How to Ace the EPA Stack Test

Preparation for an EPA stack test is crucial in the process of passing that test. While most of this seems common sense, it’s easy to overlook something and discover too late that you’re on the road to failing your test. Certain parameters are essential to your success in that testing. These two documents are what I developed over the years to ensure successful test results.

 

Pre-Stack Test Field Data

Baghouse

Date__________________                                                                                     Time____________________

General Conditions:                                                                                               Clear___ Cloudy___ Rain___

Elevation______________ FT                                                                                  Ambient Temp___________

Plant Model_______________

 

Cleaning: Remove rust, dirt, dust and scale in or on all internal surfaces.

Black light test with Visualite is mandatory prior to testing.

 

Air Ducts-House Inlet______________________ Condition___________________________

House Walls and Hopper___________________ Condition___________________________

Clean Air Plenum__________________________ Condition___________________________

Fan Housing and Wheel____________________ Condition___________________________

Exhaust Stack______________________________ Condition___________________________

Bag condition______________________________ # bags replaced______________________

 

Adjustments:

Baghouse pressure drop________ (3” to 5” recommended)

Fuel Type____________________

Fuel Pressure_________________ (adjust to minimum recommended by burner manufacturer)

Bag Cleaning Rate_____________ Seconds between pulses/rotor time.

Air Damper Control___________ (Manual position recommended)

 

Air Analysis: Bacharach Combustion Analyzer or equivalent is recommended.

CO_______ PPM. Too little air gives off carbon monoxide. ( 200 PPM or less)

O2_______ Too much air waste fuel, unburned air gives off oxygen. Normal range is 6-10%

CO2______ Maximum operating range of Carbon Dioxide is under 6-18 percent.

 

Checks:

Compressed Air Pressure_______________ (100 PSI recommended)

All Solenoids Operating________________ All Diaphragm Valves operating_________

No Compressed air leaks_______________ Pressure drop manometer tubing_________

 

Tests performed by____________________________

 

 

 

Pre-Stack Test Field Data

Wet Scrubber

Date__________________                                                                                     Time____________________

General Conditions:                                                                                               Clear___ Cloudy___ Rain___

Elevation______________ FT                                                                                  Ambient Temp___________

Plant Model_______________

 

Cleaning: Remove rust, dirt, mud, and scale from all internal surfaces.

Air Ducts-Scrubber Inlet______________________                                     Condition______________________

Scrubber Walls______________________________                                  Condition______________________

Scrubber Tube-Inside________________________                                    Condition______________________

Sludge Trough-Full Length___________________                                         Condition______________________

Fan Housing and Wheel_____________________                                        Condition______________________

Exhaust Stack______________________________                                    Condition______________________

 

Any problem above MUST be remedied prior to stack test.

 

Adjustments:

Venturi Pressure Drop______________                             (Minimum  13” to 14” recommended

Fuel Type_________________________

Fuel Pressure______________________                          P.S.I. (Adjust as low as practical to maintain flame)

Venturi Nozzles____________________                           P.S.I. (consult plant manual for pressure)

Air Damper Control_________________                            (Manual position recommended)

 

Air Analysis: Bacharach Combustion Analyzer or equivalent is recommended.

CO_______ PPM. Too little air gives off carbon monoxide. ( 200 PPM or less)

O2_______ Too much air waste fuel, unburned air gives off oxygen. Normal range is 6-10%

CO2______ Maximum operating range of Carbon Dioxide is under 6-18 percent.

 

Ponds: An ample supply of clean natural water is vital for passing an EPA Compliance Test

Number of ponds being used_____   Pond size in gallons of water___________________

Date Pond Cleaned___________ Is a setting agent being used_____ Type_____________

 

Tests performed by____________________________

 

Once all of this data has been gathered you can easily determine if you will pass or fail the upcoming tests.

It’s important to remember that your stack test is the most important process that you are doing on that day. The results of that test dictates HOW you are permitted to operate for the rest of the permitted period. I strongly recommend that the focus be on passing the stack test and not on the paving operations.

In recent years I have seen a number of plants fail a stack test because the plant operator ignored good plant operational practices in an attempt to satisfy the demands of a paving superintendant who simply did not understand the importance of this one day of compliance testing.