ETV/APCT/BFP Test/QA Plan
Revision 2
February 21, 2006
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TEST/QA PLAN
FOR THE VERIFICATION TESTING OF
BAGHOUSE FILTRATION PRODUCTS
EPA Cooperative Agreement No. CR829434-01-1
RTI Project No. 0209309
ETS Project No. 98-277
Prepared by:
ETS, INC.
1401 Municipal Road, N.W.
Roanoke, VA24012
540-265-0004
540-265-0131 (fax)
Research Triangle Institute
Research Triangle Institute
P.O. Box 12194
Research Triangle Park, NC 27709-2194
919-541-6072
919-541-6936 (fax)
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PART A. PROJECT MANAGEMENT
Al.O Title and Approval Sheet
Al.l Title
Test/Quality Assurance Project Plan (Test/QAPP) for the Verification Testing of Baghouse
Filtration Products (BFPs).
NOTE: This Test/QA Plan has been structured to conform with the format of the EPA document
EPA Guidance for Quality Assurance Project Plans (EPA QA/G-5).
A1.2 Approval
This Test/QA Plan has been reviewed and approved by the following program participants:
APCT Center Director: A. R. Trenholm Signed by Andrew Date: 9/1/06
Trenholm
APCT Center Quality W.C.Eaton Signed by W. Gary Date: 9/7/06
Manager: Eaton
APCT Center Task A. R. Trenholm Signed by Andrew Date: 9/1/06
Leader: Trenholm
BFP Task Leader: J. C. Mycock Signed by J. C. My cock Date: 9/1/06
EPA APCT Project M. Kosusko Signed by Michael Date: 9/12/06
Manager: Kosusko
EPA APCT Quality P. W. Groff Signed by Paul W. Groff Date: 9/12/06
Manager:
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A2.0 Table of Contents
List of Figures 5
List of Tables 5
Appendices 6
PART A. PROJECT MANAGEMENT 2
Al .0 Title and Approval Sheet 2
Al.l Title 2
A1.2 Approval 2
A2.0 Table of Contents 3
A3.0 Distribution List 6
A3.1 List of Acronyms 7
A4.0 Project Organization 8
A4.1 Roles and Responsibilities 8
A4.1.1 EPA 8
A4.1.2 RTI 9
A4.1.3ETS 9
A4.2 Verification Test Roles and Responsibilities 9
A4.2.1 Verification Test Leader 11
A4.2.2 Test-Specific Manager 11
A4.2.3 Test-Specific Quality Assurance Officer 11
A4.2.4 Report Manager 11
A4.2.5 Sample/Equipment Manager 12
A5.0 Problem Definition 12
A5.1 Background 12
A5.2 Problem Statement 12
A5.3 Objective 13
A6.0 Project/Task Description and Schedule 13
A6.1 Description of the Work to be Performed 13
A6.1.1 Measurements that are Expected During the Course of the Project 14
A6.1.2 Schedule for the Work Performed 14
A6.1.3 Records and Reports 15
A7.0 Quality Objectives and Criteria for Measurement Data 15
A7.1 Quality Objectives 15
A7.2 Measurement Performance Criteria 17
A8.0 Special Training Requirements/Certification 17
A8.1 Training 17
A8.2 Certification 19
A9.0 Documentation and Records Management 19
A9.1 Data Reporting Packages 19
A9.1.1 Test Operation Records 20
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A9.1.2 Data Handling Records 21
A9.2 Data Reporting Package Format and Documentation Control 21
A9.2.1 Document Control 21
A9.2.2 Verification Statement 22
A9.2.3 Verification Report 23
A9.2.4 QA/QC Reports 23
PART B. MEASUREMENT/DATA ACQUISITION 24
Bl.O Process Design 24
Bl.l Test Apparatus 24
B1.2 Test Design 25
B2.0 Sampling Methods Requirements 27
B2.1 Filter Media Samples 27
B2.2 Impactor Filter Samples 27
B3.0 Sample Handling and Custody Requirements 27
B4.0 Analytical Methods Requirements 28
B4.1 Materials and Apparatus 28
B4.1.1 Test Apparatus 28
B4.1.2 Test Dust 29
B4.1.3 Analytical Balances and Associated Equipment 29
B4.1.4 Calibration Weights and Associated Equipment 29
B4.1.5 Impactor, Collection Substrates, and Associated Materials 29
B4.1.6 Absolute Filter Assembly With Untared Filters 29
B4.1.7 Ambient Humidity and Barometric Pressure Measurement Devices 30
B4.2 Procedures 30
B5.0 Quality Control Requirements 31
B5.1 Test Dust Particle Size Percentage and Mass Aerodynamic Diameter 31
B5.2 Filter Sample Diameter 32
B5.3 Flow Rates (Raw Gas, Sample Gas, and Clean Gas) 32
B5.4 Gas Temperature 32
B5.5 Inlet Dust Concentration 32
B5.6 Weight Gain of Reference Fabric and Maximum Pressure Drop 32
B5.7 Mean Outlet Particle Concentration (PM 2.5 and Mass) 33
B5.8 Initial, Final, and Average Residual Pressure Drop Across the Sample 33
B5.9 Average Filtration Cycle Time 33
B6.0 Instrument/Equipment Testing, Inspection, Maintenance 35
B6.1 Equipment Inspection and Maintenance 35
B7.0 Instrument Calibration and Frequency 35
B7.1 High Resolution Analytical Balance 36
B7.2 Low Resolution Analytical Balance 36
B7.3 Flow Meters and Flow Controllers 36
B7.4 Pressure Transducers 36
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B7.5 Barometric Pressure Transducer 36
B7.6 Thermocouple in Raw-Gas Channel 37
B7.7 Continuous Humidity and Temperature 37
B7.8 Timer Clock 37
B7.9 Dust-Feed Weight Cell 37
B8.0 Inspection/Acceptance Requirements for Supplies 38
B9.0 Data Acquisition Requirements (Non-Direct Measurements) 38
B10.0 Data Management 38
B10.1 Data Flow 38
Bll.O Reporting 40
PART C ASSESSMENT/OVERSIGHT 41
Cl.O Assessments and Response Actions 41
C2.0 Reports to Management 42
PART D DATA VALIDATION AND USABILITY 43
Dl.O Data Review, Validation, and Verification Requirements 43
D2.0 Data Transformation and Reduction 43
D3.0 Validation and Verification Methods 44
D4.0 Reconciliation with Data Quality Objectives 46
D4.1 Accuracy 47
D4.2 Precision 47
D4.3 Completeness 48
D5.0 Corrective Action Procedures 48
LIST OF FIGURES
Figure 1. Project Organization Chart 10
Figure 2. LTG/FEMA Test Apparatus 26
LIST OF TABLES
Table 1. Data Quality Objectives 16
Table 2. Test Specifications 18
Table 3. Test Apparatus Equipment 30
Table 4. Data Quality Limits 34
Table 5. Instrument Calibrations and Frequency 37
APPENDICES
Appendix A Attaining the Quality Objective for the Mean Outlet Particle Concentration
(PM 2.5 or total) 50
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Appendix B Sample Chain-of-Custody Record, Label, Record of Consumables,
Inspection/Acceptance Testing Requirements Log, Log for Tracking Supplies
and Consumables, and Daily Test Log 53
Appendix C Standard Operating Procedures for Verification Testing of Baghouse
Filtration Products Using LTG/FEMA Test Apparatus 56
A3.0 Distribution List
The following is a list of individuals who will receive copies of the approved Test/QA Plan and
any subsequent revisions.
Name Role Organization
Mike Kosusko EPA APCT Proj ect Manager EPA/APPCD
Paul Groff EPA APCT Quality Manager EPA/APPCD
Andrew Trenholm APCT Center Director Research Triangle Institute
Gary Eaton APCT Center Quality Manager Research Triangle Institute
Andrew Trenholm APCT Center Task Leader Research Triangle Institute
John Mycock BFP Task Leader ETS, Inc.
John McKenna Verification Test Leader ETS, Inc.
Sharon Winemiller Test-Specific QA Officer ETS, Inc.
Terry Williamson Test-Specific Manager ETS, Inc.
John Mycock Test-Specific Report Manager ETS, Inc.
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ETV/APCT/BFP Test/QA Plan
A3.1 List of Acronyms
The following is a list of acronyms that are used in this Test/QA Plan.
ADQ Audit of Data Quality
ANSI/ASQC American National Standard Institute/American Society for Quality Control
APCT Air Pollution Control Technology
APPCD Air Pollution, Prevention, and Control Division
ASQ American Society for Quality
ASTM American Society for Testing and Materials
BFPs Baghouse Filtration Products
DQO Data Quality Objective
EPA United States Environmental Protection Agency
ETV Environmental Technology Verification
FEMA Filter Efficiency Media Analyzer
G/C Gas-to-Cloth Ratio
LIMS Laboratory Information Management System
LTG LTG GmbH, Karlsruhe, Germany (Company that manufactures FEMA apparatus)
MSDS Material Safety Data Sheet
NAAQS National Ambient Air Quality Standards
NIST National Institute of Standards and Technology
PE Performance Evaluation
PM Particulate Matter (Includes PM 2.5)
PM 2.5 Particulate Matter 2.5 micrometers and Smaller
QA Quality Assurance
QAO Quality Assurance Officer
QC Quality Control
QMP Quality Management Plan
RTI Research Triangle Institute
SAC Stakeholders Advisory Committee
SOP Standard Operating Procedure
TSA Technical Systems Audit
VDI Verein Deutscher Ingenieure
w.g. Water Gage
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A4.0 Project Organization
The U.S. Environmental Protection Agency (EPA) has overall responsibility for the
Environmental Technology Verification (ETV) Program for Air Pollution Control Technology
(APCT). Research Triangle Institute (RTI) is EPA's verification partner in this effort. The
APCT Center has selected Baghouse Filtration Products (BFPs) as a technology to be verified.
Management and testing within the BFP program is performed in accordance with procedures
and protocols defined by a series of quality management documents. These include:
1. EPA's Quality Management Plan (QMP) for the overall ETV program,
2. RTFs Environmental Sciences and Engineering (ESE) Quality Manual,
3. the QMP for the overall APCT Center,
4. the Generic Verification Protocol for Baghouse Filtration Products, and
5. a Test/QA Plan prepared by each participating testing organization.
ETS, Inc. has indicated an interest in being and demonstrated the necessary qualifications to be a
participating testing organization for the BFP program and has prepared this Test/QA Plan to
describe BFP testing under their responsibility.
As a participating testing organization, ETS will conduct laboratory tests on baghouse filtration
products, analyze data, and prepare the draft verification reports and verification statements. The
various quality assurance (QA) and management responsibilities are divided between EPA, RTI,
and ETS key project personnel as defined below. The lines of authority between key personnel
for this project are shown on the project organization chart in Figure 1.
A4.1 Roles and Responsibilities
Project management responsibilities are assigned to personnel from:
1. The United States Environmental Protection Agency (EPA),
2. Research Triangle Institute (RTI), and
3. ETS, Inc. (ETS).
A4.1.1 EPA
EPA is responsible for the overall Environmental Technology Verification (ETV) project
oversight. The EPA Project Manager for the ETV Program is Mike Kosusko. Verification
responsibility encompasses approval of project plans and reports and ensuring that plans are
implemented according to schedule. He requests the resources necessary to meet project
objectives and requirements.
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Paul Groff is EPA's APCT Quality Manager. He is responsible for ensuring that the EPA
Quality and Management Plan (QMP) requirements are fulfilled and may perform quality audits
and evaluations of participating organizations. He will be available to resolve any QA issues
relating to conformance to EPA's QA requirements. Specific functions and duties of the EPA
Quality Manager include approving the contents of this Test/QA Plan and subsequent revisions
and reviewing QA reports prepared by RTI, including QA evaluations and audits. For further
information concerning the EPA organizational structure, see EPA QMP Part A, Section 1.0 at
http://www.epa.gov/etv/qmp.htm.
A4.1.2 RTI
RTI is responsible for the overall ETV APCT Center. Andrew Trenholm of RTI is the APCT
Center Director and will manage program activities and coordinate them with the Stakeholders
Advisory Committee (SAC). Supporting the APCT Center Director in matters of quality is Gary
Eaton who holds the position of APCT Center Quality Manager. For the BFP effort, Andrew
Trenholm is also the APCT Center Task Leader.
A4.1.3 ETS
ETS, as a participating testing organization, is responsible for the development and
implementation of this Test/QA Project Plan. John Mycock is the BFP Task Leader. All EPA
and RTI individuals listed above are responsible for approving ETS' QMP and this Test/QA
Plan, and for verifying ETS' E4 standing in accordance with the requirements set forth by the
EPA Quality and Management Plan.
ETS, Inc. will perform BFP verification testing as a participating testing organization and will
use the LTG Filtration Efficiency Media Analyzer (LTG/FEMA) test apparatus as specified in
this Test/QA Plan to meet the specifications of the generic verification protocol for baghouse
filtration products. ETS is responsible for specific test planning and execution as well as test
data evaluation and reporting. Figure 1 details the project's organization.
A4.2 Verification Test Roles and Responsibilities
The ETS verification test personnel will be organized into the following key areas of
responsibility.
• Verification Test Leader
Test-Specific Manager
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Mike Kosusko
EPA Project Manager
Paul Groff
EPA Quality Manager
Anrew Trenholm
APCTVC Director
Gary Eaton
APCTVC Quality Manager
Andrew Trenholm
APCTVC Task Leader
John Mycock
BFP Task Leader
ETS, Inc. Organization
John
CEO &
Tes
VIcKenna
Verification
Leader
Terry Williamson
Test-Specific Manager
John Mycock
Report Manager
Sharon Winemiller
Test-Specific QAO
Terry Williamson
Sample/Equipment
Manager
Figure 1. Project Organization
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Test-Specific Quality Assurance Officer
• Report Manager
• Sample/Equipment Manager
The responsibilities of each of the above positions are detailed below.
A4.2.1 Verification Test Leader
John McKenna will serve as the overall ETS Verification Test Leader and is the final link in the
ETS chain of command. The Verification Test Leader will serve as backup to the Test-Specific
Manager for technical support and any communications between the involved parties and ETS.
The Verification Test Leader will provide scheduling and administrative support to the testing
program. McKenna will supervise the development of all draft verification reports and draft
verification statements generated in this project and assist in their review and approval. The
Verification Test Leader is also responsible for any corrective action implementation procedures
that might arise from performed audits.
A4.2.2 Test-Specific Manager
Terry Williamson will serve as the Test-Specific Manager. The Test-Specific Manager's duties
include implementing verification testing procedures, test execution, and assisting in the
development of draft project reports. The Test-Specific Manager will also review all aspects of
the testing program to ensure proper communication among all parties, review the sampling and
recovery procedures as executed, and provide on-site data review. The Test-Specific Manager
is responsible for the verification of the test data, spreadsheets, template accuracy, and
preparation of the draft verification statement and the draft verification report.
A4.2.3 Test-Specific Quality Assurance Officer
Sharon Winemiller will be the Test-Specific QAO. The Test-Specific QAO will work
independently of the project management team and is responsible for procedures that determine
if the verification test is being conducted in accordance with QA/QC requirements. The Test-
Specific QAO is also responsible for inspections and technical assessments to verify compliance
with QA/QC goals. The Test-Specific QAO will independently review test data and laboratory
results, and will assist in the preparation of the draft verification reports and draft verification
statements that are generated from this project.
A4.2.4 Report Manager
John Mycock will be responsible for the draft verification report and draft verification statement
development and data validation. The Report Manager supervises the review of all raw test data
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and checks all spreadsheet templates for accuracy. He reports any inconsistencies to the Test-
Specific Manager and the Test-Specific QAO.
A4.2.5 Sample/Equipment Manager
Terry Williamson will receive and secure all incoming samples and is responsible for the correct
preparation of all sampling dust and filter media awaiting verification testing. The
Sample/Equipment Manager is also responsible for obtaining and retaining in stock reference
polyester media and aluminum oxide test dust for calibrations and comparisons. The
Sample/Equipment Manager confirms a direct chain-of-custody and reviews all sample
identification numbers against the actual test data sheets for accuracy. Any discrepancies are
reported to the Verification Test Leader. Terry Williamson also distributes the samples to the
appropriate verification testing areas.
In the event that key personnel changes need to be made, the APCT Verification Center at
Research Triangle Institute will be informed.
A5.0 Problem Definition
(The generic verification protocol provides extended discussions on problem definition from
which portions of the following have been extracted.)
A5.1 Background
Baghouses and their accompanying filter media have long been one of the leading particulate
control techniques for industrial sources. Increasing emphasis on higher removal efficiencies
has helped the baghouse to be continually more competitive when compared to other generic
control devices. With the issuance of the PM 2.5 NAAQS, owners/operators of existing
baghouses will have to consider fine particulate removal effectiveness when making decisions on
purchasing baghouse filtration media.
Since EPA has issued a National Ambient Air Quality Standard (NAAQS) for 2.5 jim primary
particulate matter (PM 2.5), 40 CFRpart 50, Section 50.7, a strong interest exists in verifying
the performance of control systems for fine particulate matter (PM).
A5.2 Problem Statement
At present, there is no independent, objective test method for characterizing the performance of
baghouse filter devices. Owners/operators wishing to evaluate baghouse performance rely on
test information that is provided by vendors. Hence, there is a need for independently verified
performance data for baghouse components. Since there are many different physical
configurations that can be used in the design of a baghouse, there is a large, but limited, offering
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of filter media from which the bags are generally fabricated. Hence, characterization of the
performance of the filter media used in bag fabrication is a more general solution, and it is
amenable to less costly test designs. For this reason, testing of the filter media itself is the
subject of this verification technology.
The specified test equipment makes it possible to conduct measurements under defined
conditions with regard to, among other parameters, filtration velocity (G/C), dust loading,
particle size distribution, and cleaning requirements. Controlled conditions make it possible for
the users to make informed decisions concerning the performance of baghouse filtration media.
A5.3 Objective
Based on discussions with the BFP technical panel, the objective of the ETV Baghouse Filtration
Products (BFP) program is to produce for the public credible test reports and verification
statements regarding PM 2.5 (particulate matter that is 2.5 jim diameter or less) removal
performance by tested baghouse filtration media. Testing will be performed according to this
Test/QA Plan which responds to the specifications of the Generic Verification Protocol for
Baghouse Filtration Products (October 8, 2001) and the SOP, Appendix C, which is derived
from VDI Method 3926, Part 2, "Testing of Filter Media for Cleanable Filters Under
Operational Conditions, " as described in section 2.3 of the generic verification protocol.
A6.0 Project/Task Description and Schedule
(The generic verification protocol provides extended discussions on project/task descriptions
from which portions of the following have been extracted.)
The purpose of this Test/QA Plan is to document the detailed procedures that ETS will follow
during the verification testing of baghouse filtration products. The test apparatus that will be
used to determine filtration media performance, and the basic approach for determining PM 2.5
outlet concentration, is derived from VDI method 3926. The complete SOP that includes these
modifications is provided in Appendix C.
A6.1 Description of the Work to be Performed
The verification test will be approximately a 5-day test to verify the performance of samples of
commercially ready baghouse filtration media relative to PM 2.5. A verification test will include
three identical test runs, on three separate sample specimens. Each verification test run will
include a 10,000 pulse conditioning period, a 30 pulse recovery period, and a performance
evaluation test period spanning 6 hours. At the conclusion of the three verification test runs the
sample media performance evaluation results, in the form of a draft Verification Report and draft
Verification Statement, will be prepared by ETS. ETS will submit the draft Verification Report
and draft Verification Statement to the APCT Center for review and approval. The APCT
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Center will submit the draft verification report and draft Verification Statement to the vendor and
will incorporate changes and resolve any issues. The APCT Center will then submit the draft
verification reports and draft Verification Statements to the EPA for review and approval. The
APCT Center will again incorporate changes suggested by EPA and will resolve any issues that
arise. The focus of the verification testing is to determine the value of the verification
parameters that are listed in Section A6.1.1.
A6.1.1 Measurements that are Expected During the Course of the Project
The filtration and cleaning conditions are specified to be comparable with conditions that prevail
in actual baghouse operation. Detailed measurement procedures can be found in the SOP, which
is located in Appendix C.
As specified in the approved Generic Verification Protocol for Baghouse Filtration Products
(October 8, 2001) the BFP Verification parameters will consist of:
• outlet particle concentration, PM 2.5 (g/dscm [gr/dscf]),
• outlet particle concentration, total mass (g/dscm [gr/dscf]),
• average residual pressure drop (3 seconds after cleaning pulse) during the 6-hour
performance test period (cm w.g. [in. w.g.]),
• initial residual pressure drop of 6-hour performance test period (cm w.g. [in. w.g.]),
• residual pressure drop increase, determined by subtracting the initial residual pressure
drop value from the final residual pressure drop value from the 6-hour performance test
period (cm w.g. [in. w.g.]),
• average filtration cycle time during the 6-hour performance test period (s),
• number of filtration cycles during performance period, and
• mass gain of verification sample filter at test completion (g), (measured from new fabric
filter mass, after 10-pulse cake removal, as stated in VDI method 3926).
A6.1.2 Schedule for the Work Performed
One verification test includes test runs on three identical, randomly selected media samples
supplied by the manufacturer requesting the test. The testing schedule for each test run requires
approximately 24 hours of LTG/FEMA apparatus operation. It commences with a conditioning
period of 10,000 rapid-pulse (i.e., 3 second) cycles to simulate long term usage. Upon
completion of the conditioning period, a recovery period of 30 normal (i.e., when the pressure
drop across the media reaches 4 inches w.g.) pulses is initiated. Once the recovery period is
concluded, a performance test period lasting 6 hours is initiated.
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A6.1.3 Records and Reports
Within 30 days from the completion of the verification test, a draft verification report and a draft
verification statement will be prepared by the Report Manager and submitted to the APCT
Verification Center for review. The report will include, but not be limited to, a description of the
test method and equipment, a summary of the test data that were recorded during the execution
of the test, calibration and maintenance data, which will include which instruments are being
calibrated, calibration dates, and a quality assurance section detailing all technical assessments
that were performed and all quality control reports. As part of the draft report, the draft
verification statement will be prepared. The statement will be a short summary of the detailed
verification report. An example verification statement can be found in Appendix A of the
Generic Verification Protocol for Baghouse Filtration Products (October 8, 2001).
For further information on records and documentation management refer to Section A9.0. Refer
to section A9.2.2 and A9.2.3 for more detailed information pertaining to the verification
statement and the verification report, respectively.
A7.0 Quality Objectives and Criteria for Measurement Data
Quality assurance (QA) encompasses the organization and program within which quality control
(QC) activities are performed. Quality control activities accompany all verification testing
activities and procedures to provide control of data quality and to quantify the quality of data
resulting from those procedures. Each verification test will include QA activities as specified in
this section.
A7.1 Quality Objectives
The Data Quality Objectives (DQOs) specified in Table 1 relate to each run and detail the
control limits that define a valid test. A test may be invalidated due to operator error, as well as
events such as breakage, equipment failure, or failure to achieve the specified DQOs. In the
event that a critical measurement is invalidated, the run will be repeated on a new test sample.
The decision to repeat a test run will be made by the Test-Specific Manager and the Verification
Test Leader at the time of the error. A review of completeness for each test run will be made by
the Test-Specific Manager in the daily test logs.
Annual calibration procedures will be performed as described in the Generic Verification
Protocol for Baghouse Filtration Products (October 8, 2001).
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Table 1. Data Quality Objectives
Verification Parameter
Wt. gain of ref . fabric [g]
[with respect to APCT reference value]
Maximum pressure drop [cm w.g.J
[with respect to APCT reference value]
Mean Outlet Particle Concentration, PM
2.5 [g/dscm]
Mean Outlet Particle Concentration, Total
Mass [g/dscm]
Average Residual Pressure Drop
[cm w.gj
Initial Residual Pressure Drop [cm w.gj
Residual Pressure Drop Increase
[cm w.g.J
Mass Gain of Filter Sample [g]
Average Filtration Cycle Time
Number of Filtration Cycles
0?
1 — '
>
•5
CD
O
>?
O
±40
±40
±15
±15
± 5
±5
±5
± 1
Depends
on cycle
time
Measurement Objectives for
Associated Critical Measurements
to
to
CD
tt
§ g>
-o s
to c-
#t
±0 127
±0.127
±0 127
Q.
E
Q_
to
co
O
S
o!
.as
£\
±0.3
±0.3
Q.
E
Q_
to
<3
a
8
o
"co •>.,
fc
s. ^.
±0.09
±0.09
c
<3
to
to
co r^>.
± 0.00005
± 0.00005
±0.05
"^^T1
fit
± 1
±1
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If measurement objectives are attained, the DQOs are attained. The measurement objectives are
assumed to be attained if a propagation of errors analysis is performed and all solutions are
within the specified ranges. Refer to Attaining the Quality Objectives for the Mean Outlet
Particle Concentration (PM 2.5 or total), Appendix A, for a propagation of errors analysis.
Section B.5 on quality control requirements describes the actions necessary to attain the
measurement objectives.
A7.2 Measurement Performance Criteria
Table 2 presents the test specifications for the proposed test program. This table shows the
acceptable levels of bias and precision needed for a valid test, along with the methods used to
determine these measurements. Refer to section D4.0 for further information pertaining to
accuracy (bias) and precision. For more information related to determining accuracy and
precision, refer to sections D4.1 and D4.2. Accuracy is the degree of agreement of a
measurement (or average of measurements) with an accepted reference or true value. Precision
is a measure of instrumental mutual agreement of replicate measurements. Completeness is a
measure of valid data compared to the amount that is expected under correct operating
conditions. Section B.5 gives more detail on the performance criteria for individual
measurements.
A8.0 Special Training Requirements/Certification
All participants of the verification test program will have completed required training courses
prior to being assigned to the BFP verification test program. The results of the training programs
will be maintained in the individual's LTG/FEMA training file. The Verification Test Leader
and the Test-Specific Manager have extensive experience in filtration efficiency measurements,
understand filtration mechanisms that lead to particle collection in filters, are familiar with the
characteristic shape of filtration efficiency curves, and are knowledgeable of particle transport in
sample lines.
The Test-Specific Manager must be thoroughly familiar with operation of the specified BFP
verification test apparatus, use of flow measurement devices, and operation and sampling
methods associated with use of the impactor.
A8.1 Training
ETS provides two training programs that are applicable to the test program. Upon employment,
each field employee is required to attend a safety training program. Once per year, ETS offers a
sampling methods training course to all new employees. The 1-week program indoctrinates the
employees to the basics of the most common test methods.
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Table 2. Test Specifications
Constant Parameter
Test Dust Particle Size Percentage
(Pural NF)
Test Dust Mass Mean Aerodynamic Diameter
(Pural NF )
Filter Sample Diameter, mm (in.)
(Exposed diameter is 140 mm, 5.51 in.)
Total Inlet Raw Gas Flowrate, m3/hr (cfm)
Clean Gas Flowrate, mVhr (cfm)
Sample Gas Flowrate, m3/hr (cfm)
Filtration Velocity
(G/C Ratio)***, m/hr (fpm)
Pressure Drop Trigger for Cleaning
Rapid Pulse Cleaning Cycles (0 - 10,000), sec.
Pulse Duration, ms
Pulse Cleaning Pressure, MPa (psi)
Gas Temperature, ° C ( °F)
Inlet Dust Concentration, g/dscm (gr/dscf)
Minimum Aggregate Mass Gain for Impactor
Substrate Filters, g
Charge Neutralizer
Dust Feeder Operation, g/hr
Nominal
Value
50% <2.5 urn
(Avg. 3 runs)
1.5 urn
(Avg. 3 runs)
150
(5.88)
5.8(3.4)
1.85(1.10)
1.13 (0.67)
120
(6.6)
1,000 Pa
(4.0 in. w.g)
3
50.0
0.52 (75.0)
(25) 77
18.4(8.0)
0.0001
100
Acceptable
Bias*
+40 - 10
± 1 um
± 1.6
(1/16)
+ 0.3 (0.2)
+0.09 (0.06)
+ 0.06 (0.03)
±6
(0.3)
±0.127 cm w.g (0.05
in. w.g)
± 1
±5.0
±0.03(5.0)
±(2)4
±3.6 (1.6)
±20
Acceptable Precision* *
±0.0001 g Filter mass
Gain per weighing
±0.0001 g Filter mass
Gain per weighing
±1.6
(1/16)
+ 0.01 (0.006)
+ 0.01 (0.006)
+ 0.01 (0.006)
± 1.2
(0.07)
± 0.127 cm w.g
(0.05 in. w.g)
± 1
±1.0
±0.007(1.0)
± 1
±0.22(0.1 )
± 0.00005
±20
Instrument
Andersen Impactor, Model 50-900
(as Determined by Analytical Balance)
Andersen Impactor, Model 50-900
(as Determined by Analytical Balance)
Filter Cutter
Mass Flow Controller
Mass Flow Controller
Mass Flow Controller
Mass Flow Controller and Filter
Sample Area
Pressure Transducer
Datalogger Clock
Pulse Regulator
Pulse Regulator
Thermocouple
Dust Load Cell and Mass Flow
Controller
Andersen Impactor, Model 50-900
(as Determined by Analytical Balance)
Polinium-210 alpha source
Dust Load Cell
Frequency
Monthly and Each New Batch
Monthly and Each New Batch
Each Test Specimen
Quarterly Flow Check
Quarterly Flow Check
Quarterly Flow Check
Each Test.
Each Test.
Beginning of Each Test
Each Test
Each Test
Each Test
Continuously
Each Test
Replace Annually
Each Dust Loading Operation
* Acceptable bias = For the test to be valid, the instrument reading must record a value within listed range. For example, the ±4 degrees accuracy means that the temperature reading of the gas must be within the
range of 73 to 81 ° Fahrenheit.
* * Precision = The precision of the instrument reading. For example the thermometer or thermocouple that is used to measure temperature must record temperature within 1 degree of actual.
*** Filtration Velocity (G/C) = Clean Gas Stream Volume / Exposed Area of Filter Sample =1.10cfm/ 0.166 ft2 = 6.6 fpm = 1.85 mVhr/ 0.01539 m2 = 120 m/hr
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Training also includes orientation to the data sheets and equipment available at ETS. Each
employee is informed of the ETS policies and procedures to ensure that accurate and complete
test data are obtained. Each operator is given a training manual that includes sample data
sheets, and ETS policies and procedures.
In addition, all personnel who will be operating the test apparatus must complete a 16-hour
LTG/FEMA operation training program by a LTG representative or an appropriate ETS
designate, three successful 30-cycle reference media tests, as stated in the Generic Verification
Protocol Section 2.4, and one complete verification test run (one conditioning period, recovery
period, and performance period) using the reference media and reference dust prior to being
considered a qualified LTG/FEMA apparatus operator.
A8.2 Certification
ETS, Inc. has submitted its baghouse filtration products quality management plan to comply with
the requirements of the American National Standard, Specifications and Guidelines for Quality
Systems for Environmental Data Collection and Environmental Technology Programs
(ANSI/ASQCE4-1994). ETS' quality management plan was submitted on June 18, 1999, and is
on file with the APCT Verification Center. ETS, Inc. also complies with the APCT and EPA
Quality Management Plans. ETS may be audited at any time by EPA, its representatives, or the
APCT Verification Center to ensure compliance with these documents and that all requirements
are met.
There is no special certification that the ETS testing staff must obtain prior to operating the
LTG/FEMA apparatus. However, the testing staff must complete the training requirements
listed in section A8.1 prior to operating the test apparatus.
A9.0 Documentation and Records Management
Proper documentation and recordkeeping is critical to ensure quality data. The proper reporting
format, combined with data validation, facilitates investigation into the quality of the data and of
the report and statement generated for the project. All verification reports and verification
statements will be submitted to the APCT Verification Center in electronic format
(WordPerfect). All records and documents will be maintained at ETS for 7 years from the date
of final payment from the APCT Center Office.
A9.1 Data Reporting Packages
Specific documentation and recordkeeping requirements for this project are separated into test
operation records and data handling records.
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A9.1.1 Test Operation Records
The following test operation records will be an integral part of the test program.
• Chain-of-Custody Records - Chain-of-custody sheets will be completed to allow
tracking of the samples from collection through verification test completion. This action
minimizes any chance of sample loss or possibility of sample tampering.
• Material Safety Data Sheets - MSDS documentation for the reference dust will be kept
on file at the test apparatus site.
• Daily Test Logs - Accurate and complete logs will be kept on all daily activities. The
LTG/FEMA operator is responsible for completing the logs. These logs document all
activities, and include sampling times, process delays, equipment failures, any deviations
from this Test/QA Plan or standard testing practices and procedures, and all quality
control measurements that were conducted. The operator records test data and notes on
daily test logs prepared specifically for these tests (presented in SOP, Appendix A). The
sheets are designed to prompt the test operator for all required test information:
- Testing date, time, and operator.
- Manufacturer and model number of filter samples.
- QA checks on the equipment and data.
- Test conditions (temperature, relative humidity, atmospheric pressure).
The Test-Specific Manager is responsible for reviewing the daily test logs for
completeness and verifying that all information has been included.
• Sample Label - Sample labels will be applied to all samples that are accepted for the
verification test. Sample labels will be applied to track sample testing and to minimize
chance of possible loss and mixup.
• Record-of-Consumables - The record-of-consumables will track the quantities of
consumable items that will be used in the verification test, the expiration date (if
applicable), and the required consumable test dates.
• Inspection/Acceptance Requirements - The Inspection/Acceptance Requirements form
for critical supplies and consumables will track the test requirements, frequency, and
acceptance status of the reference materials and dust. This form will also record the
storage condition for each material.
• Log for Tracking Supplies and Consumables - The log for tracking supplies and
consumables will contain the arrival dates of all consumable items, the required testing
for each item, and the expiration date (if applicable).
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A9.1.2 Data Handling Records
Specific measures will be used to track and ensure the generation of quality data. These records
will convert raw data into reportable quantities and units, incorporate proper use of significant
figures, and provide data validation to show that QC criteria have been met.
• Daily Test Logs - All hand-recorded data will be recorded using indelible ink. A
single line will be drawn through recording errors and initialed by the responsible person.
Standardized spreadsheets will be used to create computer generated test results.
• Data Review Records - The test logs are released to the report manager at the
conclusion of the test program. The test files are reviewed by the report manager, any
errors are corrected, and the files are given a unique file identification under a
standardized identification system. Each verification test series will be labeled with a file
number identifying the test specific identification. For example, V004-R1.
The appropriate laboratory data are entered into electronic spreadsheets, the results
reviewed for reasonableness, and the files saved. Two copies of the documents will be
created. One copy will be maintained at ETS in a fireproof cabinet, and a second copy
will be sent to the APCT Verification Center Quality Manager for BFP Verification
Testing for storage.
• QA/QC Data Records - The Report Manager and Test-Specific QAO review the data
and examine any data discrepancies or outlying data points. Any corrective actions are
recorded and documented. The Internal QAO hand-calculates one data set from the
performance test period and compares it to the computer generated spreadsheets for
accuracy. This calculation check is included in the final data package. A comparison of
the quality control measurements with the data quality objectives is also performed and
included in the final data package.
A9.2 Data Reporting Package Format and Documentation Control
The verification statement will be that found in Appendices A of the Generic Verification
Protocol for Baghouse Filtration Products (October 8, 2001). The contents of the supporting
data reporting packages will be consistent with the requirements and procedures used for data
validation and data assessment described in this Test/QA Plan. All records taken to achieve the
objective of the project and the QA performance functions will be components of the data
reporting packages.
A9.2.1 Document Control
All test documents will remain the responsibility of the Test-Specific Manager from their
generation until their release to the Report Manager. The Report Manager is responsible for and
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should be aware of the location of all documents from test completion until the draft report is
completed.
The draft verification report and draft verification statement are reviewed at ETS by the BFP
Task Leader, the Verification Test Leader, the Test-Specific QAO, the Test-Specific Manager,
and the Report Manager. Following release by ETS to APCT Center, the draft verification
report and draft verification statement are sent by APCT Center to the manufacturer for
comment. Once issues and comments from the manufacturer have been resolved, the draft
verification report and draft verification statement are reviewed by the APCT Verification
Center, including the APCT Center Task Leader, the APCT Center BFP Quality Manager, the
APCT Center Quality Manager, and the APCT Center Director. Once APCT Center issues have
been resolved the APCT Center Task Leader will send the draft verification report and draft
verification statement to the EPA Project Manager and EPA Quality Manager for review and
approval. The final Verification Statement will be signed by the Director of EPA's National
Risk Management Research Laboratory. Two copies of the verification report and verification
statement will be archived. The original copy of the draft report and statement will be stored at
ETS in a fireproof cabinet in a limited access storage room. All computer files, spreadsheets,
figures, tables, schematics, and report texts will be archived in this room. The finalized copy
will be stored at the APCT Verification Center for storage. A second finalized copy will be sent
to ETS for storage as well. Computer files are generally kept on the ETS network for 6 months
after the conclusion of the test program. All archived files and reports will be kept in ETS'
custody for a minimum of 7 years after the final payment of the assistance agreement between
ETS and the APCT Center.
A9.2.2 Verification Statement
The Verification Statement, which is a brief summary of the verification test report, will include
the following information:
• Product manufacturer,
• Model or style number,
• Brief description of tested filter media,
• Test date and location,
• Testing firm,
• Summary test conditions
• Outlet particle concentration (PM 2.5 and total mass),
• Average residual pressure drop during performance test period,
• Initial residual pressure drop of 6-hour performance test period
• Residual pressure drop increase during performance test period (final - initial),
• Average filtration cycle time during performance test period,
• Mass gain of sample media at test completion,
• Number of cleaning cycles during 6-hour performance test period, and
• Non-standard test conditions (if applicable).
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The verification statement will also include a statement that the APCT Center BFP Quality
Manager has reviewed the test results and the QC data and has concluded that the data quality
objectives given in the generic verification protocol have been attained.
A9.2.3 Verification Report
The Verification Report is a fully documented test report containing a complete description of
the test method and equipment, and the results of all measurements. The report will also contain
any QC and QA activities that are relevant to the specified verification test. The Verification
Report will include:
• All test specimen information, as stated in Verification Statement, plus
• Data from the reference media,
• Test data result spreadsheets ,
• Results of control tests,
• Quality assurance results,
• Equipment calibration data,
• Comparison between DQOs and test results, and
• Deviation from the approved generic verification protocol (requires APCT approval).
In addition the Verification Report will include all test conditions and operational data including,
but not limited to, gas velocity, gas volume, cleaning pressure drop trigger, and relative
humidity.
The Verification Report will also provide an overview of the test methods employed, facilities,
and equipment used. Data will be presented in a format to permit ready comparison with DQOs.
A discussion of problems encountered and an explanation of how these problems were resolved
will also be included.
After review of the test results and QC data presented in the draft verification report, the APCT
Center BFP Quality Manager will prepare a QA section for inclusion in the report regarding the
attainment of the data quality objectives. ETS, Inc. will maintain one copy of all archived files
and reports for a minimum of 7 years after the final payment of the assistance agreement
between ETS and the APCT Verification Center. All ETS documents that pertain to the
verification tests will be maintained on the ETS premises in a fireproof cabinet. The original
report copy will be kept at the APCT Verification Center for storage.
An example copy of the Verification Statement is included in Appendix A of'the Protocolfor
Verification Testing ofBaghouse Filtration Products.
A9.2.4 QA/QC Reports
All control test data, sample inventory logs, calibration records, and certificates of calibration
will be stored in a location that is deemed appropriate by the Test-Specific Manager at the ETS
facility. The location will ensure that the documents are easily available for reference during
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calibration, control check, and inventory periods. Calibration records will include such
information as the instrument being calibrated, raw calibration data,, calibration dates, and staff
conducting the calibration.
Final reports of self-assessments and independent assessments (i.e., technical systems audits,
performance evaluations, and audits of data quality ) will be retained in the APCT Verification
Center with a duplicate copy kept at ETS. Each verification report and verification statement
will contain a QA section, which will describe the extent that verification test data comply with
data quality objectives.
PART B. MEASUREMENT/DATA ACQUISITION
Bl.O Process Design
Table 1 lists the critical measurements that are associated with the BFP verification test. Critical
measurements are required to achieve project objectives. Table 2 identifies the BFP verification
test conditions. The BFP test conditions must be met and maintained to perform a valid test
series.
Bl.l Test Apparatus
The BFP test apparatus provides an appropriate baghouse filter media test environment. This
equipment allows the user to conduct measurements of filter performance under defined
conditions with regard to the filtration velocity (Gas-to-Cloth ratio, G/C), particle size
distribution, and cleaning requirements. Filtration and cleaning conditions can be varied to
simulate conditions that prevail in actual baghouse operations.
The test apparatus (see Figure 2) consists of a brush-type dust feeder that disperses test dust into
a vertical rectangular duct (raw-gas channel). The dust feed rate is continuously measured and
recorded via an electronic scale located beneath the dust feed mechanism. The scale has a
continuous readout with a resolution of 10 g. A radioactive polonium 210 alpha source is used
to neutralize the dust electrically before its entry into the raw-gas channel. An optical photo
sensor monitors the concentration of dust and ensures that the flow is stable for the entire
duration of the test: the optical photo sensor does not measure concentration. A portion of the
gas flow is extracted from the raw-gas channel through the test filter, which is mounted
vertically at the entrance to a horizontal duct (clean-gas channel). Two vacuum pumps maintain
air flow through the raw-gas and clean-gas channels. During the performance test period only,
the clean-gas flow shall be separated into two gas streams, a sample stream and a sample bypass
stream. The sample stream will be aerodynamically diverted into an Andersen impactor for
measurement. The flow rates, and thus the G/C through the test filter, are kept constant and
measured using mass flow controllers. A pressure transducer is used to measure the initial, final,
and average residual pressure drop of the filter sample. The pressure transducer measures the
differential pressure across the filter samples 3 seconds after the cleaning pulse. The pressure
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drop measurements are averaged as stated in the Appendix C, SOP, section 4.4.1. High
efficiency filters are installed upstream of the flow controllers and pumps to prevent
contamination or damage caused by the dust. The cleaning system consists of a compressed-air
tank set at 0.5 MPa (75 psi), a quick-action diaphragm valve, and a blow tube (25.4 mm [1.0 in.]
dia.) with a nozzle (3 mm [0.12 in.] dia.) facing the downstream side of the test filter.
B1.2 Test Design
Each Verification Test consists of three test runs. Each test run consists of three sequential
phases or test periods: a conditioning period, a recovery period, and a performance test period.
The G/C and inlet dust concentrations are maintained at 120 ± 6 m/hr (6.6 ± 0.3 fpm) and 18.4 ±
3.6 g/dscm (8.0 ± 1.6 gr/dscf), respectively, throughout all phases of the test.
To simulate long-term operation, the test filter is first subjected to a conditioning period, which
consists of 10,000 rapid-pulse cleaning cycles under continuous dust loading. During this
period, the time between cleaning pulses is maintained at 3 seconds. No filter performance
parameters are measured in this period.
The conditioning period is immediately followed by a recovery period, which allows the test
filter to recover from rapid pulsing. The recovery period consists of 30 normal filtration cycles
under continuous dust loading. During a normal filtration cycle, the dust cake is allowed to form
on the test filter until a differential pressure of 1,000 Pa (4.0 in. w.g.) is reached. At this point,
the test filter is cleaned by a pulse of compressed air from the clean-gas side. Immediately after
pulse cleaning, the pressure fluctuates rapidly inside the test duct. Some of the released dust
immediately re-deposits onto the test filter. The pressure then stabilizes and returns to normal.
Thus the residual pressure drop across the test filter is measured 3 seconds after the conclusion
of the cleaning pulse. Pressure drop is monitored and recorded continuously throughout the
filter media recovery and performance test periods of each test run.
Performance testing occurs for a 360-minute period immediately following the recovery period,
(a cumulative total of 10,030 filtration cycles after the test filter has been installed in the test
apparatus). During the performance test period, normal filtration cycles are maintained and, as
in the case of the conditioning and recovery periods, the test filter is subjected to continuous dust
loading. Outlet mass and PM 2.5 dust concentrations are measured using an inertial impactor
located downstream of the test filter at the end of the horizontal (clean-gas) duct. The impactor
consists of impaction stages needed to quantify total particulate matter and PM 2.5
concentrations. The weight gain of each stage's substrate is measured with a high resolution
analytical microbalance capable of measurement to 0.00001 g. Refer to Appendix C, SOP, for
detailed verification test sampling procedures.
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DUST FEED FROM EXTERNAL HOPPER
DUST CHARGE NEUTRALIZER
RECTANGULAR CHANNEL
43/8'x111/2'
Fl LTER FIXTURE AND TEST Fl LTER
CYLINDRICAL EXTRACTION TUBE
MASS FLOW
CONTROLLER
BACK-UP
FILTER
CLEAN GAS SAIVPLE PORT
RAW GAS SAIVPLE PORT
CLEANING SYSTEM
ABSOLUTE FILTER AND
ANDERSEN IMPACTOR
ADJUSTABLE
VALVES
CALIBRATED
ORIFICE
DIRTY AIR
FILTER
CLEAN AIR PUMP
DIRTY AIR PUMP
DUST
CONTAINER
Figure 2. LTG/FEMA Test Apparatus
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B2.0 Sampling Methods Requirements
B2.1 Filter Media Samples
Verification test filter media samples will be supplied directly to ETS, Inc. from the
manufacturer. The samples will be accompanied by a letter signed by the manufacturer's CEO,
president, or other responsible corporate representative, attesting that the media samples were
randomly selected as to production run and roll location and are representative of what is
supplied to the commercial market. Included in the signed letter will be a description of how the
samples were selected. The manufacturer will supply ETS, Inc. with nine samples (46 x 91 cm
[18 x 36 in.]); from these ETS, Inc. will select three samples to prepare test specimens. A chain-
of-custody form will be filled out when the samples are received by ETS.
For purposes of product identification (by, for example, ETS, Inc., auditors, end-users, and local
inspectors), the manufacturer must label or tag the filter media in a reasonably permanent
manner to show the name of the manufacturer, type of filter media, all applicable model numbers
pertaining to the sample, cake side, and date (year and month) of manufacture; if this information
is not present, ETS, Inc. will reject the media for BFP verification testing.
B2.2 Impactor Filter Samples
Impactor samples will be purchased from the impactor manufacturer. Each impactor substrate
filter will be stored in aluminum foil and preweighed according to the procedures detailed in the
SOP. Each piece of aluminum foil will be labeled to match its corresponding substrate filter.
Each label will be made with permanent marker directly on the foil to avoid extra label weight.
B3.0 Sample Handling and Custody Requirements
A key issue in the verification process is the integrity of the sample tested. The goal of sample
preparation and management is to ensure that proper sample custody and management practices
are implemented to respond to this issue. Sample preparation consists of providing the proper
test specimen for verification testing purposes. Sample management is the overall process by
which samples are controlled, transferred, handled, and stored from the time of collection
through analysis. Sample management refers to those activities aimed at ensuring sample
integrity. Chain-of-custody involves establishing accountability for the sample, documenting
how the sample is received, tracked, and stored, and defining who has access to the samples and
who handles the samples.
• Sample Chain-of-Custody - The purpose of sample chain-of-custody is to ensure the
traceability of the handling and possession of each sample from the time of collection
through the completion of analysis. The following information is requested when
samples are shipped to ETS: ETS' name and address, sample identification and letter of
sample integrity as described previously in Section B2.0, and test that will be conducted.
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A log generated by the Test-Specific Manager is utilized for chain-of-custody. Examples
of a chain-of-custody record can be found in Appendix B.
Sample Labels - Exclusive test method sample labels are generated for each incoming
sample. These labels must be used on each sample and will be used in sample number
order to avoid confusion on a test job. Labels for the impactor filters are written with
marker directly on the storage foil so that measurements do not include additional label
weight.
B4.0 Analytical Methods Requirements
To simulate dust loading conditions within a baghouse ETS will be using the procedure specified
in Appendix C. The performance of the fabric will be determined relative to the verification
parameters listed previously in Section A6.1.1.
B4.1 Materials and Apparatus
The required materials that will be used to perform an accurate and valid test are listed below.
Any substituted equipment will be comparable to the equipment and performance requirements
of the following list and will receive APCT Center approval prior to verification testing and will
also be noted in the verification report. For greater detail pertaining to the following equipment,
refer to Appendix C, which contains the verification test SOP.
The LTG/FEMA test apparatus, based on the German VDI method 3926, provides an appropriate
baghouse filter media test apparatus. This equipment allows the user to measure filter
performance under defined conditions with regard to the filtration velocity (G/C), particle size
distribution, and cleaning requirements. Filtration and cleaning conditions can be varied to
simulate conditions that prevail in actual baghouse operations. For a discussion of components
within the test apparatus, refer to section B1.1. For a list of equipment makes, model numbers,
and ranges proceed to Table 3.
B4.1.1 Test Apparatus
ETS will perform the BFP verification tests using the specified LTG/FEMA test apparatus. The
APCT Center-approved components used with the BFP test apparatus consist of the following
items:
- Electronic data logger or programmable logic controller.
- Dust feed weight measurement device.
- Dust feed hopper.
- Thermocouple.
- Pressure transducer.
- Removable clean gas channel.
- Manual pulsing function.
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- Test dust (aluminum oxide).
B4.1.2 Test Dust
ETS has obtained Pural NF as the verification test dust to comply with the requirements
specified in the Generic Verification Protocol For Baghouse Filtration Products (October 8,
2001). The shipment of Pural NF will be tested for conformance with requirements of the
generic verification protocol. The Pural NF must conform to the specification of greater than
99.6% A12O3 content, a mass mean aerodynamic diameter of 1.5 ± 1.0 jam, and a particle size
weight percentage of 50% (+40 -10 %) less than 2.5 jim, as determined by the average of three
Andersen impactor test runs performed with the test conditions specified in the generic
verification protocol, Table 2. The impactor will utilize all five of the manufacturer designed
particle size separation stages above the 2.5 |im stage. The stages that capture particles larger
than 2.5 jim are used as a filter to prevent larger particles from removing smaller particles in the
succeeding stages.
B4.1.3 Analytical Balances and Associated Equipment
- Low resolution analytical balance for sample filters.
- High resolution analytical balance for impactor filter stages.
B4.1.4 Calibration Weights and Associated Equipment
- Dust feed scale.
- Aluminum foil.
- Permanent marker for labeling.
- Tweezers.
- Humidity- and temperature-controlled work space.
- Recovery brush.
- Continuous temperature and humidity monitor with data-logging capabilities.
B4.1.5 Impactor, Collection Substrates, and Associated Materials
- Andersen model 50-900 impactor.
- Collection substrates.
- Acetone.
- Wash bottles.
B4.1.6 Absolute Filter Assembly With Untared Filters
- Absolute filter assembly with untared filters.
- Paraffin film or Teflon tape.
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Table 3. Test Apparatus Equipment
Revision 2
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Page 3 Oof 86
Component
Optical Photo Sensor
Impactor
Mass Flow Controllers
Dust Feeder
Thermocouple
Pressure Transducer
High Resolution
Analytical Balance
Low Resolution
Analytical Balance
Absolute Filter
Temperature and
Humidity Monitor
Vacuum Pump
Barometer
Make
Sick Optic Electronic
Andersen
Hastings Instruments
Sensor Techniques Limited
LTG GmbH
Hastings Instruments
Precisa
Mettler
Andersen Instruments, Inc.
ACR Systems, Inc.
Rietschle
Princo
Model Number
FW 56-D/T
50-900
HFC-202
NDF100
"K" Type
223DB-00010AABS
262SMA-FR
P 1210N
50-31 (Oor2)
Smart Reader 2
VLT15
Nova Full Range
Mercurial
Performance Capability
± 0.4 %
0 to 12 nfVhr
(Oto7.1ftVmin.)±l%
20 to 200 g/hr
(0.044 to 0.44 Ib/hr)
0 to 250 °C
(32 to 482 °F)
0 to 2000 Pa
(0 to 0.29 psi) ± 0.5 %
0.00001 g
0.0001 g
99.99 %
-20 to 40 °C
(.4 to 104 °F)
±10%RH
15 m3/hr (ftVmin.)
636 to 838 mm Hg
(25 to 33 in. Hg).
B4.1.7 Ambient Humidity and Barometric Pressure Measurement Devices
- Barometer.
- Sling psychrometer.
- Ambient humidity measurement monitor.
B4.2 Procedures
Detailed procedures are provided in the attached SOP, Appendix C. Prior to loading the sample
filter, the LTG/FEMA test apparatus must be set at a G/C of 120 m/hr (6.6 fpm) and a dust
loading of 18.4 g/dscm ( 8.0 gr/dscf). Before the performance evaluation test can be performed,
the sample filter media must be subjected to a conditioning period consisting of 10,000 rapid
pulses and a recovery period consisting of 30 pulses at normal test conditions. The sample filter
and the absolute filter are loaded into the LTG/FEMA test apparatus, and a sufficient amount of
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test dust is placed in the dust feed hopper (see Appendix C, SOP section 3.2 for detailed dust
amount requirements). Once the LTG/FEMA test apparatus has been prepared, the sample filter
media will be subjected to 10,000 rapid pulses at 3-second intervals. The dust loading and the
G/C will be calculated on a block average for each 60 consecutive minutes during the test and
for the last 60 minutes of each test. The parameters as listed in SOP section 4.4.1 must be
measured and recorded to confirm that the conditioning period requirements are maintained.
The recovery period will be a continuation of the conditioning period, except the pulse filtration
frequency will be reduced to normal pulse frequency, determined by the 1,000 Pa (4.0 in. w.g.)
residual pressure drop. The recovery period does not have to be run immediately after the
conditioning period, but the test apparatus and the sample filter must remain unchanged and
untouched.
Prior to the commencement of the performance test, the dust must be replenished within the dust
feed hopper (see SOP section 3.2), and the impactor must be inserted into the LTG/FEMA test
apparatus. The performance test will be performed using normal pulse filtration cycles as
required in the recovery period. The performance test will be run for 360 continuous minutes.
The recording requirements, as listed in the attached SOP, sections 4.4.1 and 4.4.3.2, will
continue to be followed during the performance test period.
If the G/C and the dust loading requirements are not maintained throughout the performance test
period, the test will be voided and will be repeated using a new filter sample.
Refer to the SOP, Appendix C, for detailed step-by-step procedural directions.
B5.0 Quality Control Requirements
Data quality objectives and test specifications are shown in Tables 1 and 2, respectively. The
quality control limits are specified in Table 4. The means of measuring and verifying the
attainment of the data quality objective, and corrective actions that will taken if needed, are
discussed below for each item.
B5.1 Test Dust Particle Size Percentage and Mass Aerodynamic Diameter
The mass mean diameter and particle size distribution of the test dust will be measured monthly
(or with each new shipment). The determination will be made by the average of three Andersen
impactor runs conducted on the raw-gas channel upstream of the test filter. The values obtained
from these dust particle size checks will be accumulated in spreadsheet form to allow
construction of trend lines with all accumulated data.(see Appendix C, sections 4.3.3 and 4.3.4
for testing procedures).
In the event the mass mean diameter and weight percent <2.5 jim do not meet the criteria
specified in Table 2, the APCT Center will be notified and testing will be suspended until
corrective action is taken.
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B5.2 Filter Sample Diameter
Procedures for the filter sample preparation are detailed in Appendix C, section 4.2. The
procedure for cutting the filter sample is to use the test apparatus sample clamping ring as a
template for cutting. This is a go/no-go procedure, samples cut either too small or too large are
unusable.
B5.3 Flow Rates (Raw Gas, Sample Gas, and Clean Gas)
The raw-gas, sample-gas, and clean-gas flow controllers will be calibrated quarterly against a
dry gas meter as described in section B7.3. The dry gas meter will be calibrated annually by the
manufacturer.
B5.4 Gas Temperature
The thermocouple is calibrated quarterly against an ASTM mercury-in-glass thermometer. The
thermocouple must agree with the reference thermometer to within ± 1 °F.
B5.5 Inlet Dust Concentration
The dust feed weight cell is calibrated prior to each test series. The calibration is conducted by
placing a 2-3 kg NIST-traceable span weight in the weigh hopper prior to each test series. In
addition the dust concentration is measured in the raw gas channel. This measurement is made
in conjunction with impactor tests described in section B5.1.
B5.6 Weight Gain of Reference Fabric and Maximum Pressure Drop
Once each quarter the test apparatus is calibrated against the APCT supplied reference fabric
employing the test dust and test conditions as used for the verification tests. The calibration
procedures will comply with those described in section 2.4 of the Generic Verification Protocol
for Baghouse Filtration Products (October 8, 2001) and consists of three 30 cycle reference
fabric test runs. As specified in Table 1, the weight gain of the reference fabric and the
maximum pressure drop recorded on each of the three reference value test runs must fall within
±40% of the weight gain and maximum pressure drop averages of the APCT reference values.
Specifically,
0.65g
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B5.7 Mean Outlet Particle Concentration (PM 2.5 and Mass)
Quality Control procedures for the calibration, inspection, and operation of the test apparatus are
described in sections B5.0 - B7.0 of this Test/QA Plan. In addition, procedures for proper pre-
test, test, and post-test impactor are described in Appendix C, sections 4.2 - 4.2.3, 4.4.3.1, and
4.5 - 4.5.2. If all of the above procedures are followed, the DQO of ± 15% for these parameters
is satisfied.
B5.8 Initial, Final, and Average Residual Pressure Drop Across the Sample
The residual pressure drop across the filter sample is measured 3 seconds after the conclusion of
the cleaning pulse (once per filtration cycle). It is monitored and recorded continuously
throughout the recovery and performance periods of each test. The pressure transducer is
calibrated annually by the manufacturer and is checked against an oil manometer, Dwyer model
424-5, 0.1-in. with accuracy of ± 1%, prior to each test series.
B5.9 Average Filtration Cycle Time
The time between filtration cycles is monitored and recorded continuously throughout the
recovery and performance periods of each test. The timer clock is calibrated quarterly to NIST
time. If the timer clock is not within 1-second agreement with the NIST signal over a 1-hour
period, the timer clock is replaced with a unit that maintains 1-second agreement with the NIST
signal over a 1-hour period.
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Parameter
Test Dust Particle Size Percentage
Test Dust Mass Mean Aerodynamic Diameter
Filter Sample Diameter
Inlet Raw-Gas Flow rate
Filtration Velocity
Gas Temperature
Inlet Dust Concentration
Weight Gain of Reference Fabric
Maximum Pressure Drop (with respect to reference fabric)
Mean Outlet Particle Concentration PM 2.5 (g/dscm)
Mean Outlet Particle Concentration Mass (g/dscm)
Average Residual Pressure Drop Across Sample (cm w.g.)
Initial Residual Pressure Drop (cm w.g.)
Residual Pressure Drop Increase (cm w.g.)
Average Filtration Cycle Time (sec.)
Frequency and
Description
Monthly and each new
shipment
Monthly and each new
shipment
Each test specimen
Each test run
Each test run
Raw gas temperature
measured each test run
Raw gas dust concentration
measured each test series
Quarterly
Quarterly
Each test run
Each test run
Each test run
Each test run
Each test run
Each test run
Control Limit
+40 - 10 %
±1.0 urn
± 1.6 mm
(0.063 in)
±0.3 mVhr
(O.lSftVm)
±6m/hr
(0.3 ft/m)
±2°C
(4°F)
± 3.6 g/dscm
± 40 %
± 40 %
± 15 %
± 15 %
±5%
±5%
±5%
± 1%
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B6.0 Instrument/Equipment Testing, Inspection, Maintenance
As part of each test series, tests are performed to assess the reliability and accuracy of the test
apparatus. In compliance with the BFP generic test protocol section 2.4, quarterly testing using
the reference fabric is conducted to verify the accuracy of the pressure drop transducer and the
dust feed rate. Prior to each test series the appropriate instrument settings necessary to achieve
the test specification filtration velocity and dust feed rate are determined by physically
measuring the gas flow, and calibrating and monitoring the dust-feed load cell. In addition, a
dust-feed check consisting of three dust characterization tests will be performed monthly to
confirm the concentration and dispersion of dust in the raw-gas channel. These procedures are
detailed in Appendix C, Standard Operating Procedures. Should any of these checks not meet
the specified criteria, testing is stopped until corrective adjustments are made and re-inspection
meets the criteria.
Periodic preventive and corrective maintenance is conducted according to manufacturer's
instructions on apparatus and equipment components such as the compressed air system, raw-
and clean-gas pumps, and the dust feed system.
B6.1 Equipment Inspection and Maintenance
An effective preventive maintenance program is a necessary step in ensuring quality data.
Before each test series the equipment is inspected and its components are cleaned, repaired,
reconditioned, and recalibrated when necessary.
Occasional equipment failure is unavoidable despite the most rigorous inspection and
maintenance procedures. For this reason, ETS keeps spare equipment for critical testing
components.
B7.0 Instrument Calibration and Frequency
Calibration will be performed as outlined in Table 5. In addition to these calibrations, a series of
calibration checks are conducted on each instrument at least on a quarterly basis and in many
cases prior to each use.
Sections B7.1 through B7.9 provide the calibration check procedure and frequency of checks for
each instrument.
If no testing is being performed within the BFP verification program, no calibrations will be
performed. Prior to the recommencement of any BFP verification testing, calibrations on all
required equipment will be performed.
B7.1 High Resolution Analytical Balance
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The high resolution analytical balance will be calibrated by a factory service representative on an
annual basis. Prior to each use, the balance will be calibrated using the zero and span functions
of the balance. A calibration check will be performed prior to each use using the 1 g calibration
weight plus the clean substrate and the aluminum foil it is wrapped in. The tare weight of the
clean substrate/aluminum foil is approximately 750 mg. Typical substrate weight gains after
testing are expected to range between 1 and 4 mg. The balance should read to calibration weight
to within 0.00005 g. If not, repeat the procedure or adjust the balance until the value is obtained.
B7.2 Low Resolution Analytical Balance
The low resolution analytical balance will be calibrated by a factory service representative on an
annual basis. Prior to each use the calibration will be checked using the 100-g span weight. The
balance should display within 0.05 g of the NIST-certified calibration weight. If not, repeat the
procedure or adjust the balance until the value is obtained.
B7.3 Flow Meters and Flow Controllers
The dry gas flow meter will be calibrated annually by the instruments manufacturer. Quarterly
calibration checks will be conducted at a single point corresponding to the verification test
specification air flows for each instrument. The clean-gas flow instrument will be calibrated at a
flow of 1.10 ± 0.06 cfm (flow rate equivalent to a filtration velocity of 6.6 fpm). The raw-gas
flow instrument will be calibrated at a flow of 2.32 ± 0.1 cfm. The raw gas flowrate and the
clean gas flowrate will equal the total inlet raw gas flowrate of 3.4 ± 0.2 cfm. The sample-gas
flow instrument will be calibrated at a flow of 0.67 ± 0.03 cfm. Each calibration will be
conducted for a minimum of 10 minutes. A calibration factor will be used to adjust the
measurement to that of the wet test meter. If the pretest check deviates by more than 3 %, the
flow controller must be re-calibrated.
B7.4 Pressure Transducers
The pressure transducers will be calibrated annually against a reference pressure standard that
has been certified against NIST-traceable standards within the past year. Prior to each test series
each pressure transducer will be checked against an oil manometer to within 0.25 cm w.g. (0.1
in. w.g.). The pressure transducers will be calibrated at three points, zero, span, and at a pressure
typically encountered during the verification tests.
B7.5 Barometric Pressure Transducer
If a barometric pressure transducer is used, it will be calibrated prior to each test against the
mercury-in-glass barometer.
B7.6 Thermocouple in Raw-Gas Channel
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The thermocouple will be calibrated quarterly against an ASTM mercury-in-glass reference
thermometer at 77 ± 4 °F.
B7.7 Continuous Humidity and Temperature
This instrument will be returned to the factory for annual calibration with NIST traceability.
B7.8 Timer Clock
The timer clock should be calibrated quarterly to NIST time, which is obtained from the WWV
radio reference signal or from the NIST World Wide Web site, www.boulder.nist.gov/timefreq/.
If the timer clock is not within 1-second agreement with the WWV or website signal over a
1-hour period, the timer must be replaced with a unit that meets calibration requirements.
B7.9 Dust-Feed Weight Cell
This Instrument will be calibrated prior to each test series. The calibration will be conducted
with the dust-feed hopper empty, and placing a 2 kg span weight into the weigh hopper.
Calibration weight must meet ASTM class 4 with a NIST/NVLAP-traceable certificate.
Table 5. Instrument Calibrations and Frequency
Instrument
Low Resolution Analytical Balance
High Resolution Analytical Balance
Dry Gas Flow Meter
Pressure Transducers
Barometric Pressure Transducer
Thermocouple
Continuous Humidity and
Temperature
Timer Clock
Dust Feed Weight Cell
Calib. Frequency
Annual
Annual
Annual
Annual
Prior to each use
Quarterly
Annual
Quarterly
Prior to each test
series
Calibration Method
Factory calibration with NIST-traceable standards.
Factory calibration with NIST-traceable standards.
Factory Calibration
Against reference pressure with NIST traceability
Against mercury -in-glass barometer
Against ASTM mercury -in-glass reference
thermometer
Factory calibration with NIST traceability
Calibrate to NIST time
NIST certified span weights
The above calibrations will be recorded for inclusion in the Verification Report.
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B8.0 Inspection/Acceptance Requirements for Supplies
The Sample/Equipment Manager will receive reference filter media from the APCT Center .
The APCT Center will include a letter attesting that the fabric is identical to the components that
were identified in the generic verification protocol. The ETS Sample/Equipment Manager is
responsible for maintaining an adequate supply of all other consumable products, including but
not limited to, reference dust, absolute filters, impactor substrate filters, and acetone. The
Sample/Equipment Manager will verify the manufacturer's information (type, model number,
style, etc.,) for consistency and correctness. A supplies log and a chain-of-custody record will be
filled out and the correspondence from the APCT Center and other manufacturers will be marked
accepted and retained on file.
B9.0 Data Acquisition Requirements (Non-Direct Measurements)
Any data or reference source that is required while determining the verification parameters or
compiling the Verification Report, that is not a measured value, will be disclosed within the
Verification Report. The reference will include all pertinent information, including the reference
source title, section, and important information taken. This requirement includes databases that
might be used, programs, literature, and files. All existing data must meet the same quality
assurance requirements as are applicable to data generated during the verification tests and must
be generated independently from the sample media manufacturer as stated in the ETV quality
manual, Appendix C.
B10.0 Data Management
Interim stages of data review and validation will be provided for several key points in the
process to minimize revisions if corrections or changes are needed.
Test data will be input into computer spreadsheets following testing. Process data will consist
of logs and continuously monitored data. Data will be reduced and analyzed using computer
spreadsheets.
B10.1 Data Flow
All testing, data generation, and data analysis are performed within the ETS building. All data is
acquired in real time. The following shows the flow of data from its origin in the test laboratory
to final storage.
A. Data origination in test laboratory:
Data generated by the LTG/FEMA apparatus:
- Read in real time by a data acquisition computer located at the test rig.
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• Temperature.
• Air flow, raw gas, and filtration velocity.
• Filtration cycle time.
• Residual pressure drop.
• Maximum test pressure drop [1,000 Pa (4.0 in. w.g.)].
• Dust feed rate.
• Dust feed concentration stability (photometer)
Data generated manually or by observations:
- Readings are recorded manually on a test run sheet.
• Relative humidity.
• Atmospheric pressure.
• Impactor weight gains.
• Filter specimen weight gain.
B. Inspection of LTG/FEMA data for acceptance at the test site:
After each verification test, the data from the LTG/FEMA data acquisition computer are
transferred to a CD labeled with the corresponding test number.
The LTG/FEMA data from the CD is loaded into a spreadsheet program template. The
spreadsheet program computes the sample's verification parameters that will be reported
in the verification report.
The spreadsheet program is saved to the network and then to a diskette, using the
designated test number, to be filed in the data package.
C. Spreadsheets:
Two main spreadsheets are used during data reduction. A data analysis spreadsheet is
used to analyze the data from each individual run. There is a data analysis spreadsheet for
each of the conditioning, recovery and performance test period. An impactor analysis
worksheet is included as part of the performance test spreadsheet to determine impactor
data. A data summary spreadsheet is used to combine the results from the triplicate tests
and their associated control tests, and to record verification parameter results. Further
details pertaining to the spreadsheets, spreadsheet equations, and example spreadsheets
are located in the attached SOP, Appendix B.
D. Draft Report Preparation:
The test run sheets are delivered to the Report Manager. The Report Manager inspects
the test run sheets for completeness; if there are any omissions, the Report Manager
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immediately follows up with the Test-Specific Manager to fill in any missing
information.
Following the formats for the verification statement and report, as specified in the generic
verification protocol, the Report Manager prepares these documents.
The Report Manager will inspect all results for reasonableness and correctness relative to
test number, date and times of samples, and sample identification.
The Report Manager will maintain the data package in an appropriate storage area as
specified in Section A9.2.1.
E. Long-term Storage:
The original copy of all verification test data, calibration data, certificates of calibration,
assessment reports, verification reports, and verification statements will be retained by
ETS for a period of not less than 7 years after the final payment of the assistance
agreement as per Part A, Section 5.3 of the ETV QMP. A duplicate copy of the
verification reports and verification statements will be sent to the APCT Center Office
for storage.
Bl 1.0 Reporting
Upon completion of testing, the Report Manager will be responsible for compiling the data
summary into a Verification Report. The results of the test program will be evaluated for
completeness and representativeness and will include all valid data collected. The report will be
submitted in electronic form to the APCT Task Leader within 30 days after completion of
sampling. Data and results interpretations will be presented as necessary in the report. The
report will contain all items specified in Section 4.0 of the generic verification protocol including
but not limited to the following sections:
A: Title Page. The title page includes the client's name, ETS' laboratory information, the
client's location and company information, and the date(s) on which the testing was
conducted.
B: Table of Contents. The table of contents contains an outline of the test report and page
numbers on which the sections appear.
C: Figures & Table. The figures and tables page contains a listing of all figures and tables
located throughout the report including corresponding page numbers.
D: List of Abbreviations & Acronyms. A list of all acronyms and abbreviations located
throughout report and their definitions.
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E: Introduction. The introduction includes a background statement addressing sampling
purpose, and sampling type, Also included is the testing objectives for the program
F: Verification Test Description. Verification Test description section describes the
principles of operation for the test equipment, the advantages and limitations of the test
equipment, and any performance characteristics that affect testing, and the sampling and
analytical methods used and their applicability to the testing performed. Sampling data
and results, raw data, and laboratory data are referenced to their appropriate sections in
the Appendix.
G: Results . The summary of results section presents a summary and comparison of
verification parameters and critical measurements determined from the testing performed.
This section also includes a summary of laboratory QA/QC characteristics.
Any sampling or analytical problems encountered during the test program are also
discussed in this section.
H: References. The reference section includes all material and author information that was
used or cited during testing and report procedures.
I: Appendices.
APPENDIX A - Description of the test rig and the methodology
APPENDIX B - Data on Certificates of Calibration
APPENDIX C - Verification Testing Sheets
PART C ASSESSMENT/OVERSIGHT
Cl.O Assessments and Response Actions
The Test-Specific QAO may elect to perform a self-assessment during BFP testing. APCT
and/or EPA quality assurance staff may perform an independent assessment, including TSAs,
and PEs, during BFP verification tests to determine that the DQOs are met. The Test-Specific
QAO will conduct an ADQ for 10 % of all verification test data at the end of each round of the
verification tests and will determine if these measurements allow one to determine if the DQOs
have been attained. These technical assessments will be performed in accordance with EPA
Guidance for Technical Assessments for Environmental Data Operations(EPA QA/G-7).
The Test-Specific QAO will report the findings of these internal technical assessments to the
Verification Test Leader. The assessment report will recommend corrective actions, if such are
indicated by these findings. The Verification Test Leader and the Test-Specific QAO are
responsible for developing, documenting, and implementing corrective actions. They will
provide a written response to all assessment findings. Each finding will be addressed with
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specific corrective action steps and a schedule to implement them. Responses to adverse findings
are required within 10 working days of receiving the assessment report in accordance with the
requirements of Part B, Section 4.3 of EPA's Quality and Management Plan for the
Environmental Technology Program. The APCT Center Director will review and approve all
corrective actions.
Technical assessments and corrective actions are described in detail in Sections 3.4 and 3.5 of
the APCT QMP.
Technical personnel working on each task will have the direct responsibility for ensuring that the
Test/QA plan is implemented, that the operating parameters are within acceptable limits, and that
corrective actions are taken when appropriate. Corrective action will be taken whenever
measurements fall outside the limits of the data quality objectives for the critical measurements.
Corrective actions include:
• Problem identification,
• Attempting to find the cause,
• Attempting immediate repairs (if possible),
• Reporting or documenting the problem,
• Planning for corrective action (if major repairs are needed),
• Documenting the corrective actions taken, and
• Recommending changes to instruments, SOPs, etc. to
avoid similar future occurrences.
ETS will cooperate with EPA on scheduling EPA's assessments on this program.
C2.0 Reports to Management
The Test-Specific Manager will notify the Verification Test Leader and the Test-Specific QAO
when testing under this project is being conducted. The Test-Specific Manager will submit
verification reports and verification statements to the Test-Specific QAO. After technical
assessments, the Test-Specific QAO will submit the verification reports, and verification
statements to the Verification Test Leader. The Verification Test Leader will submit the reports,
and verification statements, to the APCT Center for review. After review is complete, the
APCT Center will submit the verification reports and the verification statements to the EPA
Project Manager for review.
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PART D DATA VALIDATION AND USABILITY
Dl.O Data Review, Validation, and Verification Requirements
Data quality audits will be conducted using data quality indicators that require the detailed
review of: (1) the recording and transfer of raw data; (2) data calculations; (3) the
documentation of procedures; and (4) the selection of appropriate data quality indicators. The
data quality indicators that will be used are as follows:
- Use of correct test conditions, as specified in Table 2, for the LTG/FEMA apparatus.
- Adherence to calibration schedule.
- DQOs attained as specified in Appendix A..
- Adherence to standard operating procedures.
All data and/or calculations for flow rates, dust feed rates, moisture content, isokinetic rates, and
particle concentrations and mass rates made using a computer software program will be validated
by an independent check. All calculations will be spot checked for accuracy and completeness.
In general, all measurement data will be validated based on the following criteria:
• Process conditions are at the required conditions during testing.
• Sample collection procedures are performed as required by SOP.
• Data are consistent with expected results.
• Sampling procedures adhere to prescribed QC procedures.
Any suspect data will be flagged and identified according to the specific deviation from
prescribed criteria and their potential effect on the data quality.
All QA/QC results will be reviewed before the data are released; any data that fail to meet the
program's QA/QC requirements will be documented and discussed.
D2.0 Data Transformation and Reduction
Standardized forms will be used to record data for each test method. These forms are provided
as attachment A to the SOP. All run sheets are to be reviewed daily by the Test-Specific
Manager for evaluation of progress, completeness, and nonconforming items. Standardized
computer spreadsheets will be used to reduce and analyze data. At the end of each test series,
test data will be input into these spreadsheets. Laboratory analytical results may not be available
at the end of each test day; however, results will be input as they become available. A standard
data set that has been verified by hand will be used to demonstrate the accuracy of the
spreadsheet calculations after the test program. Example spreadsheets and run sheets can be
found in the SOP Appendices A and B.
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D3.0 Validation and Verification Methods
Data validation is a systematic procedure of reviewing data against a set of established criteria to
provide a level of assurance of the data's validity prior to their use. Data will be validated
internally by QC personnel. All measurement data will be validated based upon process
conditions during sampling or testing, acceptable sample collection/testing procedures,
consistency with expected and/or other results, adherence to prescribed QC procedures, and the
specific acceptance criteria. The data will be coded as valid or invalid based on their adherence
to these criteria. Data validation will be conducted at several critical stages of data reduction:
Checks of raw and reduced data by the Test-Specific Manager;
• Analytical laboratory QC checks by the Test-Specific QAO;
Spot checks of reduced raw data by the Test-Specific QAO;
• Review of summary tables for consistency with reduced raw data by the Test-Specific
QAO; and
• Final report review by the Test-Specific QAO, Verification Test Leader, and Test-
Specific manager.
Data validation consists of verification of calculation methodology, consistency of raw, reduced,
and summarized data tables, comparison of expected results, and consistency of results among
multiple measurements.
Data will be initially validated by the Test-Specific Manager based on the representativeness of
the sample, maintenance and cleanliness of sampling equipment, and adherence to the sample
collection procedures. The data will also be validated on a daily basis based on process
conditions during sampling and adherence to acceptable criteria.
When the data set is complete, the ETS QA personnel will perform an overall review of the data.
The review will consider the above listed criteria and the reasonableness and consistency of the
data based on a knowledge of the site characteristics and the specific location of the samples.
The review will also contain an evaluation of the data in terms of meeting the quality assurance
objectives of the program. The acceptance or rejection of the data will be in a uniform and
consistent manner based on the established validation criteria. Data will be rejected only if a
valid and documented reason is identified.
Validation of spreadsheet calculations used for data reduction will be conducted by entering a
QA data set that has been verified by hand. Data flags will be added to all tables to identify
special handling procedures or unusual data results. These flags will include:
• Quantities including analytical results that are at or below method minimum detection
limits;
• Results for which contamination is suspected;
• Average results that exclude individual test run results; and
Other special handling procedures or qualifications.
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The purpose of validation and verification is to assess the degree to which the data meet the
quality specifications outlined in the generic verification protocol and this Test/QA Plan. If
deviations are noted, the validation procedures can be used to assess the effect the deviation will
have on data usability.
The first step in data validation and verification is to assess that the project, as executed, meets
the sampling design. Specific steps are listed below:
• Process data will be reviewed to ensure that the unit was operating within the limits
outlined in the project.
• Test dates and times will be reviewed to ensure that testing was performed as scheduled
and checked against the project design.
• The methods performed and the reference dust will be checked against the project design.
• Actual procedures documented in the test logs and on test data sheets will be checked
against the procedures described in this Test/QA Plan and the SOP.
• Deviations from the Test/QA Plan will be documented.
• Sample custody and preservation will be checked for each sample component against the
Test/QA Plan.
• The analytical procedures performed during the test program will be checked against
those described in this Test/QA Plan.
Any deviations will be documented in the report. The review of quality control data such as
duplicate sampling data and sampling verification checks can be used to validate test collection
activities. The review of data from calibration checks, reference media test runs, and other
quality control can be used to validate the analytical process. Acceptable precision and bias in
these samples would lead one to conclude that the analytical procedures are adequate. Any data
that indicate unacceptable levels of bias or precision will be flagged and investigated. This
investigation could lead to the discovery of inappropriate sampling activities or analytical
procedures, requiring corrective action.
Validation of QC procedures will require a review of the documentation of corrective actions
that were taken when QC samples failed to meet acceptance criteria, and the potential effect of
corrective actions on the validity of the data.
Validation of data reduction and processing procedures will require selection of 10 % of the data
chosen at random. Raw data files including pre-sampling, sampling, calibration, sample
handling/custody, analysis, corrective action, and data reduction will be reviewed and sample
calculations will be performed. The data will also be reviewed to ensure that data qualifiers have
been appropriately associated with the data and appropriate corrective actions have been taken
where needed.
All data will follow a chain-of-custody containing checks at each level. The chain-of-custody
for all test data collected will be as follows:
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1) The data is collected on standardized data sheets.
2) These data sheets are completed, organized, and reviewed by the Test-Specific Manager.
3) The Test-SpecificManager presents the test data package to the Report Manager, who
performs an additional review and prepares or organizes the preparation of the draft
Verification Report and draft Verification Statement.
4) The draft Verification Report and draft Verification Statement, including the test data, are
given to the Test-Specific Manager for review.
5) The draft Verification Report and draft Verification Statement, including the test data, are
given to the Test-Specific QA Officer for review.
6) The draft Verification Report and draft Verification Statement, including the test data, are
given to the Verification Test Leader for review.
7) The draft Verification Report and draft Verification Statement are sent to the APCT
Center for review, approval, and signature.
8) The draft Verification Report and draft Verification Statement are sent to the EPA for
review, approval, and signature.
During review of the verification report and verification statement, a Document Control and
Review form shall be maintained to track operational review and document custody.
D4.0 Reconciliation with Data Quality Objectives
ETS will complete a Reconciliation of Verification Test Results with Data Quality Objectives
form during the verification test series to record if the test results attain the DQOs. Using the
results obtained from the project and the comparison with quality assurance objectives, ETS will
investigate to identify any abnormal pattern or potential anomalies. ETS and the APCT Center
quality assurance staff will have the final evaluation as to whether or not the project met the
objectives of the sampling design, and whether or not departures, if any, from QA/QC guidelines
are significant and acceptable. The conclusions will be presented in the verification report.
Quality objectives for this project were designed to evaluate various phases (sampling,
preparation, analysis) of the measurement process to ensure that total measurement uncertainty is
within the range prescribed by the DQOs in Section A7.0. More specifically, the quality
objectives were defined in terms of the following data quality indicators:
• Accuracy,
• Precision, and
Completeness.
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D4.1 Accuracy
Accuracy results obtained during the test program will be checked against accuracy criteria in
Section A7.2 Measurement Performance Criteria. If data do not meet the accuracy quality
objectives, ETS will conduct an investigation to uncover and explain the cause.
Accuracy is defined as the agreement between a measurement and the actual (i.e., true) value.
For example, accuracy of an analytical measurement is expressed as the percent recovery of an
sample at a known concentration prior to analysis, and is expressed by the following formula:
y^T-r -^*~c\
Accuracy - % Recovery - x 100
AF
Where:
AT = Total amount found in known concentration or standard
A0 = Amount found in sample, and
AF = Amount added to sample.
D4.2 Precision
In this project, precision will be based on results for triplicate samples in terms of relative
standard deviation (RSD). Using the RSD of triplicate samples collected (three sampling runs)
and analyzed will provide an evaluation of the overall sampling and analysis precision.
Precision results obtained during the test program will be checked against precision criteria in
Section A7.2 Measurement Performance Criteria. If data do not meet the precision quality
objectives, an investigation will be conducted to uncover and explain the cause.
Precision is defined in EPA Requirements for Quality Assurance Project Plans for
Environmental Data Operations, EPA QA/R-5, as the measure of mutual agreement among
individual measurements of the same property, usually under prescribed similar conditions
expressed generally in terms of analysis of samples relative to the average of those results for a
given sample using the formula:
Where:
%RSD=— jclOO
X
%RSD = Relative standard deviation,
a = Standard deviation of the triplicate sample results, and
X = Average of the triplicate results.
D4.3 Completeness
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In this project, completeness is measured by the amount of valid data obtained from the
measurement system compared to the amount that was expected to be obtained under correct,
normal conditions. Completeness results obtained during the test program will be compared to
completeness criteria in Section A7.2 Measurement Performance Criteria. If data do not meet
the completeness quality objectives, an investigation will be conducted to uncover and explain
the cause.
Completeness is a measure of the relative number of analytical data points that meet all of the
acceptance criteria for accuracy, precision, and any other criteria required by the specific
analytical methods used. The level of completeness can also be affected by loss or breakage of
samples during transport, as well as external problems that prohibit collection of the sample.
As part of the data verification and validation process, these data quality indicators will be
calculated and compared to data quality objectives for the program. The final test report will
address whether or not objectives were met and, if not, the impact on the final data will be
determined.
D5.0 Corrective Action Procedures
The following occurrences will require corrective action:
1. QA Goals Not Achieved: This occurrence includes failure to achieve the specified
accuracy and completeness criteria.
2. Audit Deficiencies: Two types of audits will be conducted in this program. Internal
audits are conducted by the Test-Specific QAO, and external audits are conducted by the
APCT Center and/or EPA QA staff. Deficiencies may be identified during systems
and/or performance audits.
It is the responsibility of the Test-Specific QAO to bring to the attention of the Verification Test
Leader any of the problems listed above. The Test-Specific Manager, Test-Specific QAO, and
Verification Test Leader will then review and compare the QA and program goals to determine if
the specific QA problem will actually cause a problem in achieving the program goals. If it is
determined that the QA goals are too stringent, they will be modified (with approval of the
APCT Center Quality Manager) to reflect the current program objectives.
If the QA and program goals are determined to be satisfactory, the Verification Test Leader will
review the subject measurement systems and procedures. The Verification Test Leader will
proceed to solve measurement system problems as required. When the Verification Test Leader
has determined that the problems have been solved, the Test-Specific Manager and the Test-
Specific QAO will verify the results. This process may include specific calibration, and systems
and/or performance audits. Any remaining problems will be resolved by the Verification Test
Leader.
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APPENDIX A
Attaining the Quality Objectives for the Mean Outlet
Particle Concentration (PM 2.5 or total)
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Attaining the Quality Objective for the Mean Outlet Particle Concentration
(PM2 5 or total)
3
Let Mean Outlet Particle Concentration = MOPC = ^ (Cpo)i
7=1
whereCpo = a single measurement of the concentration of the ith run, for i = 1,2,3 (triplicate
runs), and
eMopc - error in MOPC,
Quality objective is: eMOPC < 15% for triplicate runs.
1. Apportion Total MOPC error as:
__
fcMOPC fcBias ^ fc Random -^
eBias < 10°/0 (maximum allowable deviation from reference fabric results)
(O.I)2 + (eRandom/3)2 < (0.15)2 => eRandom2 < 3[(0.15)2 - (O.I)2] = 0.0375
eRandom<0.19=19%
i.e., total random error in each measurement of the outlet particle concentration must be held to
19 percent or lower in order to attain the quality objective.
2. Each measurement of Outlet Particle Concentration (Cpo):
Cpo = Dmass/V0utlet where:
5
Dmass = 2^ [(SubstmteMass^Finai - (SubstrateMass}imtiai\i for impactor stages,
7=1
= [(MasslFinal + eMass) - (MasslMtial + eMass)] +
(Mass2Final + eMass) - (Mass2Initial + e^J +
(Mass3Final + eMass) - (Mass3Initial + eMass) + ...]
= [(Mass lFinal-Mass llnitial) + (Mass2Final-Mass2Initial)+ . . . + E^M™)]
for impactor stages i = 1, 2, ...., 5 for the 5 stages of the impactor that will be used.
where eMass = measurement error in each handling and weighting of each substrate.
= Sampled Volume = (Flowrate)^^, x (Sampling Time)
= Vimp since the entire sampled volume of the clean gas is drawn through the
impactor.
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Then (sc/Cpo)2 = (sD/Dmass)2 + (sv/Vimp)2;
= 2*5[0.000005/0.00013 ]2 + [0.42/7.0 ]2 = 0.0184
where sc, SD, and sv are the measurement errors in Cpo, Dmass, and Vimp, respectively, and it is
assumed that the cumulative substrate mass gain is uniformly distributed over all 5 stages
(Cpo x Vimp = 0.000644 g/5 stages, = 0.00013 g/stage), with 2 weighings per stage (pre-
and post-sampling weighing).
Sc/Cpo ~ 14%, computed using the following assumed values:
SD
n
^mass
Cpo
sv
imp
Value
0.000005 g
5
0.000644 g
0.000092 g/dscm
0.42 m3
7m3
Source
l/2 balance resolution (weighing by difference effectively removes
systemmatic error)
Number of impactor stages + filter
=Cpo x Vimp (expected cumulative mass gain per 5 stages
Assumes 99.9995% removal efficiency at inlet concentration of
18. 4 g/dscm
Table 2, generic verification protocol (0.06 m3/dscm)
Sampled volume - through impactor
Since it is estimated that sc/Cpo < ^^nAom (that is, 14% < 15%) for this plan, then it can be
reasonably expected that the operating specifications will satisfy the DQOs of Table 2.
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APPENDIX B
Example Sample Chain-of-Custody Record
Example Label
Example Record of Consumables
Example Inspection/Acceptance Testing Requirements
Example Log for Tracking Supplies and Consumables
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Example
Chain-of-Custody Filter Media Samples
Station
Location
Receiving
Selection and
Preparation
Pre-test
Weighing
Testing
Post-test
Weighing
Storage
Date
10-17-99
10-25-99
10-25-99
10-26-99
10-27-99
10-28-99
10-27-99
10-28-99
10-29-99
10-25-99
10-28-99
10-29-99
10-30-99
Time
4:20 pm
09:00 am
09:00 am
08:00 am
08:00 am
08:00 am
10:00 am
10:00 am
10:00 am
11:00 am
11:00 am
11:00 am
11:00 am
Sample
Manufacturer
BASF
BASF
BASF
BASF
BASF
BASF
BASF
BASF
BASF
BASF
BASF
BASF
BASF
Sample ID
Number
99-577BFP3-A
99-577BFP3-A
99-577BFP3-A
99-577BFP3-A
99-577BFP3-A
99-577BFP3-A
99-577BFP3-A
99-577BFP3-A
99-577BFP3-A
99-577BFP3-A
99-577BFP3-A
99-577BFP3-A
99-577BFP3-A
No. of
Samples
9
9
3
1
1
1
1
1
1
9
1
1
1
Responsible
Individual
TW
TW
FC
AH
AH
AH
FC
FC
FC
TW
TW
TW
TW
Example
Sample Label
Manufacturer
Contract No.
Test Method
Sample ID No.
Type of Media
Example
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Record for Consumables
Unique Identification No.
Date Received
Date Opened
Date Tested
Date to be Retested
Expiration Date (If Applicable)
Example
Inspection/Acceptance Testing Requirements
Critical
Supplies and
Consumables
Inspection/
Acceptance
Testing
Requirements
Acceptance
Criteria
Testing
Method
Frequency
Responsible
Individual
Handling/Storage
Conditions
Example
Log for Tracking Supplies and Consumables
Critical
Supplies and
Consumables
(Type, ID No.)
Date
Received
Meets
Inspection/
Acceptance
Criteria (Y/N,
Include Date)
Requires
Retesting
(Y/N, If yes,
Include Date)
Expiration
Date
Comments
Responsible
Individual
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APPENDIX C
Standard Operating Procedures for Verification Testing
of Baghouse Filtration Products
Using FEMA Test Apparatus
(July 2005)
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STANDARD OPERATING PROCEDURES FOR
ETV VERIFICATION TESTING OF
BAGHOUSE FILTRATION PRODUCTS
July 2005
ETS, INC.
ETS, Inc.
1401 Municipal Road, N. W.
Roanoke, VA 24012
540-265-0004
540-265-0131 fax
Pollution Control Consultants
Specializing In
Toxic Emission Measurement and Control
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Contents
1.0 Principal and Applicability 60
1.1 Principal 60
1.2 Applicability 60
2.0 Definitions 60
2.1 Conditioning Period 60
2.2 Conditioning Period 60
2.3 Dust Shipment 60
2.4 Gas-to-Cloth Ratio 60
2.5 Residual Pressure Drop 60
2.6 Recovery Period 61
2.7 Filtration Cycle 61
2.8 Filtration Cycle Time 61
2.9 Performance Test Period 61
2.10 Test Phase 61
2.11 Test Run 61
2.12 Test Series 61
3.0 Materials and Apparatus 61
3.1 Test Apparatus and Materials 61
3.2 Test Dust 62
3.3 Analytical Balances and Associated Equipment 62
3.4 Impactor, Collection Substrates and Associated Materials 63
3.5 Absolute Filter Assembly With Untared Filters 63
3.6 Ambient Humidity and Barometric Pressure Measurement Devices 63
4.0 Procedure 63
4.1 Pretest Preparation 63
4.2 Sample Filter Preparation 63
4.3 Preliminary Determinations 65
4.4 Verification Test Series 66
4.5 Sample Recovery and Handling 67
5.0 Calibrations 68
5.1 Prior to Each Use 68
5.2 Every Three Months 68
5.3 Once per year 69
6.0 Calculations 69
6.1 Nomenclature 69
6.2 Area of Fabric - Af 70
6.3 Actual Gas flow Rate - Qa 70
6.4 Gas-to-Cloth Ratio - G/C 71
6.5 Standard Dust Feed Rate - Fs, for a specified time -1 71
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6.6 Actual Raw-Gas Dust Concentration - Fa 71
6.7 Dry Standatd Clean-Gas Particulate Concentration, Total Mass - Cds 71
6.8 Dry Standard Clean-Gas Particulate Concentration, PM25 - C25ds 71
6.9 Filtration Cycle Time - tc 71
6.10 Average Residual Pressure Drop - APavg 72
7.0 Data Reduction and Analysis 72
7.1 Data Flow 72
7.2 ASCII Text Files 73
7.3 Files Containing Detailed Summary and Results of VDI Data 73
7.4 Impactor Data Files 74
8.0 Verification Report 75
Appendix A: Example Data Sheets 76
Appendix B: Verification Testing Spreadsheets 80
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1.0 Principal and Applicability
1.1 Principal
A fabric filter sample is subjected to a dust loading under simulated baghouse conditions using a
FEMA test apparatus, which is modified from the Verein Deutscher Ingenieure (VDI) Method
3926 test apparatus. The performance of the fabric is determined relative to the following
verification parameter:
• Outlet particle concentration, PM 2.5 g/dscm (gr/dscf).
• Outlet particle concentration, total mass g/dscm (gr/dscf).
• Average residual pressure drop (3 seconds after cleaning) cm w.g. (In. w.g.).
• Initial residual pressure drop of 6-hour performance test period, cm w.g. (in. w.g.)
• Residual pressure drop increase (final - initial) cm w.g. (in. w.g.).
• Average filtration cycle time (time required to reach a specified pressure drop after
cleaning) s.
• Number of filtration cycles during performance test period
• Mass gain of test sample filter at test completion g.
1.2 Applicability
This method is applicable for the determination of the above verification parameters for flat
baghouse filtration fabrics. If a filter structure other than flat swatches are to be tested, the
vendor/manufacturer needs to work with ETS to propose a modification for the test apparatus
that is acceptable to EPA/APCT and meets all aspects of the data quality objectives identified in
the generic verification protocol.
2.0 Definitions
2.1 Residual Pressure Drop Increase
The difference in residual pressure drop over the performance test period calculated by
subtracting the average residual pressure drop of the first ten filtration cycles from the average
residual pressure drop of the final ten filtration cycles
2.2 Conditioning Period
The period during which the fabric sample is conditioned within the test apparatus by subjecting
it to 10,000 pulses with 3 seconds between pulses. Thus, the conditioning period should require
8 hours and 20 minutes for completion. Use a dust load during the conditioning period of 18.4
+ 3.6 g/dscm (8.0 +1.6 gr/dscf) as specified in the generic verification protocol and Test/QA
Plan.
2.3 Dust Shipment
All test dust received in the same shipment and having the same lot number.
2.4 Gas-to-Cloth Ratio
The filtration velocity of the gas stream entering the test fabric in meters per hour as determined
by the flow measured in the clean-gas channel (in cubic meters per hour) divided by the exposed
surface area of the fabric (in meters squared). The verification test shall maintain a G/C of 6.6
(120 m/hr).
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2.5 Residual Pressure Drop
The pressure drop in centimeters, water gauge across the fabric sample contained in the test
apparatus three seconds after a specified cleaning pulse.
2.6 Recovery Period
A time period following the conditioning period during which the fabric is allowed to recover
from rapid pulsing. The recovery period requires 30 filtration cycles under normal test
conditions. Use a grain loading during the fabric recovery period of 18.4 + 3.6 g/dscm (8.0 +
1.6 gr/dscf).
2.7 Filtration Cycle
The time period between two consecutive cleaning cycles or pulses during testing.
2.8 Filtration Cycle Time
The duration or time expressed in seconds defined by one filtration cycle.
2.9 Performance Test Period
A 360-minute test period following the fabric recovery period during which the verification
testing is performed. Pulsing shall occur at a differential pressure of 1,000 Pa (4.0 in. w.g). Use
a grain loading during the performance test period of 18.4 + 3.6 g/dscm (8.0 +1.6 gr/dscf).
2.10 Test Phase
The particular phase of a test run consisting of either the conditioning period, recovery period, or
performance test period.
2.11 Test Run
The sum of three test phases including the conditioning period, recovery period, or performance
test period.
2.12 Test Series
Three test runs performed in series.
3.0 Materials and Apparatus
3.1 Test Apparatus and Materials
3.1.1 Test Apparatus: The test apparatus complies with the specifications that are stated in the
Generic Verification Protocol for Baghouse Filtration Products (October 8, 2001), which
consists of the following component modifications as specified in the following sections.
3.1.1.1 Electronic Datalogger or Programmable Logic Controller: With the ability to record
residual pressure drop and filtration cycle time for each filtration cycle during the performance
test period and the ability to record dust feed weight, raw-gas flowrate and clean-gas flowrate
(including sample bypass and sample-gas flowrate during the performance test period).
Recording frequency must allow calculation of all necessary verification data, but must not be
less than once per minute.
3.1.1.2 Dust Feed Weight Measurement Device: A scale beneath the entire dust feed
mechanism including the dust hopper with a continuous readout capable of measurement to the
nearest 10 g.
3.1.1.3 Dust Feed Hopper: A dust feed hopper with a minimum capacity of 1.0 kg of aluminum
oxide. Dust
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3.1.1.4 Thermocouple: Located in the raw-gas channel upstream of the filter sample. This
temperature can be assumed constant throughout the test apparatus.
3.1.1.5 Removable Clean-Gas Channel: The cylindrical clean-gas channel behind the test filter
shall be constructed to allow for cleaning as specified in Section 4.2.4.4.
3.1.1.6 Adjustable Sample and Sample Bypass Channels: Following the clean-gas channel,
the clean-gas flow shall be separated into two gas streams, a sample and sample bypass. An
aerodynamic "Y" shall be used for this purpose. The aerodynamic "Y" shall be designed for
isokinetic separation of the clean-gas with 60.2 percent of the clean-gas entering the sample-gas
channel without change in gas velocity. The sample-gas channel shall contain an impactor (see
section 3.4) for particle separation and measurement. The bypass channel shall contain the
absolute filter assembly used in the FEMA test apparatus The sample-gas channel shall be
operated at a flow rate of 1.13 + 0.06 m3/hr (0.67 + 0.03 acfm), and a sample bypass channel
shall be operated at a flow rate of approximately 0.45 nrVhr (0.43 acfm). Flow in the two gas
streams shall be continuously monitored and maintained by adjustable valves. A single pump
and mass flow controller may be used on the clean-gas side by joining the sample and sample
bypass channels downstream of the impactor and flow control valves, provided proper gas flow
rates are monitored and maintained.
3.1.1.7 Manual Pulsing Function: The test apparatus must be configured to allow for manual
pulsing when the dust feeder and the air compressor are not in operation.
3.2 Test Dust
Aluminum Oxide Pural NF or equivalent, having an A12O3 content of greater than 98.6 percent.
The test dust must meet the following specifications as determined by the procedures of Section
4.3.3. mass mean diameter: 1.5±1.0wm
weight percent < 2.5 um: 40-90%
At a dust feed rate of 18.4 g/dscm, approximately 100 g/hr of test dust is required in the test
apparatus. A conditioning period of 10,000 pulses at 3 seconds per pulse requires a duration of 8
hours and 20 minutes for a total estimated dust feed of approximately 833 g. The fabric recovery
period of 30 pulses may require up to 90 minutes or greater. A dust capacity of at least 300 g is
recommended. Likewise, the performance test period of 6 hours requires an estimated dust feed
of approximately 600 g. Allow at least an additional 10 percent of dust to account for variations
in test conditions.
3.3 Analytical Balances and Associated Equipment
3.3.1 Low-Resolution Analytical Balance for Sample Filters: Capable of measurement to
within 0.01 g.
3.3.2 High-Resolution Analytical Balance for Impactor Substrates: Capable of
measurement to 0.00001 g. The balance must be equipped with a draft shield enclosure and an
anti-static device within the enclosure.
3.3.3 Calibration Weights:
3.3.3.1 Dust Feed Scale: 2 kg span weight. Calibration weights must meet ASTM Class 4 with
a NIST/NVLAP Traceable Certificate.
3.3.3.2 Low-Resolution Analytical Balance: 100 g span weight. Calibration weights must meet
ASTM Class 4 with a NIST/NVLAP Traceable Certificate.
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3.3.3.3 High-Resolution Analytical Balance: 1 g daily-check weight and 50 g span weight for
calibration. Calibration weight must meet ASTM Class 1 standards with NIST/NVLAP
certification.
3.3.4 Aluminum Foil
3.3.5 Permanent Marker for Labeling
3.3.6 Single Thickness Class 100 Wipes: Crew 33330 by Kimberly-Clark, or equivalent.
3.3.7 Tweezers
3.3.8 Recovery Brush: Suitable for recovery of loose dust from the impactor plates.
3.3.9 Humidity- and Temperature-Controlled Work Space
3.3.10 Continuous Temperature and Humidity Monitor with Data-Logging Capabilities:
Smart Reader 2 - Temperature & Relative Humidity Logger by ACR Systems, Inc., or
equivalent.
3.4 Impactor, Collection Substrates and Associated Materials
3.4.1 Andersen Model 50-900 Impactor or Equivalent: Capable of capturing total
particulate matter and measuring particulate matter having a mean aerodynamic diameter of 2.5
urn.
3.4.2 Collection Substrates: Glass fiber substrates and backup filter. Andersen Instruments
Incorporated Product Number 50-31(0 or 2) or equivalent.
3.4.3 Acetone: Reagent grade, < 0.001 percent residue in glass bottles.
3.4.4 Wash Bottle: Polyethylene or glass for use in the acetone rinsing of Impactor
components only. Do not store acetone in the wash bottles.
3.4.5 Paraffin Film or Teflon Tape: For sealing the impactor after assembly and when not in
use.
3.5 Absolute Filter Assembly With Untared Filters
As specified in VDI Method 3926, suitable to protect the clean-gas flow measurement device
and pump. The filters used in this assembly are not required to be subjected to the handling
procedures of Section 4.2.2, as they are not subject to gravimetric analysis. The tester may
choose to use these filters for analysis, in which case the procedures of Section 4.2.2 are
recommended.
3.6 Ambient Humidity and Barometric Pressure Measurement Devices
3.6.1 Barometer: Capable of reading atmospheric pressure to within 2.5 mm (0.1 in) Hg. In
many cases the barometric pressure may be obtained from a nearby National Weather Service
station, in which case the tester must subtract 2.5 mm (0.1 in) Hg per 100 feet of elevation
increase. (Add 2.5 mm (0.1 in) Hg per 100 of elevation decrease.)
3.6.2 Sling Psychrometer or Ambient Humidity Measurement Monitor: Capable or
measuring ambient humidity to within 1 percent relative humidity.
4.0 Procedure
4.1 Pretest Preparation
4.1.1 Data Recording: Prepare data sheets for each test series as shown in Attachment B. All
raw data shall be recorded on the data sheets for inclusion in the data package.
4.2 Sample Filter Preparation
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4.2.1 Selection: From the nine samples that were received from the manufacturer, randomly
choose three sample fabrics.
4.2.1.1 Cutting: Using the clamping ring (see VDI Method 3926, Figure 2b) as a template. Cut
at least one sample filter from each of the randomly chosen sample fabrics. Additional sample
filters are recommended in preparation for voided test runs. The outer diameter of the sample
shall match that of the clamping ring when laid flat. Make sure that the sample filter is
homogeneous and free from seams or imperfections.
4.2.1.2 Handling: The sample filter shall be weighed and transported within a labeled, sealable,
lightweight container such as aluminum foil or a plastic Ziploc™ bag or equivalent. The
container is necessary to capture any loose dust from the filter after testing is completed.
4.2.1.3 Pre Weighing: Calibrate the scale, as stated in section 5.2.2, and weigh the sample filter
and container to the nearest 0.01 g.
4.2.2 Impactor Substrate Preparation:
4.2.2.1 Weigh Foils: Cut aluminum foil into sections of at least 6" x 3" sufficient to completely
contain an impactor filter and any loose dust captured on the filter. Each foil shall be labeled to
match its corresponding filter with a permanent marker that will not rub off during handling.
4.2.2.2 Conditioning: The impactor filters and weigh foils must be equilibrated to a constant
temperature between 73-81 °F (23-27 ° C) and relative humidity of 40-60 % for at least 24 hours
prior to weighing.
(1) Place each filter and its corresponding foil in an open petri dish with the foil
unfolded and filter open to the atmosphere.
(2) Arrange the petri dishes on a clean tray or surface. Cover the petri dishes with
dust free wipes or dust free boxes with one side open to atmosphere.
(3) Allow the filters, foils, and petri dishes to equilibrate for 24 hours constant
temperature between 73-81 °F (23-27 °C) and relative humidity of 40-60 %. The
temperature and relative humidity must be continuously measured and recorded.
Use a Smart Reader 2 - Temperature & Relative Humidity Logger by ACR
Systems, Inc., or equivalent for this purpose.
4.2.2.3 Pre-Weighing: Maintain the temperature between 73-81 °F (23-27 °C) and relative
humidity at 40-60 % during weighing. Prior to each weighing, and every hour during extended
weighings, calibrate the balance using the zero and span functions of the balance. Check each
calibration using the 1 g calibration weight. The balance shall read the calibration weight to
within 0.00005 g. If not, repeat the calibration procedure or adjust the balance. Weigh the filters
within the weigh foils.
4.2.2.4 Handling: Keep the filters and weigh foils in a closed petri dish to cover and protect the
filter and weigh foil during handling. After conditioning, always handle the filters and weigh
foils with tweezers. The filters and weigh foils shall not come in contact with any surface except
the clean petri dish, tweezers, and the impactor during handling.
4.2.3 Impactor Preparation: Prior to each use:
(1) Rinse all internal surfaces of the impactor including the cone, body, plate holder,
and all plates, gaskets and separators that will contain substrates with acetone.
(2) Dry these surfaces with single thickness Class 100 wipes taking care that the
impactor parts are not contaminated with ambient dust, oils or fibers.
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(3) Assemble the impactor as specified in the manufacturer's operating manual. To
reduce the cumulative error caused by multiple weighings, eliminate all stages
that separate less than 2.5 jim particle sizes. Stages may be modified to produce
the required jet velocity to facilitate separation at 2.5 + 0.25 jim. The backup filter
may be moved forward to eliminate unnecessary stages and the remaining stages
may be loaded without substrates behind the backup filter, or a suitable spacer
may be used.
(4) Seal each opening of the impactor with clean paraffin film or Teflon tape to
prevent sample contamination until ready for use.
4.2.4 Test Apparatus:
4.2.4.1 Sample Filter: Load the sample filter into the test apparatus as specified in VDI Method
3926.
4.2.4.2 Absolute Filter Assembly With Untared Filters: Load the absolute filter with an
untared filter as specified VDI Method 3926.
4.2.4.3 Test Dust: Load the dust feed hopper with a sufficient quantity of test dust for the phase
of testing being performed.
4.2.4.4 Cleaning: Prior to each test series. Use Kimberly-Clark Kimwipes or an equivalent lint-
free laboratory-grade fabric to clean the surfaces of the clean-gas channel. Rinse the
aerodynamic Y and associated fittings with acetone and discard used acetone. Thorough
cleaning of the test apparatus is necessary to prevent interference caused by dust reentrainment.
4.3 Preliminary Determinations
4.3.1 Trial Operation: Prior to each test series, determine the instrument settings necessary to
obtain an air-to-cloth ratio of 120 m/hr (6.6 fpm) and a dust feed rate of 100 grams/hr. Perform
this operation using an untared sample filter not to be used in the test series.
4.3.2 Reference Fabric Verification: Perform once per three months. Obtain a sample of
reference fabric from:
APCT Center
APCT Center Director
Research Triangle Institute
3040 Cornwall! s Road
Research Triangle Park, NC 27709-2194
Verify the performance of the test apparatus by performing three 30-cycle tests using the
reference fabric and the procedures herein. The reference fabric verification is acceptable if the
following criterion is met:
0.65g
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(1) Prepare the test apparatus as specified in Section 4.2.4. Use an untared sample
filter that will not to be used in the test series.
(2) Prepare the impactor for isokinetic sampling as specified in the manufacturers
operating manual using all the available stages. Equip the impactor with a
stainless steel sampling nozzle capable of isokinetic sample withdrawal from the
raw-gas channel. Note, custom sampling nozzles are required for isokinetic
sampling in this application. In the development of this method, a nozzle having
a sample opening of 1.895 in was required to maintain isokinetic sampling at a
sample rate of 5 liters per minute.
(3) Insert the nozzle into the raw-gas channel upstream of the test filter. The nozzle
shall be located at least two inches from the channel walls. A bulkhead fitting is
recommended between the nozzle and impactor body to seal the nozzle in place
with the nozzle inside and the impactor housing outside of the raw-gas channel.
(4) Operate the impactor at a sample rate of 3.5-7.0 liters (0.1-0.2 cubic feet) per
minute for a sample duration of 3-5 minutes. A total sample volume of 15-25
liters (0.53-0.88 cubic feet) is recommended.
(5) Follow the impactor preparation, sample recovery, and analyses procedures in
Sections 4.2.2, 4.2.3, 4.5.2 and in the manufacturers operating manual.
(6) Using the data reduction procedures in the manufacturers operating manual,
calculate the mass mean diameter and weight percent < 2.5 urn for the test dust.
(7) Repeat the procedures (1) through (6) above to obtain three valid test runs.
In the event that the mass mean diameter and weight percent < 2.5 z/m, does not meet the criteria
of Section 3.2, the test dust or dust feed system must be corrected and the dust feed verified prior
to testing.
4.4 Verification Test Series
Perform one verification test series consisting of three test runs for each fabric tested. A test run
consists of the following test phases.
4.4.1 Conditioning Period: Prepare the test apparatus as specified in Section 4.2.4. Subject
the fabric to 10,000 pulses at 3 second intervals under the following conditions:
dust loading: 18.4 + 3.6 g/dscm (8.0 +1.6 gr/dscf), calculated on a block
average for each 60 consecutive minutes during the test and for the
last 60 minutes of each test. For example, if a test ran 125
minutes, block averages are required for 1-60 minutes, 61-120
minutes, and 66-125 minutes.
gas-to-cloth ratio: 120 ± 6 m/hr (6.6 + 0.3 fpm), calculated on a block average for
each 60 consecutive minutes during the test and for the last 60
minutes of each test.
At minimum, the following parameters must be measured and recorded to confirm that the above
requirements are met:
Parameter Units Minimum Recording Frequency
Fabric Pressure Drop (Pa or in H20) 1 minute
Raw-Gas Flow* (sm3/hr) 1 minute
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Total Clean-Gas Flow* (sm3/hr) 1 minute
Sample-Gas flow* (sm3/hr) 1 minute
Dust Feed Weight (grams) 1 minute
*Includes measurement of absolute gas pressure and humidity (which shall be taken
once per test day) and gas temperature . Sample-gas flow measurements are necessary
during each performance test period.
The conditioning period may be stopped and restarted provided that the above conditions are met
and the sample fabric is not manipulated in any way.
4.4.2 Fabric Recovery Period: Continue to operate the test apparatus under the conditions
specified in Section 4.4.1, except subject the fabric to normal pulsing, as required for 30
filtration cycles. The fabric recovery period does not need to immediately follow the
conditioning period, but must proceed without additional handling, dust loading or pulsing of the
sample filter. During the fabric recovery period, ensure that the dust loading and gas-to-cloth
requirements of Section 4.4.1 are met.
4.4.3 Performance Test Period:
4.4.3.1 Preparation: Prior to each performance test period, load the test apparatus with dust.
Load the sample-gas channel with an impactor which is prepared as described by the procedures
of Section 4.2.3. Load the sample bypass channel with an absolute filter.
4.4.3.2 Performance Testing: Operate the test apparatus as specified in Section 4.4.1, except
subject the fabric to normal pulsing, as required for a period of 360 minutes. Continue following
the dust loading, gas-to cloth, and data capture and recording requirements of Section 4.4.1. In
addition, record the following:
Parameter Units Recording Frequency
Filtration Cycle Time (seconds) once per filtration cycle
Residual Pressure Drop (Pa or in. H20) once per filtration cycle, recorded
three seconds after each cleaning
pulse
Filtration cycle count number each filtration cycle
In the event that the dust loading and gas-to-cloth requirements of Section 4.4.1 are not met, the
test run is void and repeated using a new sample filter.
4.5 Sample Recovery and Handling
4.5.1 Sample Filter: Following each test run:
(1) manually pulse the sample filter ten times while the test apparatus is not in
operation. This will facilitate removal of the filter cake.
(2) Remove the filter assembly from the test apparatus and place it on a flat surface
with the collection side up. Brush or wipe any excess dust from the filter
assembly taking care not to add weight to the sample filter.
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(3) Remove the sample filter from the filter assembly and place the filter in its
labeled weigh container.
(4) Weigh the sample filter to the nearest 0.01 g.
4.5.2 Impactor Substrates and Backup Filter:
(1) Remove the impactor assembly from the test apparatus and transport to a clean,
dry surface.
(2) Recover each impactor stage or backup filter into the corresponding weigh foil
using clean tweezers taking care not to loose any of the sample. Brush any excess
dust or substrate fibers that remain on the impactor stages into the weigh foils
using the recovery brush.
(3) Condition the impactor samples by the procedures of Section 4.2.2.2.
(4) Record the post weight of each impactor stage using the weighing and handling
procedures of Section 4.2.2.3 and 4.2.2.4.
5.0 Calibrations
Perform the following calibrations for inclusion in the Verification Report referenced in Section
8.0.
5.1 Prior to Each Use
5.1.1 Dust Feed Weight Measurement Device: Check the calibration of the dust feed weight
measurement device by placing the 2-3 kg span weight into the weigh hopper. It may be
necessary to protect the span weight using a tared Ziploc™ plastic bag or equivalent. The dust
feed weight measurement device shall display a weight increase within 10 g of span weight plus
the protective bag.
5.1.2 Low-Resolution Analytical Balance: Check the calibration of the low-resolution
analytical balance using the 100 g span weight. The low resolution analytical balance shall
display within O.OSg of the calibration weight.
5.1.3 Pressure Transducers: Calibrate each pressure transducer against an oil manometer to
within 0.1 in. w.g. The pressure transducers shall be calibrated at three points, zero, maximum,
and at an intermediate pressure typically encountered during the test program. A simulated
pressure may be produced using a squeeze bulb and a vice.
5.1.4 High-Resolution Analytical Balance: Check the calibration of the high-resolution
analytical balance using the 1 g span weight. The high resolution analytical balance shall display
within O.OOOOSg of the calibration weight.
5.2 Every Three Months
5.2.1 Microbalance: Use a 1 mg ASTM Class 1 or 2 mass for the quality control check. This
weights must be traceable to NIST. Do not use the same weights for the QC check as is used for
the day-to-day calibration verifications of the microbalance. The balance display shall agree
with the certified value of the QC check weight to within ± 0.00005 g.
5.2.2 Flow Measurement Devices (Calibrated Orifices or Mass Flow Controllers):
Calibrate all flow measurement devices using the procedures specified in 40 CFR 60, Appendix
A, Method 5, Sections 5.3 or 7.1. The reference standard for the calibration shall be a
spirometer/bell prover or a wet test meter that has been certified against NIST-traceable
standards within the past year. Calibrate the clean-gas flow measurement device at a single
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point corresponding to a flow of 1.85 + 0.9 nrVhr (1.1+ 0.06 cfm). (equivalent to a gas-to cloth
ratio of 120 m/hr, or 6.6 fpm). Calibrate the raw-gas flow measurement device at a flow of 3.95
+ 0.2 m3/hr (2.32 + 0.1 cfm). Calibrate the sample-gas measurement device at a flow of 1.13 +
0.06 m3/hr (0.67 + 0.03 cfm). Conduct each calibration for a minimum often minutes. Use a
calibration factor to adjust the signal to that of the wet test meter or calibrated dry gas meter.
5.2.3 Thermocouple in Raw-Gas Channel: Calibrate the thermocouple in the raw-gas
channel against an ASTM mercury-in-glass reference thermometer at 25°C (77 + 4°F.)
Alternatively, calibrate the thermocouple at a thermometric fixed point above and below 25°C
(77 + 4 °F, for example use an ice bath and boiling deionized distilled water correcting the
reference temperatures for barometric pressure). The thermocouple must agree with the
reference point to within + 1 °F.
5.24 Aneroid Barometer (if used): If a mercury barometer is not used, calibrate the aneroid
barometer against a mercury barometer every six months. The aneroid barometer shall agree
with the mercury barometer to the nearest 0.2 in Hg.
5.2.5Timer Clock: The timer clock shall be calibrated quarterly to NIST time, which is
obtained from the WWV radio reference signal or from the NIST World Wide Web site. If the
timer clock is not within one second agreement with the WWV or website signal over a one-hour
period, the timer must be replaced with a unit that meets calibration requirements.
5.3 Once Per Year
5.3.1 Humidity and Temperature: Either calibrate the continuous humidity and temperature
measurement device according to the manufacturer's specifications or obtain a manufacturer's
calibration certificate.
5.3.2 Low Resolution Analytical Balance: The low-resolution analytical balance will be
calibrated by its manufacturer annually.
5.3.3 High-Resolution Analytical Balance: The high-resolution analytical balance will be
calibrated by its manufacturer annually.
5.3.4 Flow Meter: The dry gas meter will be calibrated annually be the manufacturer.
5.3.5 Weights: The weights will be calibrated to NIST traceability annually.
5.3.6 Pressure Transducer: The pressure transducers will be calibrated annually by the
manufacturer.
6.0 Calculations
6.1 Nomenclature
6.1.1 Acronyms
Af = Exposed area of sample filter, m2
Ca = Actual outlet particulate concentration of total mass, g/m3
Cds = Dry standard outlet parti culate concentration of total mass, g/dscm
C25a = Actual outlet particulate concentration of PM 2.5, g/m3
C25ds = Dry standard outlet parti culate concentration of PM 2.5, g/dscm
d = Diameter of exposed area of sample filter, m
Fa = Dust feed rate corrected for actual conditions, g/m3
G/C = Gas-to-Cloth Ratio, m/hr
Mt = Total mass gain from Andersen Impactor, grams
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M25 = Total mass gain of particles less than 2.5 um in diameter from Andersen
Impactor, grams - this value may need to be linearly interpolated from test
data, g
N = Number of filtration cycles in a given performance test period
AP; = Residual pressure drop for filtration cycle i, cm w.g.
APavg = Average residual pressure drop, cm w.g.
Ps = Absolute gas pressure as measured in the raw-gas channel, mbar
Qa = Actual gas flow rate, m3/hr
Qat = Actual gas flow rate for a specific averaging time, t, m3/hr
Qs = Standard gas flow rate, m3/hr
Qst = Standard gas flow rate for a specific averaging time, t, m3/hr
t = Specified averaging time or sampling time, min.
tc = Average filtration cycle time, s
wf = Weight of dust in feed hopper following the specified time, g. Because of
vibrations causing short-term fluctuations to the feed hopper, it is
recommended that this value be measured as a one-minute average.
w; = Weight of dust in feed hopper prior to the specified time, g. Because of
vibrations causing short-term fluctuations to the feed hopper, it is
recommended that this value be measured as a one-minute average.
6.1.2 Unit Conversions
To convert to in. w.g. from in. Hg, multiply by 13.6.
To convert to grains from pounds, multiply by 7000.
To convert to ft3 from m3, multiply by 35.313.
To convert to grams form pounds, multiply by 453.59.
To convert to seconds from minutes, multiply by 60.
6.1.3 Equivalence Values
Standard atmospheric pressure, in. Hg = 29.92.
Standard temperature at 0 °F = 460 °R.
Standard temperature at 68 °F = 528 °R.
6.2 Area of Fabric - Af
At = -
6.3 Actual Gas F low Rate Qa
(T. + 460) x 1013
Qa = Qs
P x528
o
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6.4 Gas-to-Cloth Ratio - G/C
G/C =
6.5 Standard Dust Feed Rate - Fs, for a specified time -1
(w, - wf)
r- _ v ; t'
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6.6 Actual Raw-Gas Dust Concentration - Fa
(Ts + 460) x 1013
F = F x
a s
Px528
o
6.7 Dry Standard Clean-Gas Particulate Concentration, Total Mass - Cds
QH* x t X
%H20
100
6.8 Dry Standard Clean-Gas Particulate Concentration, PM-2.5 - C2
5ds
"2.5ds
%H2O
100
6.9Filtration Cycle Time - tc
L =
N
3600
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6.10 Average Residual Pressure Drop - AP
avg
7.0 Data Reduction and Analysis
The procedures in this section apply to the specific data reduction practices used at ETS, Inc. in
operation of the FEMA test apparatus. Operating procedures using other equipment at other
facilities may be significantly different.
7.1 Data Flow
7.1.1 Types of Data: The verification test apparatus creates two types of data, computer
recorded data and test operator recorded data. Test operator recorded data are the data that are
recorded onto the verification test runsheets, which will be transferred into computer
spreadsheets in future data reduction as described in section 7.4.2. Computer recorded data is
the information recorded by the Loggy Program.
7.1.2 Computer Recorded Data: The computer recorded data are saved directly onto the ETS
network by the Loggy program. All data and spreadsheet files shall be saved on the ETS
network system on the R:\FEMA subdirectory. A separate subdirectory (within R:\FEMA ) shall
be created for each test series. The files are saved into a file name that is described in section
7.2.
7.1.3 Operator Recorded Data: All information that is recorded by the operator is recorded
onto verification runsheets (test log). The operator records the start and stop times, media
information, and ambient conditions for the conditioning period, recovery period, and the
performance test period. Once all information has been recorded onto the verification test
runsheets and the verification test has ended, the test operator signs the runsheet to validate the
recorded information. The Test-Specific Manager then releases the verification runsheets into
the custody of the data processing operator.
7.1.4 Data Reduction, Report Generation, and Report Review: The data processing
operator performs all data reduction and analysis for the verification test. The data processing
operator enters the runsheet information into the verification test spreadsheets and reduces the
Loggy recorded data as described in section 7.3 and 7.4. Once all information from the Loggy
program and the verification runsheets have been entered into the spreadsheets and all analysis
has been completed, the runsheets and the summary data sheets are transferred into the Report
Manager's custody who prepares the draft verification report and draft verification statement.
The Report Manager transfers the draft verification report and draft verification statement to the
Test-Specific Manager for review. The Test-Specific Manager transfers the draft verification
report, the draft verification statement, the verification runsheets, and the data summary forms to
the Test-Specific QAO. The Test-Specific QAO verify's the results for the verification test by
performing hand calculations on one spreadsheet data set. The Test-Specific QAO verifies that
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all QA/QC requirements have been obtained. If all QA/QC requirements have not been satisfied,
the Test-Specific QAO notifies the Test-Specific Manager and the Verification Test Leader and
the run is voided. If all QA/QC requirements have been satisfied, the Test-Specific QAO
transfers the information to APCT Center for final draft preparation.
7.2 ASCII Text Files
Raw data from the Loggy program used in the FEMA test apparatus shall be saved in the
appropriate directory as an ASCII text file. Files will be named by the following designation:
aaaabbcd.txt
aaaa - four-letter test series designation
bb - two-letter test phase designation as follows:
cp - conditioning period
rp - recovery period
pt - performance test
c - numerical designation for the test run within a test series (usually 1,2, or 3). Use
additional numbers (4, 5, 6, etc) in the event of a voided test runs.
d - one-letter designation of "x" to signify the residual pressure drop files for the
recovery and performance test periods (no designation is given for the complete
data file).
7.3 Files Containing Detailed Summary and Results of VDI Data
The first step in reduction of the ASCII text files shall be conducted using Microsoft Excel 2000.
The Loggy program will produce two types of files; a basic data files consisting of periodic
readings of all data channels, and an "msx" file consisting of the residual pressure drop three
seconds after each cleaning pulse. A step-by-step procedure for data reduction is as follows:
7.3.1 Open the ASCII text file in Microsoft Excel using the [File] [Open] commands. Select
"Fixed Width" as the type of data in the data file and click on "Next". Identify the appropriate
column placements. For the non msx file use the following to separate columns: |Time|irr
msx|Raw Gas|Clean Gas|DiffPress|Balance|Fotometer|Pressure|Temperature|Sample
(performance test only)|. For the msx text file use the following column separation: |Time|irr
msxRaw GasClean Gas|Diff Press|BalanceFotometerPressureTemperatureSample (performance
test only)|. When using the "fixed Width" option 7.3.2 is skipped. "Delimited" option can also
be used. If "Delimited" option is used, The data will appear un-parsed separated by spaces in
column A.
7.3.2 Select column A, and parse the data using the [Data] [Text to Columns] commands.
Select Fixed Width as the target data type.
7.3.3 Prepare the data for calculations by deleting all unnecessary columns and arranging as
follows.
For the basic data file:
Column A: Time (s)
Column B: Raw-Gas Flow (scm/hr)
Column C: Clean-Gas Flow (scm/hr)
Column D: Fabric Pressure Drop (Pa)
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Column E: Dust Feed Weight (g)
Column F: Absolute Gas Pressure (mbar)
Column G: Raw-Gas Temperature (°C)
Column H: Sample-Gas Flow (scm/hr, if applicable - for performance tests only)
For the residual pressure drop file:
Column A: Time (s)
Column B: Residual Pressure Drop (Pa)
The first row of data (for time = 0 seconds) must begin in row 10.
7.3.4 Reduction of The Basic Data File
7.3.4.1 Rename the current data sheet as "A" and insert a blank worksheet after sheet A.
7.3.4.2 Copy the corresponding worksheet from the R:\FEMA\Template directory onto the
blank worksheet following sheet A. A separate template is necessary for each test phase.
7.3.4.3 Delete all references to the template file using the [Edit] [Replace] command. Replacing
the name of the template file with nothing will delete the reference to the template file from the
subject data file. Thus, the calculations within the subject worksheet will reference the data
within the subject file rather the data within the template file.
7.3.4.4 For the fabric recovery period, change the averaging times in the template to facilitate
averaging of each 60-minute block during the test and for the final 60 minutes of each test.
7.3.4.5 Enter the required data from the applicable run sheets, the residual pressure drop file,
and the impactor file. Average residual pressure drop, average pulse interval, and number of
pulses are calculated in the residual pressure drop file. Total weight gain and backup filter
weight gain are calculated in the impactor file. All other data are obtained from the run sheets.
Data are to be entered only in the green-colored fields. Do not enter data over black-colored
fields.
7.3.5 Reduction of the Residual Pressure Drop File.
7.3.5.1 Average the residual pressure drop for each pulse throughout the run. This value is
entered in the basic data file as the average residual pressure drop.
7.3.5.2 In column C, calculate the pulse interval for each row of data. The first pulse interval is
the time of measurement for the first pulse minus three seconds. For each subsequent pulse
(number n), the pulse interval is calculated by subtracting the time of the previous pulse (n-1)
from the time of pulse n. The average of pulse intervals throughout the run is entered in the
basic data file as the average pulse interval.
7.3.5.3 In column D, number each pulse. Enter the number of the last pulse as the number of
pulses in the basic data file.
7.4 Impactor Data Files
The impactor files are used to reduce the Andersen Impactor data from the performance test
period.
7.4.1 Using Excel 2000, select the impactor file template from the R:\FEMA\Template directory
and rename it in the directory for the test series. Files will be named by the following
designation:
aaaaimpc.wb2
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aaaa - four-letter test series designation
imp - designation signifying an impactor run
c - numerical designation for the test run within a test series (usually 1,2, or 3). Use
additional numbers (4, 5, 6, etc) in the event of a voided test runs.
7.4.2 Enter the required data from the applicable run sheets and the basic data file. Sample-gas
flow (in scm/hr), raw-gas pressure (in mbar), average fabric pressure drop (in Pa), and average
gas temperature (in °F) are calculated in the basic data . All other data are obtained from the run
sheets. Data are to be entered on the "Sampling" and "Gravimetric" pages only in the green-
colored fields. Do not enter data over black colored fields.
7.4.3 On the "Calculations" page, ensure the proper material density is entered in cell F5. Use a
material density of 2.65 g/cc for the Pural NF dust.
7.4.4 On the "Calculations" page, check the number of jets used to obtain a 2.5 urn cut point on
plate no. 3 (entered in cell Q13). Plate 3 should be configured with 154 jets for the Pural NF
dust and the operating parameters specified herein.
7.4.5 Engage the macro used for calculation of the particle-size cut point by right-clicking the
[Solve for D-50's] macro button on the "Calculations" page
8.0 Verification Report
A fully documented test report is required. The verification report shall adhere to the format as
specified in the Generic Verification Protocol for the Baghouse Filtration Products and the
Test/QA Plan.
Attachment A Example Data Sheets
Attachment B Verification Testing Spreadsheets
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Attachment A
Example Data Sheets
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BAGHOUSE FILTRATION PRODUCTS
VERIFICATION TESTING
TEST RUN ID: __ FABRIC ID:
TEST FACILITY; " " DUST:
Conditioning Period
CONOmOMNG - 0-10000 PULSES
DATE:
START TIME:
STOP TIME: __
RUN TIME:
AMBIENT CONDITIONS
Temperature |F). __ WelBufc(F}:
Pressure fm H§) Hurrudfly
Recovery Period
FABRIC RECOVERY-10000-10030 POLSES
DATE: ' ^
START TIME: '
STOP TIME;
RUNTIME:
AMBIENT CONDITIONS
Temperature (F): ____^__^ WtetBdb (F);
Pressure Cm Hfl) Homk% |%RH):
Performance Test Period
PERFORMANCE TEST PERIOD - 6-HOURS
OATE.:
START TIME; '
STOP TfME:
RUN TIME:
AMBIENT CONDITIONS
Temperate
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HIGH RESOLUTION ANALYTICAL BALANCE DATA SHEET
(USE ONE PER IMPACTQR SET|
TEST FACILITY:
(MPACTOR SET ID;
FABRIC 10:
TEST RUN ID:
PRE-WEIGHING
Date:
Start Time:
Stop Time:
CONDITIONING
Conditioning Start;
Conditioning Stop:
Conditioning Successful?:
(Attach Temperature and
Humidity Data)
CALIBRATION DATA:
Time:
Response to 1g weight
Within O.OOOOSg?
Date
Time
yes/no
Stage
0
1
2
3
4
5
6
7
8
Filter
Pre-Weight*
ft)
• Includlrtg labeled weigh foils
POST-WEIGHING
Date:
Start Time:
Stop Time:
CONDITIONING
Conditioning Start:
Conditioning Stop:
Conditioning Successful?:
{Attach Temperature artd
Humidity Data)
CALIBRATION DATA:
Time:
Response to 1g weight:
VWtWn Q.OQOOSg?
Data
Time
yes/no
_yes/hg
Post-WefeM*
(g)
Weight
Operates- Signature:
-------
LOW RESOLUTION ANALYTICAL BALANCE
DATA SHEET
O
H
TEST FACILITY:
FABRIC ID:
CALIBRATION (PRE)
Date:
Tim a:
Response to iDOgWt.:
Within 0.05 g?
H
re
VI
P4-
O
>
2
£T
=
CALIBRATION (POST)
Fabric Sampla ID
Test Run ID
Pre-Wteight
fg>
— —•• -
Post Weight
..
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Attachment B
Verification Testing Spreadsheets
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VERIFICATION TESTING OF BAGHOUSE FILTRATION PRODUCTS
REFERENCE FABRIC SUMMARY OF RESULTS AT 2 IM/MIN
CTS CONTRACT NUMBER: 98-277 DATE: 10/23/02
RUN ID.
FABRIC DESIGNATION
MANUFACTURER
OUST FEED
Date Started
Time Started
Time Ended
Test Duration (ruin.)
RECOVERY PERIOD
Date Started
Time Started
Time Ended
Test Duration (tnia)
PERFORMANCE TEST PERIOD
Date Started
Time Started
Time Ended
Test Duration (min.)
VERIFICATION TEST RESULTS
Mean Outlet Particle Cone,
PM 2.5 (g/dscm)
Mean Outlet Particle Cone,
Total mass (g/dscm)
Initial Residual Pressure
Drop (cm w.g.)
Change in Residual Pressure
Drop (cm w.g,)
Average Residual Pressure
Drop (cfn w.g.)
Mass Gain of Filter
Sample (g)
Average Filiation Cycte
Time (s)
Number of Pulses
RESIDUAL PRESSURE DROP
At Start oft
Conditioning Period {crn w.g.)
Recovery Period (on w.g.)
Performance Test Period (cm w.g.)
RF-1
101602-1
NA
Rural NF
10/17/2002
13:28
21:48
500
10/18/2002
7:03
7:46
43
10/18/2002
7:57
13:57
360
0.0001518
0.0001518
3.92
1,72
5.06
1.85
43
499
0.12
3.52
3.92
RF-2
101602-2
NA
PuralNF
10/18/2002
14:10
22:30
500
10/21/2002
6:40
7:24
44
10/21/2002
7:32
13:32
360
0,0001553
0.0001553
3,94
1.85
5.18
1,77
41
525
0.12
3.44
3,94
AVERAGE
Ref. Fabric
500
44
360
0.0001536
0.000153S
3.93
1.79
5.11
1.81
42
512
0.12
3.48
3.93
-------
VERIFICATION TESTING OF BAGHOUSE FILTRATION PRODUCTS
DETAILED SUMMARY OF DATA AND RESULTS
CONDITIONING PERIOD - 2 M/MIN
RUN ID. RF-1
FABRIC DESIGNATION 101602-1
MANUFACTURER NA
DUST FEED Rural NF
DATE STARTED 10/17/2002
TIME STARTED 13:28
TIME ENDED 21 '48
TEST DURATION 500 min.
QA/QC DATA
Test Duration
(min.) Time
0-60 13:28
61-120 14:29
121-180 15:29
181-240 16:29
241-300 17:29
301-360 18:29
361-420 19:29
421-480 20:29
441-500 ' 20:49
Dust Feed
14:28
15:28
16:28
17:28
18:28
19:28
20:28
21:28
21:48
Initial
1448.3
1356.0
1262.0
1166.6
1072.4
980.9
883.6
790.2
757.0
Final
1356.0
1262.0
1166.6
1072.4
980.9
883.6
790,2
696.6
665,4
AVERAGE FOR 500 MINUTE RAW DATA
ACCEPTANCE
* Test duration is a rolling 60 minute average. The test 60
from the last minute of the test.
j>
NUMBER OF PULSES
PULSE INTERVAL
Moisture
(g) Average Gas Flow
Total
92
94
95
94
92
97
93
94
92
94
100
+/-20
minute frame
^y
Raw
3.77
3.78
3.78
3.78
3.78
3.78
3.78
3.79
3.79
3,78
was
Clean
1,75
1.76
1.76
1.76
1.76
1.76
1.76
1,76
1.76
1.76
determined
10000
3s
1.67 %WV
(srn3/hr) Avg. Temp Avg Press
Total
5.52
5.54
5.54
6.54
5.54
5,54
5.54
5.55
5.55
5.54
fC)
24
23
23
23
23
23
23
23
23
23
25
+/-2
by counting 60 minutes
(mbar)
975,59
976.05
976,61
976.67
977.32
977,45
978.23
978,48
978.60
977.12
back
Dust Cone
(g/dsem)
17.0
17.3
17.5
17.3
16,8
17,9
17.1
17,2
16.8
17.2
18.4
*/- 3.6
G/C Ratio
(m/h)
120
120
120
120
120
120
120
120
119
120
120
+1-6
DATA PROCESS! NG OPERATOR: ^^^ '^^^^^^^
Sharon M, Winemler - ETS, Inc.
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VERIFICATION TESTING OF BAG HOUSE FILTRATION PRODUCTS
DETAILED SUMMARY OF DATA AND RESULTS
RECOVERY PERIOD - 2 M/MIN
RUN ID,
FABRIC DESIGNATION
MANUFACTURER
DUST FEED
DATE(S)
TIME STARTED
TIME ENDED
TEST DURATION
RF-1
101602-1
NA
Purai NF
10/18/2002
7:03 *
7:46
43 rnin.
NUMBER OF PULSES
AVG. PULSE INTERVAL
AVG. RESI DUAL AP
INITIAL RESIDUAL AP
FINAL RESIDUAL AP
CHANGE IN AP
MAX, PRESSURE DROP
% Moisture
30
85 s
368.53 Pa
344,70 Pa
389,60 Pa
44.90 Pa
1000 Pa
1,29 %VW
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QA/QC DATA
Test Duration Dust Feed (g)
(mm.) Time Initial
1-43 * 7:04 7:48 1441.4
AVERAGE FOR 43 MINUTE RAW DATA
ACCEPTANCE
Final Total
1374.5 67
94
100
.+/- 20
Average
Raw
3.8
3,77
Gas Flow
Cleen
1.8
1,77
(sms/hr) Avg. Temp Avg Press
Total
5.60
5.54
rq
22,2
22
25
+/-2
(mbaij
983,0
982.95
Dust Cone.
(g/dscm)
12.1
17.2
18.4
+/- 3.6
G/C Ratio
(m/h)
121
119
120
+/-6
* First minute Is not considered in calculations due to equipment stabilization.
** Test duration is a rolling 60 minute average. The last 60 minute frame was determined by counting 80 minutes back
from the last minute of the test,
DATA PROCESSING OPERATOR:
Sharon M. Winemiiler- ETS, Inc.
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OQ ^
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8, K> 5-
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-------
VERIFICATION TESTING OF BAGHOUSE FILTRATION PRODUCTS
DETAILED SUMMARY OF DATA AND RESULTS
PERFORMANCE TEST PERIOD- 2 M/'MIN
RUN ID.
FABRIC DESIGNATION
MANUFACTURER
DUST FEED
DATE STARTED
TIME STARTED
TIME ENDED
TEST DURATION
QA/QC DATA
Test Duration
(min.)
RF-1
101602-1
NA
Rural NF
10/18/2002
7:57
13:57
360 min.
Dust Feed (g)
Time Initial Final Total
NUMBER OF PULSES
AVG. PULSE INTERVAL
AVG. RESIDUAL AP
INITIAL RESIDUAL AP
FINAL RESIDUAL AP
CHANGE IN AP
MAX. PRESSURE DROP
Moisture
Average Gas Flow {sm3/hr)
Raw Clean Total Sample
499
43 s
495.24 Pa
384.00 Pa
552.30 Pa
168.30 Pa
1000 Pa
1.29 %WV
Avg. Temp Avg Press Dust Cone.
f C) (mbar) (g/dscm)
G/C Ratio
(m/h)
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0-60 • 7:57
61-120 8:58
121-180 9:58
181-240 10:58
241-300 11:58
301-360 12:58
AVERAGE FOR 360 M1NU
8:57
9:57
10:57
11:57
12:57
13:57
TE RAW DAI
1365.3
1272.1
1 178.6
1086.3
990.1
889.1
FA
1272,1
1178.6
1086,3
990,1
889.1
782.9
93
94
92
96
101
106
97
3.79
3.80
3.80
3.80
3.80
3.80
3,80
1.73
1,78
1.78
1.78
1.78
1.78
1.78
5.57
558
5.58
5.58
5.68
5.58
5.58
1.09
1.09
1.09
1.10
1.10
1.10
1.09
22
23
23
23
24
24
23
983.60
983.91
984,03
984.02
983.83
983,25
983.78
17.0
17.0
16.8
17.5
18.3
19.3
17.6
120
120
120
120
121
121
120
ACCEPTANCE
GRAVIMETRIC DATA
IMPACTOR SUBSTRATES
Backup Filter (PM 2.5) 0.00098 g
Total Mass Gain 0.00098 g
OUTLET CONCENTRATION
Total Volume Sampled
Mean Outlet Particle Concentration - py 2.5
Mean Outlet Partide Concentration - Total Mass
100
+/-20
SAMPLE FILTER
Tare Mass
Final Mass
Mass Gain
6.87 m3
0.0001427 g/m3
0,0001427 g/ma
25 18.4 120
+/- 2 +/- 3.6 +/- 6
1188 g
13.73 g
1.85 g
DATA PROCESSING OPERATOR:
^^^-^^^^^
Sharon M. VWnemiller - ETS, Inc.
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2000
Residual pressure drop across filter fabric during performance tost period RF-1
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1250
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500
250
£000
10000
15000
20COO
Time (s)
25000
8-
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-------
Change in Rural NF dust scale reading with time during performance test period RF-1
2000
1750
1500
1250
* s
s
I
1000 -I
/bO
500
250
0
5000
10000
15000
20000
25000
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