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Mandatory Calibration and Tests for SmokeStack Testing Equipment (Malaysian Standard MS 1596 and MS 1723)

Doc ID: AERHQWW-ecy3-en
Last revised: 0, 23.07.06

 

This page contains a summary of the mandatory calibration (and tests/checks/verifications) required for equipment used in Malaysian Standard MS 1596 and MS 1723 for smokestack testing ("stack testing" and isokinetic sampling on stationary sources of air pollution). 

For smokestack testing (and especially isokinetic sampling), the sampling procedures are more important than the analytical procedures. This is because of the difficulty in getting a representative sample of the flue gas inside the smokestack. The pollutants could be in solid, liquid, or gaseous states, or a mixture (e.g., solid in gas) which is not well mixed, and with many other interferences.

We strongly recommend attaching proof of the below calibrations and tests/checks to the final smokestack testing report. 

  

Notes:

  • Please note that this page will be focusing on the more uncommon calibrations and tests, which are special to smokestack testing.
  • This page is based on what is written in MS 1596:2003 and MS 1723:2003. Refer to local authorities for actual local rules!
  • MS 1596:2003 and MS 1723:2003 are only for general particulate matter "dust", and not any specific chemical (in any state: solid, liquid, or gaseous)
    • MS 1596:2003 is based on ISO 9096:1992, and ISO 10780. Refer to the "Foreword" of the Standard.
    • As stated in section 10.1 of MS 1723:2003, a [smoke-stack] test shall be done a minimum of three times, to ensure reasonable accuracies and make it possible to compare results.
      • This is the same for US EPA Methods, where 1 stack "test" = 3 sampling "runs"
      • Refer also to the Environmental Quality Act (Clean Air) Regulations 2014, Regulation 23

       

      Other useful links:

      • Aer Sampling Basic Training Video with names of equipment and their individual components
      • Click here to order Malaysian Standards at the Department of Standards
      • To order ISO Standards, click here to visit ISO online store
      • Why is calibration important? Click here to link to YouTube videos:
      • To return to Aer Sampling's Smokestack Testing Encyclopedia content page, click here, or scan the QR Code below:

       

      Overview of this webpage:
      1. Images of entire sampling train of equipment for MS 1596:2003 (Method i, dry gas measurement)
      2. Table of mandatory calibrations
        1. Integrating Dry Gas Meter (DGM)
        2. Critical Orifices (to calibrate DGM)
        3. Temperature Sensor
        4. Thermocouple Simulator (to calibrate temperature sensor)
        5. Field Balance
        6. Analytical Balance
        7. Orifice Meters, Rotameters
        8. Manometers and Pressure Gages
        9. Calipers (to test S-type Pitot Tubes)
        10. Angle Indicator or Inclinometers (to test S-type Pitot Tubes)
        11. Profile Projector or equivalent (to test S-type Pitot Tubes)
        12. Flue Gas Analyzers
        13. Timer
        14. Internal Diameter Micrometers (to test Sampling Nozzle)
        15. Other Analytical Instruments
        16. Rod to measure internal diameter of smoke-stack
      3. *Table of mandatory tests/verifications
        1. Leak Check - Pitot Line
        2. Leak Check - Sampling Gas Line
        3. Leak Check - Meter Console (Vacuum side, "Front-Half")
        4. Leak Check - Meter Console (Pressure side, "Back-Half")
        5. S-type Pitot Tube - in a Combination Probe
        6. S-type Pitot Tube - by itself
        7. Suction Nozzle - Entry Wall Thickness
        8. Suction Nozzle - Diameter "Size"
      4. Optional Calibrations
        1. Barometer
        2. S-type Pitot Tubes
        3. L-type (Standard) Pitot tubes
        

       Table of mandatory calibrations (click individual item for details):

      • Including calibrations to ensure metrological traceability

        What to calibrate

        Frequency

        Calibrated Against

        1. Integrating Dry Gas Meter (DGM), inside the Meter Console

         

         

         

         

        Once a year (minimum)

         

        Refer to:

        • MS 1596:2003, Section 7.6g
        • MS 1596:2003 Section 7.6, last paragraph

        Not mentioned

         

        Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

         

        Recommend to use Critical Orifices

        2. Critical Orifice (to calibrate DGM)

         

         

        Once a year (minimum)

         

        Refer to:

        • MS 1596:2003, Section 7.6 (c) and (g), and last paragraph

        Not mentioned

         

        Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

           

          Recommend to use Bell Gas Provers 

           

          Click here (or scan QR Code below) to view Aer Sampling's traceable calibration service for Critical Orifices

          3. Temperature Sensor, inside the Meter Console

           

          Need to calibrate every thermocouple connected to Temperature Sensor too (via all the thermocouple plugs and sockets)

          Once a year (minimum)

           

          Refer to:

          • MS 1596:2003 Section 7.6, last paragraph

           

          Not mentioned

           

          Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

           

          Recommend to use Thermocouple Simulators

           

          4. Thermocouple Simulator

           

          Used to calibrate the Temperature Sensor

           

          Not mentioned

           

          Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

           

          Recommended: Minimum once a year

           

          Refer to:

          • MS 1596:2003, Section 7.6, last paragraph

          Not mentioned

           

          Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

          5. Field Balance

           

          Used for weighing contents of impingers

           

           

          Once a year (minimum)

           

          Refer to:

          • MS 1596:2003 Section 7.6b, last paragraph

           

          Not mentioned

           

          Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

           

          6. Analytical Balance

           

          Used to measure weight of filter papers (MS 1596:2003: "particle separator")

           

          Once a year (minimum)

           

          Refer to:

          • MS 1596:2003 Section 7.6b, last paragraph

           

          Not mentioned

           

          Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

          7. Flow rate measuring devices

          • Orifice Plate (Orifice Tube, Orifice Meter)
            • Used as a guide to adjust the pump valves, to vary velocity of gas entering sampling nozzles
            • Usually done together with Dry Gas Meter (DGM) calibration, refer to DGM section below
            • Location
              • Method i: Downstream of DGM
              • Method ii: Downstream of Particle Separator (Filter holder)
          • Rotameters (If in use)

           

          Once a year (minimum)

           

          Refer to:

          • MS 1596:2003 Section 7.6c, last paragraph

          Not mentioned

           

          Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

           

          Recommended to use Critical Orifices, refer to section below

           

           8. Manometers and Pressure Gages

           

          Used to measure differential pressure head "Delta P" of flue gas inside smokestack, which is then used to calculate velocity

          Once a year (minimum)

           

          Refer to:

          • MS 1596:2003 Section 7.6c, last paragraph

           

          Not mentioned

           

          Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

           

          9. Calipers 

           

          This is used to test S-type Pitot Tubes construction specifications (lengths and widths), to avoid having to calibrate the S-type Pitot Tubes.

           

          Refer to:

            • MS 1596:2003, Appendix D
            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

             

            Recommended: Minimum once a year

             

            Refer to:

            • MS 1596:2003, Section 7.6, last paragraph

            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

            10. Angle Indicator or Inclinometer, with Bull's Eye Level

             

            These are used to test S-type Pitot Tubes construction specifications (angles), to avoid having to calibrate.

             

            Refer to:

            • MS 1596:2003, Appendix D

             

            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

             

            Recommended: Minimum once a year

             

            Refer to:

            • MS 1596:2003, Section 7.6, last paragraph

            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

            11. Profile Projector "Optical Comparator", or Microscope with image analysis software, or equivalent

             

            This is used to test S-type Pitot Tubes construction specifications; dimension L1 and L2 of MS 1596:2003, Figure D1.

             

            Refer to:

            • MS 1596:2003, Appendix D, paragraph 1, "dimension L1 and L2 in Figure D1 shall be equal for each leg"

             

            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

             

            Recommended: Minimum once a year

             

            Refer to:

            • MS 1596:2003, Section 7.6, last paragraph

             

            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

            12. Flue Gas Analyzers

            • Wet-Chemistry Type (Orsat, Fyrite)
            • Instrumental Type (NDIR, electrochemical etc.)

            Once a year (minimum)

             

            Refer to:

            • MS 1596:2003, Section 7.6 (f)

            Not mentioned (but usually calibration gases of specified and traceable purity) 

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

             

            Recommended standards:

            • US EPA Method 3
            • US EPA Method 3a, 7e
            • ISO 10849
            • ISO 7935

             

            13. Timer

             

            Used to countdown to sampling at the next traverse points inside the smokestack

            Once a year (minimum)

             

            Refer to:

            • MS 1596:2003 Section 7.6 (h), last paragraph

             

            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

            14. Internal Diameter Micrometers

             

            Used to test entry diameter of Sampling Nozzles, which are used to determine flow rate etc.

             

            Refer to:

            • MS 1596:2003, Section 7.3, and Section 14.g.iii.
            • MS 1596:2003, Table 1
              • dn1: Inner nozzle diameter
              • dn2: Outer nozzle diameter
            • MS 1596:2003, Figure 2 and Figure 3 (Suction Nozzle Diameter XIII)

             

            Not mentioned
             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

             

            Recommended: Minimum once a year

             

            Refer to:

            • MS 1596:2003, Section 7.6, last paragraph
             
            Not mentioned 

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

            15. Other Analytical Instruments

            Not mentioned in MS 1596:2003 and MS 1723:2003, because these Standards are for "dust" only

             

            Some examples:

            • High Resolution Gas Chromatograph/Mass Spectrometer (HRGS/HRMS)
            • Ion Chromatograph (IC)
            • Atomic Absorption Spectrometer (AAS)
            • Etc.

             

            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

             

            Recommended: Minimum once a year

             

            Refer to:

            • MS 1596:2003, Section 7.6, last paragraph
            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

            16. Rod to measure internal diameter of smokestack

             

            Refer to:

            • MS 1596:2003, Table 3, Part number 27

            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

             

            Recommended: Minimum once a year

             

            Refer to:

            • MS 1596:2003, Section 7.6, last paragraph

             

            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

            Related topics: ISO/IEC 17025, ILAC MRA, scope of accreditation, stationary/fixed sources of air pollution, SAMM

             

            ------

             

            List of mandatory tests/verifications (click individual item for details):

             What to test/verify

             

            Frequency

             

            Test Using

             

            1. Leak Check: Pitot Line

             

            The "Pitot Line" consist of three items: Pitot Tubes, Pitot Tube connections (Umbilical Cable), Manometers or Pressure Gages (inside Meter Console)

             

            Refer to:

            • MS 1596:2003, Section 9.2, paragraph 2
            • MS 1596:2003, Appendix C, Section C2, paragraph 4

             

             

             

             

            Before sampling starts (after equipment assembled)

             

            Refer to:

            • MS 1596:2003, Section 9.2, paragraph 2

             

            --

             

            After each period of use (each stack test)

             

            Refer to:

            • MS 1596:2003, Appendix C, Section C1, last paragraph
            • MS 1596:2003, Appendix C, Section C2, paragraph 4

            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

             

            Recommend to use Manometers or Pressure Gages, both in meter console

            2. Leak Check: Sampled Gas Line

             

            From the Suction Nozzle to the pump valves and fittings, and Dry Gas Meter (DGM) inside the Meter Console

             

            Leak rate shall be less than 1% of the volumetric flow rate at a vacuum of at least 50 kPa (14.765 inHg)

             

            Refer to:

            • MS 1596:2003, Section 9.2, paragraph 4

             

            Before start of sampling (after assembling entire sampling train, from the nozzle to meter console)

             

            Refer to:

            • MS 1596:2003, Section 9.2, paragraph 3, 5

             

            Recommend to check for leaks after the sampling too

            Dry Gas Meter (DGM), usually inside the Meter Console
            3. Leak Check - Meter Console (Vacuum Side, "Front-Half")

             

            From the Sampled Gas inlet to the pump valves and fittings inside the Meter Console

             

            When necessary (This is part of the sampling gas line train leak check, but just for the meter console)

            Dry Gas Meter (DGM), which is inside the Meter Console

             

            Recommend to use procedures in US EPA Method 5

             

            4. Leak Check - Meter Console (Pressure Side, "Back-Half")

             

            From the pump valves and fittings to the Orifice Meter (downstream after the DGM)

             

            When necessary (This is part of the 
            sampling gas line train leak check,
             but just for the meter console)

            Manometers or Pressure Gages); Analog or Digital), which are inside the Meter Console

             

            Recommend to use procedures in US EPA Method 5

             

            5. Suction Nozzle - Entry wall thickness

             

            If the wall thickness at the mouth of the Nozzle is too thick, the diameter of the nozzle is calculated using a specified formula.

             

            Refer to: 

            • MS 1596:2003, Section 7.3, paragraph 2, and Figure 5

             

             

            Not mentioned

             

            Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

             

            Recommended: Before each use, to test if nozzle still in original shape, given the importance of the nozzle in determining isokinetic velocity

             

            Refer to:

            • MS 1596:2003, Section 7.3, Figure 5
            • MS 1596:2003, Appendix A, Section A4

              Not mentioned

               

              Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

               

              Recommended: Vernier Calipers

              6. Suction Nozzle - Diameter "Size"

               

              The diameter of the sampling nozzle where the flue gas enters the nozzle. This directly impacts the isokinetic rate calculations.

               

              Refer to:

              • MS 1596:2003, Section 7.3, paragraph 3, and Note 2
              • MS 1596:2003, Section 14.g.iii.

               

              Not mentioned

               

              Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

               

              Recommended: Before each use, to test if nozzle size is still valid, and not dented or damaged in any way, because you would have to select the correct nozzle size to sample isokinetically

               

              Refer to:

              • MS 1596:2003, Section 9.2, paragraph 5
              • MS 1596:2003, Section 10.2, paragraph 2
              • MS 1596:2003, Section 10.4.1, paragraph 7

               

              Not mentioned

               

              Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

               

              Recommended: Internal Diameter Micrometers

              7. S-Type Pitot Tube -  as part of a Combination Probe

               

              Combination Probes are probes where the suction nozzle, S-type pitot tubes, and temperature sensor are combined for sampling.

               

              Construction dimensions to test and assign S-type Pitot Tube Calibration Factor ("Coefficient", "Calibration Constant") of 0.84. If failed any tests below, replace or repair pitot tube, or calibrate using Wind Tunnel (together with the Combination Probe), per MS 1596:2003 Appendix D. For clearer procedures, we recommend using procedures in US EPA Method 2, Section 10.1 and 10.1.1.

               

              MS 1596:2003 Appendix D (Refer to ISO 10780 for more details):

              • Angles
                • Figure D1a): Transverse Tube Axis must be perpendicular to the Face opening planes (i.e., Zero degrees variation)
                • Figure D1a): Face opening plane must be parallel to one another (i.e., Zero degrees variation)
                • Figure D1b): A-side plane and B-side plane must be parallel to the Longitudinal Tube Axis (i.e., Zero degrees variation)
                • Figure D1c): The pitot tube must look like this in this view. The back leg cannot exceed the dimension of the front leg on any sides (i.e., Zero degrees variation on all sides)
                  • Refer to US EPA Method 2, Figure 2-3 for the clearest diagrams on this
                • Lengths and Widths
                  • Paragraph 1 and Figure D1b): L1 = L2
                  • Paragraph 1: L1 or L2 must be between 1.05 and 10 times the external diameter of the tubing
                  • Figure D2: Distance between opening of Impact Orifice (of Pitot Tube) and Nozzle Entry Plane must be sufficiently far apart
                    • MS 1596:2003, Section 10.2, paragraph 5
                    • Refer to Jabatan Alam Sekitar or ISO/IEC 17025 assessors for definition of "sufficiently far apart"
                    • Figure D2: Dimension X > 19 mm (between S-type Pitot Tube and 13 mm diameter nozzle)
                    • Figure D3: Dimension X > 75 mm 
                    • Figure D3: Dimension X > 19 mm (between thermocouple and S-type Pitot Tube)
                    • Figure D3: Dimension X > 50 mm

                     

                     

                    After use at each field site

                     

                    Refer to: 

                    • MS 1596:2003, Appendix E, paragraph 3
                    • MS 1596:2003, Appendix C, Section C1, last paragraph

                    Not mentioned

                     

                    Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

                     

                    Recommended to use:

                    • Calipers
                    • Angle Indicators or Inclinometers
                    • Profile Projectors or equivalent etc. (For L1 = L2 test only)

                    8. S-Type Pitot Tube -  Without Probe

                     

                    Pitot Tubes by itself, without nozzles, thermocouple etc.

                     

                    Construction dimensions to test and assign S-type Pitot Tube Calibration Factor ("Coefficient", "Calibration Constant") of 0.84. If failed any tests below, replace or repair pitot tube, or calibrate using Wind Tunnel, per MS 1596:2003 Appendix D. For clearer procedures, we recommend using procedures in US EPA Method 2, Section 10.1 and 10.1.1.

                     

                    MS 1596:2003 Appendix D (Refer to ISO 10780 for more details)

                    • Angles
                      • Figure D1a): Transverse Tube Axis must be perpendicular to the Face opening planes (i.e., Zero degrees variation)
                      • Figure D1a): Face opening plane must be parallel to one another (i.e., Zero degrees variation)
                      • Figure D1b): A-side plane and B-side plane must be parallel to the Longitudinal Tube Axis (i.e., Zero degrees variation)
                      • Figure D1c): The pitot tube must look like this in this view. The back leg cannot exceed the dimension of the front leg on any sides (i.e., Zero degrees variation on all sides)
                        • Refer to US EPA Method 2, Figure 2-3 for the clearest diagrams on this
                      • Lengths and Widths
                        • Paragraph 1 and Figure D1b): L1 = L2
                        • Paragraph 1: L1 or L2 must be between 1.05 and 10 times the external diameter of the tubing

                         

                         

                        After use at each field site

                         

                        Refer to: 

                        • MS 1596:2003, Appendix E, paragraph 3
                        • MS 1596:2003, Appendix C, Section C1, last paragraph

                         

                        Not mentioned

                         

                        Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

                         

                        Recommended to use:

                        • Calipers
                        • Angle Indicators or Inclinometers
                        • Profile Projectors or equivalent etc. (For L1 = L2 test only)

                         

                          

                         

                        Optional Calibrations

                        These are calibrations that are not mentioned inside Malaysian Standards MS 1596:2003 and MS 1723:2003, and are not used to calibrate other instruments.

                         What to Calibrate

                         

                        Frequency

                         

                        Calibrated Against

                         

                        1. Barometer

                         

                        Used to measure barometric pressure, which is used in isokinetic rate calculations

                        Not mentioned

                         

                        Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

                         

                        Recommended: Minimum once a year

                         

                        Refer to:

                        • MS 1596:2003, Section 7.6, last paragraph

                         

                        Not mentioned

                         

                        Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

                         

                        Recommended: Mercury Barometer

                         

                        2. Pitot Tubes (S-type)

                         

                        If failed tests on constructions specifications, a calibration in a Wind Tunnel against a Standard (L-type) Pitot Tube (MS 1596:2003: "Standard Pitot Static Tube"), is required.

                         

                        Refer to:

                        • MS 1596:2003, Appendix D and E

                         

                        Prior to use

                         

                        Refer to:

                        • MS 1596:2003, Section 9.1, paragraph 4
                        • MS 1596:2003, Appendix E

                         

                        --- 

                         

                        After use at each field site (if it fails construction specification tests)

                         

                        Refer to:

                        • MS 1596:2003, Appendix D, paragraph 2, and Figure D1, D2, D3
                        • MS 1596:2003, Appendix E, paragraph 1 and 3

                         

                        ---

                         

                        Once a year (minimum)

                         

                        Refer to:

                        • MS 1596:2003 Section 7.6e, last paragraph

                        Standard (L-type) Pitot Tube in a Wind Tunnel

                         

                        Refer to:

                        • MS 1596:2003, Appendix E, paragraph 1 to 5

                        3. Pitot Tubes (Standard; L-type)

                         

                        Other names:

                        • MS 1596:2003, Appendix C
                          • "Standard Pitot Static Tube"
                          • "Pitot Static Tube"
                        • ISO 10780:1994(E)
                          • Prandtl Pitot tube

                        Once a year (minimum)

                         

                        Refer to:

                        • MS 1596:2003 Section 7.6e, last paragraph

                        Not mentioned

                         

                        Refer to Jabatan Alam Sekitar or ISO/IEC 17025 Technical Assessors

                         

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