GUIDELINES FOR STACK SAMPLING FACILITIES
Formerly “Chapter 2, Stack Sampling Facilities” of the
TCEQ Sampling Procedures Manual
General
The following guidelines should be utilized for safe and accessible stack sampling
configuration and conditions. No attempt has been made to incorporate any official
safety rules, but all such applicable requirements should be followed. These guidelines
do not and are not intended to waive compliance with any law regarding safety which is
applicable for the location and activities conducted at the location of the facilities to be
sampled.
These guidelines cannot anticipate all situations, and special cases will occur. Non-
standard or alternate installations are therefore evaluated on an individual basis, and in
such instances detailed plans should be sent to the local TCEQ Regional Office
sufficiently in advance for review and approval before the construction of stack sampling
equipment is initiated.
Most sampling for representative results requires appropriate sampling equipment for
which the TCEQ has established the guidelines presented in this document.
Various regulations require that safe and easy access be provided for sampling. If a
TCEQ observer determines that the conditions for sampling activities would be unsafe,
crowded, or otherwise dangerous, the observer may preclude the observation of the
sample and, in turn, the acceptance of any results.
Physical Features
Stack sampling operations utilize a system of equipment to traverse a cross-section of
the stack or duct through ports located such that a representative sample can be
obtained. Typically, a monorail structure is erected so the cross-section of the stack may
be traversed on two axes for circular stacks and on a matrix layout for rectangular or
other shaped stacks. Before consideration is given to the installation of sampling ports
and platforms, certain dimensions and other features of the stack and stack gas should
be verified to ensure a representative sample is possible.
Stack diameter should be at least four inches.
Stack gas velocity pressure head should be at least 0.05 inches of water or a low
flow manometer, capable of greater sensitivity should be made available.
The stack should have a uniform undisturbed run of at least 2.5 stack diameters
clear of any disturbance. The port should be located at a minimum, 2 stack
diameters from a disturbance following the flow of the gas stream to the port,
commonly referred as “downstream” by United States Environmental Protection
Agency (USEPA) Title 40 Code of Federal Regulations Part 60, Appendix A
Method 1 (USEPA Method 1); and 0.5 stack diameters from a disturbance going
against the gas stream to the port, commonly referred to as “upstream” by
USEPA Method 1. Alternative methods may be approved by the administrator.
Rev. July 19, 2016
Sampling Ports
Port Location
The USEPA criteria for optimum location of sampling ports is (1) at least eight stack
diameters downstream from any flow disturbance; and (2) at least two stack diameters
upstream from a flow disturbance. A duct diameter is used for non-circular stacks and is
defined later in this guidance. This location permits a sample traverse to be taken using
a minimum of twelve sampling points. A greater number of sampling points is necessary
on stacks which fail to meet these location criteria. If a minimum 0.5 diameter upstream
and 2 diameters downstream criteria from a port location is not available, then stack
modification should be made or an alternate sampling location should be chosen which
will satisfy this criteria. Alternatively, administrator approved methods may be used.
To minimize an increase in the number of sampling points necessary on stacks with an
undisturbed cross-section less than 10 but greater than 2.5 stack diameters in length,
the sampling ports should be located such that the distance from the ports to the nearest
upstream disturbance is four times the distance from the ports to the nearest
downstream disturbance. Due to varying stack shapes, refer to USEPA Method 1 to
determine acceptable port location(s).
Port Size
For stacks that are constructed of 3/16 inch or greater thickness metal, ports should be a
minimum three-inch internal diameter standard industrial flanged pipe with a six-inch
bolt circle diameter and closed by a removable blind flange. Larger port sizes are
necessary on large diameter, double-walled stacks which necessitate longer ports, and
six-inch ports are necessary for proportional PM-10 sampling. The larger-size ports
should also be standard industrial flanged pipe. Ports, no smaller than four inches in
internal diameter, should be used on stacks greater than ten feet in diameter.
Port Installation
Ports should be installed flush with the interior stack wall and should extend outward
from the exterior stack wall no less than three inches nor more than eight inches unless
additional length is required for gate valves. Gate valves should be installed only when
extreme stack conditions or the presence of hazardous materials require such devices for
the safety of personnel. Ports should be installed no less than five feet nor more than six
feet above the floor of the platform and the clearance zone described later in this chapter
should be maintained.
Rev. July 19, 2016
Figure 1 - Minimum Number or Traverse Points
Number and Location of Ports on Circular Stacks
A minimum of two ports should be installed on diameters ninety degrees (90o) apart if
the stack diameter plus one port length (stack inside wall to end of port extension) is
less than ten feet. Four ports should be installed on diameters 90o apart if the stack
diameter plus one port length is equal to or greater than ten feet. One traverse should be
located in the plane of any bend or other disturbance that may have inertial effects on
particles in the flow stream.
Rev. July 19, 2016
Number and Location of Ports on Non-Circular Stacks
The upstream and downstream distance requirements discussed in previous sections of
this guidance also apply to non-circular stacks. The duct diameter (four times the area
divided by the perimeter) is used in place of the circular diameter. This becomes
(2AB)/(A+B) for a rectangular stack, where A and B are the cross-sectional dimensions
of the stack. The stream wise location of the sampling ports is determined in the same
manner as for circular stacks using the duct diameter. The duct diameter is used only for
determining the location of sampling ports and the required number of sampling points.
The duct diameter is not used in data reduction.
The cross-stream location of the sampling ports is dependent upon the total number of
sampling points required. Refer to USEPA Method 1 to determine the minimum number
of sampling points by reading the curve corresponding to the number of upstream duct
diameters (A) and downstream duct diameters (B) and selecting the higher number.
The stack cross-section of square or rectangular stacks is divided into a matrix (i, j) of
equal area rectangles such that i = j or i = j + 1 and i + j is equal to or greater than the
total number of sampling points required. The number of necessary sampling ports is
either i or j located along one side of the stack such that the centerline of each port is
collinear with the centroid of each row of sampling points.
Stacks with cross-sections which are not circular, rectangular, or have unequal
perpendicular diameters, the stack should be equipped with an adequate arrangement
of sampling ports so that the stack cross-section may be divided into a sufficient number
traverse points for a representative sample. If equal area increments are not possible,
time weighting of the sample at the various sampling points may be necessary. Due to
varying stack shapes, refer to USEPA Method 1 to determine acceptable port location(s).
Detailed plans of such installations should receive advance approval by the TCEQ to
ensure representative sampling will be achieved.
Monorail Support Structure
The installation of a permanent monorail support structure is recommended to reduce
set-up time and to eliminate the load-bearing requirements for the sampling ports. This
bracket is intended to be compatible with several types of sampling equipment. The
loading requirements for ports or the monorail support structure are shown below.
Source operators are encouraged to install permanent monorail systems on large stacks.
Monorails should extend the full radial length of the clearance zone, described below.
Rollers should be properly lubricated and maintained in working condition. The sample
box attachment hooks should be six inches above the port centerline. If the monorail is
installed with the hooks more than six inches above the port centerline, suitable
adapters should be provided.
Rev. July 19, 2016
Figure 2 - Monorail Support
Port or Monorail Support Loading
The port or monorail support installation should be capable of supporting the following
loads:
Vertical load of 200 pounds
Horizontal load of 200 pounds
Radial load of 1000 pounds (along stack diameter)
Work Platform
A work platform should be provided around the stack perimeter between the sampling
ports and extend at least five feet beyond each port. If four ports are used, the work
platform should extend around the entire perimeter of the stack. The minimum
platform width should be at least five feet measured radially with stack diameter. The
work platform should be capable of supporting at least 2000 pounds.
Safe and easy access to the work platform should be provided via ladder, stairway, or
other suitable means. Safe guardrails should be provided around the platform. No open
ladder well, stairwell, or other such opening should be located within five feet of any
sampling port. Ladder wells should be covered at the platform and any opening to the
platform
Rev. July 19, should
2016 be equipped with a safety bar or chain at the opening.
A temporary work platform for sampling operations is acceptable if proper safety and
accessibility is provided. All other requirements detailed in this document such as for
monorails, ports, loading, clearance, and power should be met by the temporary
equipment. If any there is any doubt on the proper installation, please refer to the
standards in American Society of Mechanical Engineers (ASME) Steel Stacks (STS)-1-
2011.
Clearance Zone
A three-dimensional obstruction-free clearance zone should be provided around each
sampling port. The zone should extend one foot above the port, two feet below the port,
and two feet to either side of the port. The zone should extend outward from the exterior
wall of the stack at least one stack diameter (or stack radius, if four ports are used), plus
one port length (inside wall to end of port extension) plus five feet. Although this
clearance zone is generally adequate for most sampling efforts, adjustments can be
made as necessary.
Power Supply
Power requirements may vary from site to site. The test personnel and source
owner/operator should verify that adequate power is available prior to testing. For
routine testing, electrical power outlets should be provided as follows:
Platform Power
At least one 120-volt, 15-amp, single phase, 60 hertz alternating current circuit with a
grounded, two-receptacle weather-proof outlet. Receptacles should accept standard
three-prong grounded household-type plugs or suitable adapters should be provided.
Should any issues arise, please refer to the National Fire Protection Association (NFPA)
70: National Electrical Code
Stack Base Power
Two 120-volt, 15-amp, single phase 60 hertz alternating current circuits with grounded,
two-receptacle weather-proof outlets. Receptacles should accept standard three-prong
grounded household-type plugs or suitable adapters should be provided. Should any
issues arise please refer to the NFPA 70: National Electrical Code.
Vehicle Access and Parking
Vehicle access and parking space should be provided near the base of the stack for
various communications and equipment transport lines to be strung to the stack
platform.
Gaseous Sampling - Concentration Only
Standard sampling ports and platforms are typically necessary for gaseous sampling
because a velocity traverse is needed for flow rate determination in most cases. In
sampling situations for which only pollutant concentration is needed or for which an
accurate flow rate is available by other approved methods, sampling equipment that
does not meet all of the recommendations for standard sampling ports may be
Rev. July 19, 2016
acceptable. All equipment should, however, meet strength and safety requirements.
Figure 3 - Stack Equipment
Other Considerations
Power hoists should be provided for sampling platforms 200 feet or more above
ground level.
Non-circular horizontal ducts should have provisions for vertical sampling.
Circular horizontal ducts should have one vertical and one horizontal port.
Suitable work platforms are necessary in both cases.
Heat insulation should be installed as necessary on high temperature stacks for
safety in the vicinity of the work platform.
Rev. July 19, 2016
The sampling equipment should be maintained in a safe, useable condition at all
times.
Stacks may taper by as much as 15° without the taper being considered a
disturbance.
Cyclonic Flow
Cyclonic or swirling flow may be encountered in a stack or duct due to certain
circumstances such as cyclone collectors or tangential duct entry. The existence of
cyclonic flow may be determined as described in 40 Code of Federal Regulations, Part
60, Appendix A, Reference Method 1. Corrective measures such as straightening vanes
may be necessary to alleviate the cyclonic condition.
Rev. July 19, 2016