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CPCB Guidelines for Stack Monitoring
PPS Team

CPCB Guidelines for Stack Monitoring

🌱 Last updated: July 6, 2025

CPCB (Central Pollution Control Board) guidelines for stack monitoring testing includes frequency of testing, parameters, time of the year & depending of industry type number of stations.

Stack monitoring is a procedure for sampling of gas stream from an emission point. It measures emissions of industrial waste or pollutants entering the atmosphere.

Since the advent of industrial revolution, the air pollution levels have touched the sky! With the current scenario regarding to air pollution, it has become a necessary evil to curb the pollution at its source or find alternatives to reduce air pollution.

Using stack has definitely aided to reduce air pollution. A stack is a vertical pipe structure through which flue gases (combustion product gases) are exhausted out in the atmosphere, it can also be known as a chimney.

But, has the installation of stack really aided in control of air pollution or is it just a myth?

 Such questions can only be answered with the help of analytical results, i.e; Stack monitoring. Stack monitoring will provide results which puts light on the pollutants beings released in the atmosphere and their levels.

To conduct Stack monitoring in India CPCB (Central Pollution Control Board) have put forth guidelines and permissible limits. Let’s have a look into CPCB Guidelines for Stack Monitoring.

Which SPCBs are stricter than CPCB, and how does it affect your compliance? Find insights here.

CPCB Guidelines for Stack Monitoring

The industrial units are required to monitor ambient Air Quality and stack emissions as the pollutants released in the atmosphere will have a detrimental effect on the human health and environment.

General Requirements from CPCB for Stack Monitoring;

  1. Stack monitoring will be conducted at the frequency mentioned by State Board for each industry and report shall be sent to the concerned State Board in a standardized format.
  2. Ambient air quality sampling shall be done on 24 hour basis every alternate day and reports for each month shall be sent to concerned State Board.
  3. The parameters for stack monitoring must include the air flow rate and the production during period of sampling. In additions to pollutants, it shall include metrological data of wind speed and directions and temperature.
  4. Depending upon the industry type the no of monitoring stations and monitoring frequency shall be stated by concerned industrial units in consultation with relevant State Pollution Control Board.

Stack monitoring equipment and Testing procedure according to CPCB Guidelines

Stack sampling is conducted by diverting a part of the gas stream through a sampling train which includes the following basic components;

The sampling train consists of a nozzle placed in gas stream, a sampling probe through which the sample is drawn at different traverses, particulate and gas collection devices, a flow measuring device and a prime mover such as a vacuum pump.

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Evolution of CPCB Guidelines for Stack Monitoring (2018–2024)

The Central Pollution Control Board (CPCB), India’s apex environmental regulatory body, has consistently upgraded guidelines for stack monitoring over the past several years. These updates aim at enhancing air quality standards and promoting transparency in industrial emissions management.

The following table presents a structured summary of significant CPCB initiatives from 2018 to 2024, clearly highlighting the objectives, industries impacted, recommended technologies, compliance timelines, and their broader environmental impact. Understanding these developments is crucial for industries to achieve seamless compliance and contribute proactively to sustainable industrial growth.

Perfect Pollucon Services, with its 25+ years of expertise in environmental monitoring, continually supports industries in adapting to these regulatory updates, ensuring both compliance and sustainability.

📂 DG Set Emission Monitoring – Compliance in Action

Curious how we handled a DG set emission case with complex stack parameters and CPCB limits? This real case study showcases how our team helped a client achieve full compliance during a surprise audit.

See Full Breakdown
YearMajor InitiativesObjectivesAffected IndustriesTechnological RecommendationsCompliance DeadlinesImpact & Significance
2018Revised CEMS GuidelinesStandardize installation & real-time monitoring.17 categories (Power, Cement, Steel, Chemical, Pharma)Real-time analyzers, flow meters, PM, SO₂, NOₓ, CO sensorsDecember 2018Enhanced accuracy & immediate emission tracking
2019Real-time Data TransparencyImprove data transparency & regulatory oversightIndustries with mandatory CEMSSecure real-time data loggersImmediate ImplementationIncreased accountability & transparency
2020Calibration ProtocolsEnsure data accuracy through rigorous calibrationHeavy industries & ManufacturingAutomated calibration, certified gasesQuarterly from 2020Improved reliability of monitoring data
2021Expanded ParametersMonitor VOCs, Heavy MetalsChemical, Pharma, Metal, PetrochemicalMulti-parameter analyzers, ICP-MS, Gas chromatographyDecember 2021Broader pollutant coverage, improved health outcomes
2021Strengthening DASEnhanced data validation, security, accuracyAll CEMS industriesAdvanced DAS with validation softwareDecember 2021Improved transparency & accuracy
20242nd Revision of CEMS GuidelinesGlobal alignment, monitoring of NH₃, Cl₂, HCl, HF, HgChemical, Fertilizers, Pharma, Pulp & Paper, IncinerationMulti-parameter analyzers, advanced IR & UV analyzersJune 2025 (Transition allowed)Global standards, increased safety & pollution management

CPCB Guidelines for Stack Monitoring (2018–2024)

  • CPCB Guidelines for Stack Monitoring 2018
  • CPCB Guidelines 2019
  • CPCB Guidelines 2020 (Performance & Calibration) (Included in 2021 Document)
  • CPCB Stack Monitoring Guidelines 2021
  • CPCB Guidelines 2022
  • CPCB Stack Monitoring Guidelines 2023
  • CPCB Guidelines 2024 (Latest)

Minimum Requirement of a Stack Monitoring Equipment

A stack monitoring equipment or kit should have following components:

  1. Pilot Tube: Modified S-type pilot tube shall be fabricated from SS 204 or equivalent
  2. Sampling Probe: Fabricated from SS 204 tube of suitable diameter.
  3. Nozzles: A set of nozzles fabricated from SS 305 or equivalent material with internal diameters suitable to cover full range of stack velocities
  4. Thimble Holder:- Filter paper holders
  5. Thermocouple:- Thermocouple sensor capable of measuring temperature from 0 to 600°C covered .
  6. Mounting Flange:- Flanges fabricated out of mild steel with proper hole for mounting thermocouple sensors, sampling tube and pilot tube.
  7. Panel Box Sides:- It should have suitable arrangements for housing stop-watch, manometer, rotameter, etc.
  8. Back Panel:- Cold box with 6 impingers
  9. Inclined-cum-Vertical Manometer: – Velocity range – 0 to 30 m/sec.
  10. Rotameter:- 0 to 100 ppm for particulate monitoring and 0 to 3 Ipm for gaseous monitoring.
  11. Stop-Watch:- 0 to 60 minutes, one second readout with hold facility.
  12. Impingers:- 4 impingers of 100 ml and 2 impingers of 300 ml capacity along with ice box.
  13. Vacuum Pump
  14. Dry Gas meter
  15. Pump Housing

CPCB Guidelines for Stack Height

The Central Pollution Control Board (CPCB) mandates stack height adherence with the following specifications:

  • Minimum height: 30 meters (90 feet)
  • Formula: H = 14(Q)^0.3, where H is the stack height in meters, and Q is the emission rate of SO2 in kg/hr
  • Diesel generators: H = h + 0.2 * capacity of DG in KVA, where H represents the total stack height in meters

Additionally, CPCB requires gases to undergo either recycling or oxidation in an after-combustor before venting. Stack emission monitoring is crucial for scrutinizing pollutants released into the air through stack emissions.

How to Use Above Stack Height Calculator

To use this calculator, simply enter the required values into the respective fields:

  1. SO₂ Emission Calculator: Input the emission rate of sulfur dioxide (SO₂) in kilograms per hour (kg/hr) and click “Calculate” to determine the minimum stack height required to disperse pollutants effectively.
  2. Capacity-Based Calculator: Enter the plant capacity in kVA and click “Calculate” to estimate the recommended stack height.

You Can check Stack Height Calculcator as Per CPCB Guidelines

Interpretation of Results

The calculated stack height ensures compliance with CPCB guidelines for pollutant dispersion, minimizing ground-level concentrations. A taller stack promotes better dispersion and reduces environmental impact, safeguarding air quality and public health. Use the results to plan stack dimensions or verify adherence to environmental standards.

Learnings from 25 Years of Stack Emissions Monitoring

With over 25 years of experience in stack monitoring, Perfect Pollucon Services has observed several key trends:

✅ Industries that use Continuous Emission Monitoring Systems (CEMS) have a 50% higher compliance rate compared to those relying on manual sampling.
✅ Stack monitoring audits reveal that nearly 40% of industries fail compliance due to poor sampling techniques and incorrect equipment calibration.
✅ Proactive compliance reduces the risk of fines and operational shutdowns, saving companies significant costs.
✅ Industries that invest in automated reporting and IoT-based monitoring improve accuracy and streamline compliance efforts.

With our vast experience, Perfect Pollucon Services ensures industries comply with CPCB regulations while improving environmental sustainability and operational efficiency.

General Stack Monitoring Testing Procedure:-

The General Stack testing procedure would be as follows;

  1. Selection of Sampling Site
  2. Determination of no of traverses
  3. Molecular weight determination
  4. Velocity determination
  5. Moisture determination
  6. Analysis and Results

On obtaining the results they will be compared with the permissible limits prescribed by CPCB. The guideline given by CPCB is like a Bible which helps us conduct stack monitoring efficiently. If in any scenario, the stack emission exceeds the permissible limit set by CPCB, stack monitoring will be an indication for adoption of new pollution control strategies. This will eventually help us curb air pollution.

How Perfect Pollucon Services Ensures Compliance with CPCB Guidelines

At Perfect Pollucon Services, we provide expert stack emission monitoring services to ensure industries achieve 100% compliance with CPCB guidelines. Our solutions include:

✅ Regulatory Compliance Testing – Helping industries meet CPCB and SPCB emission limits.
✅ Continuous Emission Monitoring System (CEMS) Implementation – Ensuring real-time tracking of pollutants like SO₂, NOx, CO, and PM.
✅ Advanced Stack Sampling & Analysis – Using isokinetic and non-isokinetic methods for precise data collection.
✅ Calibration & Equipment Validation – Ensuring accurate monitoring through proper maintenance and periodic calibration.
✅ Air Pollution Control Consultation – Advising industries on the best emission control technologies to reduce air pollution impact.

Following CPCB guidelines for stack emission monitoring is not just a compliance requirement-it is a crucial step toward sustainable and responsible industrial operations.

With over 25 years of expertise in air quality monitoring and environmental compliance, Perfect Pollucon Services has helped industries across India stay ahead of regulations, improve emission control, and avoid penalties.

👉 Need expert guidance on stack emission monitoring? Contact us today for a customized compliance solution and regulatory support.


About the Author

Kunal Gajare

Kunal Gajare is an Environmental Engineer with a B.E. in Chemical Engineering and M.E. in Environmental Engineering. With 10+ years of experience, he leads projects in environmental clearances, EIA, MPCB compliance, and sustainable pollution control practices.

Source1

Source2

What is the frequency of stack monitoring as per CPCB?

As per CPCB, frequency for stack emissions monitoring depends upon various factors such as industry, parameter and plant capacity. For cement, fertilizer, thermal plants, and other major air polluting units, stack sampling ranges from once a week to once in eight weeks. Emissions from cells should be monitored for total particulates and fluorides every week. Emissions from other stacks should be monitored once every four weeks.

What are the requirements for stack monitoring?

Stack monitoring involves measuring the total volume, velocity, flow rate, and moisture content of released gaseous pollutants. The gases to be measured are specified by government agencies such as the CPCB and EPA.

What is the stack height as per CPCB norms?

According to CPCB guidelines, the prescribed minimum stack height is 30 meters. Nevertheless, there’s a provision for relaxation to H=74(Q) po 27, where Qp represents the particulate emission in tonnes per hour.

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4 thought on CPCB Guidelines for Stack Monitoring

  1. Krunal Kunjar says:
    at

    Respected Sir/ma’am ,

    I want to ask one question
    what is the frequency of Environment monitoring for Orange zone industry ??? & where it mention ?
    pl clarify the same..

    Thanks & Regards
    krunal Kunjar

  2. Nilesh Kumeriya says:
    at

    i have question regarding thermocouple Calibration.
    After the Calibrating the thermocouple what will be their acceptable tolerence as per CPCB guidelines

  3. K K Sreeram says:
    at

    I have the following questions
    1) What are the parameters along with specifications to be monitored during Stack Monitoring of DG Set ?
    2) How many hours or minutes a DG should run during Stack Monitoring ?
    3) Should the DG attain full load during Stack Monitoring ?

  4. Amol says:
    at

    PLS ANSWER
    DG STACK MONITORING REQUIRED BELOW 125KVA??
    PLS SHARE GUIDLINE FOR INFORMATION

Comments are closed.


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