas Temperature:
Stack Temperature:
Inlet 02:
Stack 02:
Inlet C02:
Stack C02:
Boiler Steam Flow:
4.0 inches
Not measured
426°F
Not recorded
8.2%
Not recorded
11.3%
100,000
Lbs/hr
a. the resistance to gas flow is substantially higher, therefore,
there may be some pluggage of the spinner vanes or the outlet tube
b. the resistance to gas flow is substantially lower, therefore, there
may be some erosion of the outlet tube extensions
c. there are signs of severe air infiltration
d. no conclusions can be reached since the baseline data set
plete
is incom-
Q2-8
-------
24. Alkaline material is often injected into wet scrubber systems for the
following reason .
a. to reduce corrosion
b. to provide a convenient disposal means for unwanted waste materials
c. to prevent erosion of spray nozzles
d. none of the above
25. The pH measured in the scrubber sump was 4.2. If the scrubber is
made of carbon steel is there reason for concern?
a. no
b. yes
Q2-9
-------
LESSON 7
Inspection and Evaluation of Carbon Bed Adsorbers
Reading Assignment
Baseline Manual, Chapter 6.
Reading Assignment Topics
o Basic operating principles of carbon bed adsorbers.
o Basic configuration of carbon bed systems.
o Carbon bed system modes of failure.
o Methods of evaluating adsorption efficiency.
o Visual inspection techniques.
Learning Goal and Objectives
Learning Goal
To familiarize you with the basic operation, of a carbon bed adsorption
system and with several readily available techniques which may be
used to evaluate the effectiveness of operating systems.
Learning Objectives
When you have completed this lesson, you should be able to:
1. Draw a schematic of a typical carbon adsorption system and explain
its basic operation.
2. Explain what "breakthrough" is.
3. Discuss how carbon adsoprtion systems are controlled.
4. Describe three methods to evaluate the current efficiency of an
operating carbon adsorption system.
5. Enumerate several visual inspection points for carbon bed
adsorbers.
Reading Guidance
o The carbon bed adsorption system inspection techniques presented
in the reading are indications of present system efficiency; they
are not strict tests of compliance with regulations.
7-1
-------
In evaluating a carbon bed adsorber, the agency inspector should
always be accompanied by one or more plant representatives
(ideally including the system operator) to assist in locating
system components, explaining current process parameters, and
identifying safety hazards.
When you have finished the reading assignment, complete the review
exercise for Lesson 7. It begins on the following page.
After you have answered the review exercise questions, check your
answers. The correct answers are listed on the page immediately
following the review exercise. Note that many of the questions
have more than one correct answer.
For any review exercise questions that you answered incorrectly,
review the page of the reading asssignment indicated on the answers
page.
After you have reviewed your incorrect answers (if any), proceed to
Lesson 8 of this guidebook.
7-2
-------
Review Exercise
1. Carbon adsorption is a technique used for the removal of particulate
matter and organic vapors from a gas stream.
a. true
b. false
2. The adsorption process is made possible by the following properties
of the carbon adsorbant:
a. porosity
b. capillary action
c. secondary bonding to organics
d. high ratio of surface area to volume
e. all of the above
f. none of the above
3. Breakthrough control of carbon bed regeneration/adsorption cycles uses
an operator set time period for the adsorption cycle.
a. true
b. false
4. In the regeneration process, the organics are desorbed from the
carbon by passing steam or hot gases through the bed counter-current
to the flow of gases during adsorption.
a. true
b. false
5. Regulatory agency personnel can generally detect the following
failure modes in carbon bed adsorption systems:
a. insufficient steam flow compared to design value
b. improper setting of system controls
c. loss of carbon activity
d. poor steam distribution
e. probable decrease in efficiency compared to original
efficiency
6. It is important that an overall system material balance be taken
over a time period long enough to smooth out variability in solvent
and material usage and solvent recovery.
a. true
b. false
7-3
-------
Corrosion in the steam exhaust piping of an adsorber can be
caused by •
a. superheated steam
b. acid formed by the combination of steam and organics
c. abrasive particulate in the exhaust gas stream
d. additives at the condenser
During an inspection of a carbon bed adsorption system, plant
personnel informed the inspector that 500 Ibs. of solvent were
recovered for every 2,000 # of steam used. When the system was
first installed it was recovering 350 Ibs. for every 1,000 # of
steam. If the inspector assumes a constant solvent input into the
system and constant adsorption cycles he would conclude that
a. there has been an increase in collection efficiency
b. there has been a decrease in collection efficiency
c. there has been no change in collection efficiency
An operator should consider readjusting adsorption/regeneration
cycle times ,
a. if breakthrough is detected
b. when a visit from the agency inspector is expected
c. when there is a change in plant operating conditions
d. only if the system utilizes breakthrough control
The figure below shows the discharge concentration vs. time for a
carbon bed. Refer to it to answer Questions 10 through 12.
GOO
100
300
200
100
50
A
r
o
1
12345
us 3O
On-Stream Time (Minutes)
7-4
-------
10. Breakthrough occurs at the point labeled
a. A
b. B
c. C
d. D
e. E
f. F
11. A reasonable adsorption cycle time for this bed in a system with
set cycle automatic control would be .
a. 15 minutes
b. 25 minutes
c. 30 minutes
d. 35 minutes
e. all of the above
f. none of the above
12. An instrument to be used to detect organics in the discharge gas
stream for this system should measure accurately in the
a. 0-20 ppm range
b. 0-50 ppm range
c. 0-200 ppm range
d. 200-1000 ppm range
Klean Coaters is able to provide the following process and solvent
recovery data for one line in its plant controlled by a carbon bed
system.
solvent A: purchased is 400 Ibs./month
coating b: contains 40% solvent
purchased is 200 gals/month
density is 6 Ibs./gal
solvents recovered: 1,613 Ibs./month
recovered solvent sold: 813 Ibs./month
13. Using an overall system material balance an estimate of Klean Coaters
carbon system efficiency is:
a. 90%
b. 92%
c. 96%
d. 98%
14. Klean Coaters recycles approximately percent of the solvents
from their recovery system.
a. 35%
b. 50%
c. 75%
d. none of the above
7-5
-------
Refer to the schematic of a typical carbon bed adsorption system
(on the following page) to answer Questions 15 through 17.
15. Because this system is under pressure, the inspector
be concerned with gas leakage from sampling ports
and/or ductwork.
a.
b.
c.
d.
negative,
negative,
positive,
positive,
should not
should
should not
should
16. Discharge monitoring would most likely be accomplished at
a.
b.
c.
d.
e.
f.
g.
h.
point A
point B
point C
point D
point E
points A
points B
none of
and
and
the
C
D
above
17. If valves #1 and #2 are open then Vessel 2 must be
a. in the cooling and drying cycle
b. in the adsorption cycle
c. in the regeneration cycle
d. off-line
7-6
-------
Steam
To Atmosphere
Vessel 1
'• *.•'•;• •'•• i- '••.••" •:.:: :.'•*\'-.
-V.Y-.-.Car bbn Bed •'.•''-
Vessel
Solvent
Laden
Air
Cooling
Water
Condenser
Recovered
Solvent
1-1
-------
Revciew Exercise Answers and Reading Information
Question
Number and
Answer
1. b
2. e
3. b
4. /*
5. a, b, e
6. /b j
7. d'i
8. a-, — e- *>
9 . d ''i -> cT
10. £ _:_
11. /^
12. .c L
13. c
14. d r.
15. d
16. f
17. b
Page(s) in
Baseline
Manual
6-1
6-1
6-4
6-4 to 6-%
6-7
' > -' A .'.
6-l^.ie-^?
;-1 <>" ~'
6-1 to 6-4
6^6 ^- r
general
6-5
6-1 to 6-4
f*-*--
•-Z- c.- /
-49 ;-
-6^5-
-------
LESSON 8
Inspection Safety
Reading Assignments
Baseline Manual, Chapter 11, Appendix D. and Appendix E.
Field Inspection Notebook, inside front and back covers and page 68.
Reading Assignments Topics
o Potential hazards of inspecting air pollution control equipment.
o Recognition of and dealing with potential hazards.
o Personal protective equipment.
o Confined and partially confined area entry.
o Relationship between agency safety procedures and plant
safety requirements.
Learning Goal and Objectives
Learning Goal
To familiarize you with the potential safety hazards encountered in
inspecting industrial plants and the procedures required to properly
minimize these hazards.
Learni ng Objecti ves
When you have completed this lesson, you should be able to:
1. Describe the hazards involved in moving from one place to another in
an industrial plant.
2. List at least ten nonspecific symptoms of exposure to air
contami nants.
3. Recognize the importance of personal protection equipment for a
variety of inspection situations.
4. Explain considerations in the selection and use of respiratory
protecti on.
5. Discuss the hazards involved in confined and partiallv confined
area entry, particularly as related to air pollution control
equi pment.
8-1
-------
6. Explain the significance of using probe grounding techniques in sampl-
ing process gas streams.
7. Briefly describe the consequences of heat and cold stress.
8. Explain the safety considerations for working near nuclear type
detectors.
Reading Guidance
o The reading assignments for this lesson were written for both
regulatory agency and plant maintenance personnel. Regulatory
agency personnel should be aware that some procedures are not
recommended for them such as confined area entry and have been
presented only as guidance for maintenance personnel.
o It is not possible in these reading assignments to cover every
possible hazard in an industrial plant, rather the information has
been developed to aid inspection and maintenance personnel in
considering and handling the possibilities. Every plant situation
is different and warrants separate considertion.
o One point that cannot be overemphasized is that, in the process
of evaluating air pollution control equipment performance,
inspection and maintenance personnel must constanting be alert
to their surroundings and current situation in order to recognize
potential or imminent hazards.
o It is also important to stress the observation of all plant safety
rules, knowledge of plant emergency procedures, and, for inspection
personnel, having a plant official accompanying you on the inspec-
tion to aid in forseeing hazards and to assist in an emergency.
o When you have finished the reading assignment, complete the
review exercise for Lesson 8. It begins on the following page.
o After you have answered the review exercise questions, check
your answers. The correct answers are listed on the page
immediately following the review exercise. Note that many of
the questions have more than one correct answer.
o For any review exercise questions that you answered incorrectly,
review the page of the reading assignment indicated on the
answers page.
o After you have reviewed your incorrect answers (if any), proceed
to Lesson 9 of this guidebook.
8-2
-------
Review Exercise
1. The following symptoms may indicate exposure to air contaminants:
a. headache
b. drowsiness
c. shortness of breath
d. nausea
e. loss of coordination
f. eye irritation
g. al1 of the above
h. none of the above
2. Static electricity is especially likely following
a. a wet scrubber
b. a fabric filter collection dry dust
c. electrostatic precipitation
d. mechanical collection
e. al1 of the above
3. Hearing protection is necessary whenever normal conversation
cannot he heard at a distance of feet.
a. 1
b. 2 or 3
c. 5
d. 10
4. Most types of hearing protection reduce noise intensity in the
1000 Hz to 4000 Hz range by .
a. 5 to 10 dB
b. 10 to 25 dB
c. 30 to 50 dB
d. 50 to 75 dB
5. Fan disintegration can be caused by
a. operating at excessive tip speeds
b. operating out of balance due to build-up of material or
erosion of the fan wheel
c. operating at high gas temperatures
6. At high concentrations hydrogen sulfide has odor.
a. a rotten egg
b. a sewer
c. a fragant
d. no
8-3
-------
7. If an inspector experiences the nonspecific symptoms of exposure to
gases and vapors, he or she should
a. discuss the potential exposure with plant personnel
b. continue with the inspection until more definite symptoms
develop
c. leave the area immediately and reevaluate the conditions
d. al1 of the above
8. Cartridge type respirators are usually rated at
a. concentrations twice on PEL
b. concentrations five times the PEL
c. concentrations ten times the PEL
d. concentrations fifty times the PEL
9. When climbing ladders, inspectors should keep their hands on the
a. side rails
b. foot rails
c. either
10. The use of hearing protection in high noise areas hinders normal com-
munication .
a. true
b. false
11. Common "partially" confined areas include
a. walkways between large control systems
b. weather enclosures around hoppers
c. weather enclosures around precipitator roofs
d. pump houses
e. fan houses
f. mountings for continuous emission monitors
g. all of the above
12. "Partially" confined areas are particularly dangerous when
a. the ducts or control equipment operate at positive pressure
b. the gas streams contain asphyxiants and toxic agents
c. the gas streams contain dusts and fumes
d. all of the above
13. Before inserting a probe into a gas stream it is important to check
»
a. that the grounding cable is in good physical condition
b. that the ground clamp does not interfere with the probe
c. that the clamp has penetrated any paint or corrosion layer
on the grounding point
d. all of the above
8-4
-------
14. Ionizing radiation may be a problem around
a. electrostatic precipitator rappers
b. continuous emission monitors
c. damaged hopper level monitors
d. electrostatic precipitator electrical cabinets
15. Falls may be caused by
a. slippery surfaces around wet scrubbers
b. climbing ice covered ladders
c. crossing roofs with heavy accumulations of snow or solids
d. protruding equipment in dimly lit areas
e. al1 of the above
16. Prior to using a respirator, an inspector should
a. be trained in the selection and use of respirators
b. be trained in the maintenance of respirators
c. have a physical examination
d. all of the above
17. When selecting what personal safety equipment is necessary during an
inspection, an inspector should be guided by .
a. what the plant representative and other plant personnel are
using
b. plant policies
c. agency policies
d. common sense
18. Exposure to particulate and gaseous contaminants often may result from
a. downwash of effluent from short stacks
b. fugitive leaks from ducts and hatches into partially
confined areas
c. fugitive leaks through open static pressure taps
d. fugitive leaks around process equipment
e. all of the above
19. Safety shoes should be worn
a. only when required by plant policies
b. only when required by agency policies
c. for all plant inspections
d. when specifically required for plant entry
8-5
-------
20. An inspector should not work alone during an inspection, unless
•
~~a~. plant personnel are too busy to accompany the inspector
b. the inspector is very familiar with the plant
c. no entry into partially confined or confined areas is
anticipated
d. the inspector has all the necessary personal protection
equipment
e. none of the above
21. Burns may be caused by
a. contact with hot gas ducts
b. contact with measurement probes, such as pitot tubes
c. radiation from process equipment
d. high pressure steam leaks
22. High noise levels are frequently found near
a. fans
b. pulse jet fabric filters
c. electrostatic precipitator rappers
d. process equipment such as compressors and
grinding mills
e. rotary discharge valves
23. The suspension of the hard hat needs to be checked at least .
a. once a day
b. once a week
c. once a month
d. once a year
e. never
24. Most gaseous contaminants have good "warning properties" therefore the
inspector is usually aware that they are present.
a. true
b. false
25. A self-contained rebreather is necessary whenever work is required
around areas which
a. have less than 19.5 % oxygen
b. have gaseous concentrations that exceed the safe limit of
the cartridge and canister type respirators
c. have less than 16% oxygen
d. have less than 12% oxygen
e. have high carbon monoxide levels
8-6
-------
26. The most common routes of entry of toxic compounds include
a. the eyes
b. the respiratory system
c. the skin
d. ingestion
e. al1 of the above
27. Hazards of opening access hatches include:
a. asphyxiation due to free flowing solids found in hoppers
b. positive pressure systems creating force on the interior
of hatch
c. control device fires
d. burns from hot solids
e. hand injuries from "breaking the seal" of the hatch
in a negative pressure system
28. Eye protection used during an inspection should conform with plant
requirements. It is generally recommended that the inspector carry
and use .
a. prescription glasses
b. safety glasses
c. flexible goggles
d. prescription or nonprescription safety glasses with side
shields
29. Contact lenses should not be worn during inspections.
a. true
b. false
30. Respirator or gas mask cartridges and canister air purifying capabil-
ities are identified by both worded labels and a color code.
a. true
b. false
31. The use of a respirator exposes a worker to additional stress.
a. true
b. false
8-7
-------
Review Exercise Answers and Reading Information
Question
Number and
Answer
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
g
b,c
b
c
a,b,d
d
c
c
b
b
9
d
c
c
e
d
b,c,d
e
c
e
a,b,c,d
a,b,c,d
c
b
Page(s) in Page(s) in
Baseline Field Inspection
Manual Notebook
11-5 to 11-11
11-1, 11-15, 11-16
11-2, 11-3
11-2, 11-3
11-2
11-9
11-2, 11-3
E-12
11-12
11-12, 11-13
11-17 to 11-21
11-17 to 11-21
11-15 to 121-17
11-17, 11-18
11-6, 11-12
11-5 to 11-11 and D-l to D-10
11-1 to 11-21
11-1 to 11-21
11-14
11-1, 11-2
11-12
11-13
11-5 to 11-11
front cover
front cover
front cover
front cover
front cover
front cover
front cover
back cover
back cover
back cover
front cover
back cover
8-8
-------
Question
Number and
Answer
25.
26.
27.
28.
29.
30.
31.
a,b,c,d,e
e
a.b.c
c,d
a
a
a
Page(s) in
Baseline
Manual
11-5, 11-6, 11-18
11-1, to 11-21
11-2, 11-19
11-13, 11-14
11-14
D-8
11-21
Page(s) in
Field Inspection
Notebook
front cover
8-9
-------
LESSON 9
Visible Emission Observation
Reading Assignments
Baseline Manual, Chapter 10 and Appendix C.
Field Inspection Notebook, pages 77 and 78.
Reading Assignment Topics
o Opacity readings as a diagnostic tool.
o Effect of the angle of observation on the observed opacity.
o Factors which can interfere with opacity readings such as
water vapor plumes, fugitive emissions, or detached plumes.
o Opacity-mass correlation.
o Effects of particle size.
Learning Goal and Objectives
Learning Goal
To familiarize you with the use of opacity observations as a diagnostic
tool including certain procedures for making accurate readings and the
limitations of the method.
Learning Objectives
When you have completed this lesson, you should be able to:
1. Explain the use of opacity as a diagnostic tool.
2. Discuss factors which can interfere with or affect opacity obser-
vations.
3. Know the general procedures for making opacity observations.
4. Explain the significance of opacity-mass correlations.
Reading Guidance
o The reading assignment focuses on the use of opacity as a diagnos
tic tool in evaluating control equipment performance and thus,
does not cover in detail the procedures for making an opacity
observation. It is therefore recommended that the reader who is
not familiar with visible emission observation procedures consult
Reference 1 of the supplemental references which covers them in
detail.
9-1
-------
Uhen you have finished the reading assignment, complete the review
exercise for Lesson 9. It begins on the following page.
After you have answered the review exercise questions, check your
answers. The correct answers are listed on the page immediately
following the review exercise. Note that many of the questions
have more than one correct answer.
For any review exercise questions that you answered incorrectly,
review the page of the reading assignment indicated on the answers
page.
After you have reviewed your incorrect answers (if any), proceed
to Lesson 10 of this guidebook.
9-2
-------
Review Exercise
1. Opacity is an especially useful indicator of performance for _
since the particle sizes which are collected least efficiently
attenuate light most effectively.
a. wet scrubbers
b. multicyclones
c. fabric filters
d. electrostatic precipitators
2. When making a visible emission observation the sun should be
a. within a 90° quadrant of the observer's back
b. geometrically normal to the direction of plume travel
c. within a 140° quadrant at the observer's back
d. within a 140° quadrant at the front of the observer
3. As the angle of observation increases,
a. the apparent opacity increases in relation to the
actual opacity
b. the apparent opacity decreases in relation to the actual opacity
c. the viewing pathlength across the plume increases
d. the viewing pathlength across the plume decreases
4. Opacity readings can be corrected back to an observation angle of 0°
using the following equation:
b. oc = i + [ (i - oobs) COS0]
c- oc = i - [ (oobs)
d. Oc = 1 - [ (1 - 0Qbs
where: Oc = corrected opacity
°obs = observed opacity
0 = observation angle
5. Opacity can be an excellent early indicator of developing particulate
collection problems.
a . t ru e
b. false
9-3
-------
6. A control device on a particular point source could be emitting a
substantially higher mass concentration with almost no change in
opacity levels if •
a. the slope of its opacity-mass concentration correlation is
close to vertical
b. the particle size distribution of the emissions has shifted to
favor particles greater than 2 microns in diameter
c. the particle size distribution of the emissions has shifted to
favor particles less than 1 micron in diameter
d. the slope of the opacity-mass concentration correlation is
close to horizontal
7. In cases as described above
a. continuous emission monitors must be installed
b. inspection/maintenance personnel must utilize other means to
routinely evaluate control device performance
c. only stack testing can be used for evaluation
d. none of the above
8. If there is some question as to whether or not a steam plume is
present, then .
a. the observer can compare the dissipation of steam vent effluent
at the plant with the dissipation of the plume of interest to
assist in the determination
b. the observer should make all opacity readings right at the stack
exit
c. the observer can make a determination by analyzing the
effluent gas stream and ambient meteorological conditions
using a psychrometric chart
d. al1 of the above
e. none of the above
9. Secondary plumes ^_____ .
a. are composed of condensed aerosols
b. are sometimes termed detached plumes
c. imply control device operating problems
d. can contain volatile or reactive compounds
e. eventually revaporize
f. all of the above
Match the following plume colors to the possible combustion parameters
listed in questions 10 through 14.
a. white
b. black
c. reddish brown
d. bluish white
e. grey
10. Excess combustion air; loss of burner flame in oil-fired furnace.
9-4
-------
11. Inadequate air supply or distribution.
12. Lack of air; clogged or dirty burners or insufficient atomizing
pressure, improper oil preheat; improper size of coal.
13. Excess furnace temperatures or excess air; burner configuration.
14. High sulfur content in fuel.
15. If the apparent opacity of a plume viewed at an observation angle
of 45° is 40%, then the actual opacity is
a. 40%
b. 35%
c. 30%
d. 25%
9-5
-------
Review Exercise Answers and Reading Information
Question
Number and
Answer
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
a,d
c
a,c
d
a
b,d
b
a,c
a,b,c
a
e
b
c
d
c
Page(s) in
Baseline
Manual
10-1
10-2
10-2, 10-3
10-1
10-5 to 10-9
10-9
10-4 to 10-5
10-4
10-5
10-5
10-5
10-5
10-5
10-3
Page(s) in
Field Inspection
Notebook
77
77
9-6
-------
LESSON 10
Legal and Administrative Aspects of Plant Inspections
Reading Assignment
Baseline Manual, Chapter 12 and Appendix A.
Reading Assignment Topics
o Preinspection procedures.
o Procedures for plant entry-
o Conducting the inspection.
o Collecting legally admissable evidence.
o Handling confidential information.
o Photographic documentation.
Learning Goal and Objectives
Learning Goal
To familiarize you with the legal and administrative aspects which must
be considered as part of a complete plant inspection.
Learning Objectives
When you have completed this lesson, you should be able to:
1. List and describe the preinspection procedures involved in
preparing for an inspection and in entering the plant.
2. Explain what an inspector must be aware of during an inspection.
3. List and describe post inspection procedures.
4. Outline a set of procedures for handling confidential business informa
tion.
5. Explain the uses of, sensitivity of, and procedures for photographic
documentation.
10-1
-------
Reading Guidance
o A point which is emphasized throughout the reading material,
but which might be noted again is that any time the inspector is
unsure concerning an administrative or legal matter he should
consult his supervisor, agency legal counsel, and/or the office of
the State Attorney General for clarification.
o When you have finished the reading assignment, complete the review
exercise for Lesson 10. It begins on the following page.
o After you have answered the review exercise questions, check your
answers. The correct answers are listed on the page immediately
following the review exercise. Note that many of the questions
have more than one correct answer.
o For any review exercise questions that you answered incorrectly,
review the page of the reading assignment indicated on the answers
page.
o After you have reviewed your incorrect answers (if any), proceed to
the final exam (see Section 0 of this guidebook).
10-2
-------
Review Exercise
1. It is best to avoid photographing sensitive areas of a facility and
to limit photographs to only those that are absolutely necessary.
a. true
b. false
2. Confidential business information can include
a. photographs
b. propriety information
c. special process data
d. privileged information
e. emissions data
3. The public relations liason part of an inspector's job includes
a. respecting the normal working schedule of plant personnel
b. accepting offers of free lunches and dinners
c. remaining courteous at all times
d. respecting union-company agreements
4. An inspector may enter plant premises with either the owner's consent
or a warrant.
a. true
b. false
5. Inspection data gathered prior to the withdrawal of consent (to enter
the plant) is not considered admissable in court.
a. true
b. false
6. The inspector should only sign a visitor release form or waiver
a. when the plant official offers him no other choice
b. with express permission from his employer
c. after a determination from the State Attorney General
d. after visiting the plant a number of times previously and not
encountering any hazardous situations
e. none of the above
7. A good "working file" for the inspector's use includes
a. plant layout drawing and flowsheets
b. malfunctions reports
c. chronology of control actions, inspections, and complaints
d. recent construction and/or operating permits
e. baseline performance data
f. CEM excess emissions reports
g. al1 of the above
10-3
-------
8. A preinspection survey of the areas surrounding the plant
•
a. allows time for a quick file review
b. can reveal obvious vegetation damage near the plant
c. may confirm odors downwind of the plant
d. may show significant fugitive emissions near plant
boundries
e. can allow the inspector to better make an
unannounced inspection
9. It is appropriate for the inspector to inform plant management of
excess visible emissions subsequent to their observation.
a. true
b. false
10. An important point to remember in dealing with confidential business
data during an inspection is .
a. don't let the plant official know what you are recording
until the exit interview
b. always get as much operational data as possible
c. avoid taking it unless it is necessary
11. Which of the following points should the inspector's post inspection
interview with a plant official cover?
a. plant safety requirements
b. confidential data taken
c. follow-up questions
d. compliance of inspection points
e. need for follow-up inspection
f. all of the above
12. The following items of safety gear should be carried by the inspector
at all times:
a. safety glasses or goggles
b. hard hat
c. safety belt
d. gas mask
e. safety shoes
f. dust mask
13. By Federal mandate the handling of confidential information must be
the same from agency to agency.
a. true
b. false
10-4
-------
14. It is suggested that confidential business data be
a. marked with a "confidential stamp"
b. only used by agency personnel
c. kept in a locked file cabinet
d. not be reproduced
e. in general, not be included in the inspection report
f. a, c, d and e
g. al1 of the above
15. Photographic documentation is a necessity for most inspections .
a. true
b. false
16. A(n) warrant is the type most often obtained
in the case of plant entry denial.
a. criminal
b. civil
c. administrative
17. The plant has the right to request handling as confidential business
information for all kinds of data.
a. true
b. false
18. When refused entry to a facility, the inspector should .
a. tactfully discuss the reason for denial
b. note the name and title of the plant official making
the denial
c. warn the plant official of potential penalties for the
denial of entry
d. contact his supervisor for further instructions if consent to
enter is not gained
e. al1 of the above
10-5
-------
Review Exercise Answers and Reading Information
Question Page(s) in
Number and Baseline
Answer Manual
1. a 12-15
2. a,b,c,d 12-13
3. a,c,d 12-10, 12-11
4. a 12-6
5. b 12-7
6. b,c 12-5
7. a.c.d.e 12-1, 12-2, Appendix A
8. b,c,d 12-4
9. a 12-4, 12-5
10. c 12-13
11. b,c,e 12-11
12. a,b,e,f 12-3
13. b 12-12, 12-13
14. f 12-12 to 12-15
15. b 12-15
16. b,c 12-7
17- a 12-12 to 12-15
18. a.b.d 12-16
10-6
-------
SELF INSTRUCTIONAL COURSE
ANSWERS
QUIZ 1 QUIZ 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
b
a
c
c
d
a
a,b
a
d,e
b
a,b,c,d,e,g,h
a,d,e
b
c
c
a.c.e
b
b
c
a
b
e
b,c
b
a
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
c
a
e
a,b,d
b
c
b
b
b
b
a,b,c
b,c
c
e
a
c
c,d
c
c
c
e
c
a
a
b
-------
SI:445
FINAL EXAM
Introduction to Baseline Source Inspection Techniques
SI: 445
Edition A
Note: Each question has only one correct answer.
1. In scheduling an inspection, agency personnel should
a. consider normal working hours at the plant
b. be aware of agency policy on advance announcement
c. choose a time when plant processes will probably be
operating at representative conditions
d. al1 of the above
2. During the measurement of the static pressure in a duct ahead of a
fabric filter it is suspected that there is some slight air leakage
around the probe and into the duct. If the observed static pressure
is -20 inches of water, the true static pressure would probably be
a. -18 inches of water
b. -25 inches of water
c. -30 inches of water
d. +20 inches of water
e. either b or c
3. Contact lenses should not be worn during inspections.
a. true
b. false
4. Rappers are often used on which of the following components of an
electrostatic precipitator system?
a. insulators
b. gas distribution plates
c. transformer-rectifier sets
d. none of the above
5. The most useful parameter for correlating scrubber particulate removal
efficiency is the following:
a. pressure drop divided by the gas density (average of inlet and
outlet)
b. pressure drop divided by the gas velocity (average of inlet and
outlet)
c. pressure drop divided by the gas temperature (average of inlet
and outlet)
d. pressure drop
-------
SI: 445
Edition A
Final Exam Page 2
6. Which of the following circumstances would tend to increase the value
of an opacity observation reading?
a. having to read the plume at a point after steam disippation
b. an increase in particle size distribution 1n the plume,
with no change in mass emissions
c. a decrease in the angle of observation
d. a change in plume color
e. all of the above
f. none of the above
7. The primary physical mechanism used to collect particles in wet
scrubbers is the following:
a. gravity settling
b. diffusophoresis
c. thermophoresis
d. interception
e. impaction
f. electrostatic attraction
8. In the regeneration process on a carbon bed adsorption system, '•.he
organics are desorbed from the carbon by passing steam or hot gjses
through the bed countercurrent to the flow of gases during adsorption.
a. true
b. false
9. Which of the following points should the inspector's preinspection
interview with a plant official not cover?
a. inspector's preferred inspection agenda
b. applicable regulations
c. plant safety requirements
d. photographs
e. consequences of the plant's noncompliance with regulations
f. operational status of process and control device points to
be evaluated
g. none of the above
10. The bag tension is important in which of the types of fabric filters
listed below:
a. reverse air (inside-to-outside filtering)
b. reverse air (outside-to-inside filtering)
c. shaker
d. pulse jet
e. a and b
f. a and c
-------
SI: 445
Edit! on
11.
12.
13.
14.
Final Exam Page 3
When climbing ladders, inspectors should hold on to the_
a. side rails
b. foot rails
c. either
On a square duct the length is 42 inches and the width is 36 inches.
l*nat fs the equivalent diameter?
a. 39.0 inches
b. 19.1 inches
c. 38.8 inches
d. 78.0 inches
The baseline inspection technique involves detailed internal inspec-
tions of the control systems.
a.
b.
true
false
An inspection of a multiple cyclone type collector serving a coal-
fired boiler resulted in the inspection data below. The baseline data
came from a stack test. Assuming gas flow rate is proportional to steam
rate, what conclusions can be made without making any calculations?
Inspection Data
Inlet Static Pressure: -2.8"
Outlet Static Pressure: -6.6"
Baseline Data
Pressure Drop:
4.0"
Inlet Gas Temperature:
Outlet Gas Temperature:
Inlet 02:
Outlet 02:
Inlet C02=
Boiler Steam Flow
412°F
403°F
7.4%
8.0%
12.0%
60,000 Lbs/hr
Inlet Gas Temperature: not measured
Stack
Inlet
Stack
Inlet
Stack
Boiler
Temperature:
02:
02:
C02:
C02:
Steam Flow:
426°F
not recorded
8OV
• Lie
not recorded
11.3%
100,000 Lb/hr
a. no conclusions can be reached since the baseline data set is
incomplete
b. the resistance to gas flow is substantially higher, therefore,
there may be some pluggage of the spinner vanes or the outlet tube
c. the resistance to gas flow is substantially lower, therefore,
there may be some erosion of the outlet tube extensions
d. there are signs of severe air infiltration
15. What would be the expected pressure drop 6uring the inspection above
assuming that the condition of the mechanical collector was identical
to that during the baseline stack test? (Assume a flue gas moisture
content of 0.1 pounds per pound of dry air.)
a. 1.45 inches of water
b. 2.40 inches of water
c. 3.80 inches of water
d. 4.00 inches of water
-------
SI: 445
Edition
Final Exam Page 4
16. A packed tower wet scrubber is generally used for
a. collection of sticky aerosols
b. gas pollutant absorption
c. collection of participate in sources with high mass concentrations
d. collection of submicron particulate
17. One field of an electrostatic precipitator had the following operating
conditions: secondary voltage 38 KV, secondary current 820 mi Hi amps,
spark rate 10 per minute. The power factor is 0.75 and the gas
temperature is 320°F. What is the power input from this one field?
a. 21.5 kilowatts
b. 31.2 kilowatts
c. 22,360 watts
d. 23.4 kilowatts
The figure below shows the discharge concentration vs. time for a
carbon bed. Refer to it to answer Questions 18 through 20.
coo
300
200
100
SO
A
r
C D1
B C Bu
T u3
12345
1 *5 30 If
On-Strcm Tl*t (Minutes)
-------
SI: 445
Edition A
Final Exam Page 5
18. Breakthrough occurs at the point labeled _
a. A
b. B
c. C
d. D
e. E
f. F
19. A reasonable adsorption cycle time for this bed in a system with set
cycle automatic control would be .
a. 15 minutes
b. 25 minutes
c. 30 minutes
d. 35 minutes
e. all of the above
f. none of the above
20. An instrument to be used to detect organics in the discharge gas
stream for this system should measure accurately in the .
a. 0-20 ppm range
b. 0-50 ppm range
c. 0-500 ppm range
d. 500-1000 ppm range
21. Control system designed by the same manufacturer and operated under
similar conditions can be assumed to operate in a similar manner.
a. true
b. false
22. The pH measured in the scrubber sump was 3.5. If the scrubber is
made of carbon steel is there reason for concern?
a. no
b. yes
23. If an inspector experiences the nonspecific symptoms of exposure to
gases and vapors, he or she should .
a. continue with the inspection until more definite symptoms
develop
b. discuss the potential exposure with plant personnel
c. leave the area immediately and reevaluate the conditions
d. all of the above
-------
SI: 445
Edition A
Final Exam Page 6
24. An Inspector standing 100 feet from a 175 foot stack made 6 minutes
of visible emission observations which averaged 32%. If the baseline
opacity value (from a continuous emission monitor) for that point
source was 181. Was there a significant shift in opacity?
a. yes
b. no
25. If a collector is under negative pressure, there is a tendency for
•
a. gas to leak out
b. air to leak in
26. The electrical data from a one chamber electrostatic precipitator has
been plotted below. What does the data suggest?
a. the rappers are obviously not operating properly
b. the dust resistivity has increased since the baseline period
c. the boiler load has decreased
d. one or more fields have serious malalignment problems
e. the dust resistivity has decreased since the baseline period
-------
SI: 445
Edition A
Final Exam Page 7
27. Water and oil in the compressed air lines of pulse jet fabric filters
can lead to which of the following problems?
a. seepage
b. freezing of the diaphragm valves
c. freezing of the rotary valves
d. cage erosion
28. The temperature recorder on the outlet of a reverse air fabric filter
indicated that there was a temperature excursion to 385°F for a period of
1 hour. What types of fabric would be able to tolerate this condition?
a. cotton and Orion
b. Nomex and fiberglass
c. fiberglass only
d. Ryton and orlon
e. Dacron and Teflon
29. Static pressure measurement data on a given air pollution control system
are shown in the figure below. Uhat is the pressure drop across the col-
lector?
a. 8.5"
b. 1.2"
c. 2.8"
d. 8.3"
e. it cannot be determined
f. the measurements are obviously in error
STACK
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SI: 445 .
Edition A
Final Exam Page 8
30. During the inspection of a fabric filter, it is noted that the pressure
drop has decreased substantially since the baseline period and the
opacity has dropped from 10% to almost 0%. The inspector finds some
minor corrosion on the collector shell and some very audible air
infiltration across the top access hatches. The rotary valves and
the screw conveyors seem to be performing adequately. What should
the Inspector dx>?
a. stop the Inspection, the unit is in compliance
b. continue the inspection because the data clearly indicates that
the bags are being overcleaned
c. continue the Inspection because it is quite possible that there
are substantial fugitive emissions from the process hoods
d. stop the inspection because any problems which may exist are not
causing the unit to operate out of compliance
e. evaluate start-up procedures which could contribute to corrosion
f. evaluate the bag failure charts
31. There is a two chamber electrostatic precipitator having four fieTds
in series. The Transformer-Rectifier set numbering system Is shown
on the sketch provided below. In what order should the electrical
data be recorded on the inspection notes?
a. S4, S3, S2, SI, N4, N3, N2, Nl
b. SI, S2, S3, 54, Nl, N2, N3, N4
c. Nl, SI, N2, S2, N3, S3, N4, S4
d. the way the cabinets are laid out in the control room or substation
e. none of the above
NA
54
N3
S3
N2
S2
Ml
SI
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SI: 445
Edition A
Final Exam Page 9
32. During an inspection of a wet scrubber system, it is noticed that the
I.D. fan is vibrating severely. What should the inspector do?
a. evaluate conditions which could lead to build up of material on
the fan, such as poor demister operation
b. measure the fan R.P.M. and motor current
c. check the outlet damper position
d. leave the area immediately
e. leave the area immediately and notify a responsible plant
official of the fan condition
33. The following electrical data was recorded during the inspection of an
electrostatic precipitator. What is the total power input to this
one chamber unit? (Use a spark rate of 35 in each field, a power
factor of 0.65, a gas temperature of 350*F, gas stream How rate of
320,000 ACFM, if necessary to complete the calculations.)
a. 328 watts/1000 ACFM
b. 1637 watts/1000 ACFM
c. 1936 watts/1000 ACFM
d. 2582 watts/1000 ACFM
Field Primary Primary Secondary
Voltage, Current Current
Volts, A.C Amps, A.C Milliamps, D.C.
1 259 128 730
2 298 228 1370
3 260 232 1370
34. A symptom used in baseline analyses means .
a. a significant difference between an operating
parameter at a given plant as compared against
industry norms
b. a significant difference between an operating
parameter measured during the inspection as com-
pared against the value during the baseline period
c. neither
35. At high concentrations hydrogen sulfide has odor.
a. a rotten eggs
b. a sewer
c. a fragrant
d. rvo
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Course SI:445
Introduction to ttaseline Source Inspection Techniques
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Final Examination A
Answer Sheet
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c d e f 20. a b
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c d e f 22. a b
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Quiz Supervisor
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