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PCME STACK 990 - Particulate Measurement System

PCME STACK 990

Particulate Measurement System

PCME STACK 990 - Particulate Measurement System

The PCME STACK 990 is an approved particulate Continuous Emission Monitor suited to industrial applications in stacks after bag filters, cartridge filters, cyclones and process driers. The instrument combines regulatory approvals (TUV BlmSchV 17 and 13) for both dust measurement and leak monitoring, with reliable automatic quality assurance features, rugged operation and advanced diagnostics for the management and optimization of arrestment plant.

Identical PCME technology to the PCME STACK 990 is used in the PCME STACK 991 instrument which can be used to be MACT compliant.





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Contact Altech USA Enviromental sales@altechusa.com

Options include Ex Gas Zone 2 and Dust Zones 20, 21 and 22, up to 800°C stack temperature operation and Hastelloy® enhanced corrosion protection; The PCME STACK 990 is used extensively for particulate measurement (mg/m3) and bagfilter leak location across a broad range of challenging applications.

Patented ElectroDynamic™ Probe Electrification technology extracts a specific frequency band from the induced AC current signature and filters out the DC current caused by particle collisions. The technology outperforms conventional DC triboelectric systems and alternative AC systems by extending the velocity range over which the instrument has no cross sensitivity to changing velocity, and is unaffected by contamination of the sensor rod eliminating concerns of signal drift.

  • Patented probe rod insulation monitor providing operator with early warning of possible probe short circuit. Unique to PCME, this technology enables predictive sensor maintenance scheduling, lower down times and additional confidence in signal quality

  • Additional system self-checks to validate measurement integrity including automatic Zero and Span checking

  • ATEX / IECEx category 3G/1D/2D/3D for gas zone 2 and dust zones 20, 21, 22

  • PC-ME Dust Tools PC software option to provide secure and powerful emissions reporting, real-time and historical data analysis

  • Entry and Standard control unit with advanced graphic and user interface screens, features including alarming, graphical trending, data logging, 4-20mA output.

  • PRO control unit option for sensor networking (up to 32 sensor channels) via industry standard Modbus, multiple inputs for external devices (e.g. for Temp and O2 normalization)

The PCME STACK 990 supersedes the DT990, an instrument proven in demanding CEM applications worldwide.

Process Conditions

The PCME STACK 990 is suitable for:

  • Stacks after bag filters, cartridge filters, cyclones

  • Constant or variable velocities within range 8-20m/s (typical bagfilter velocity ranges), constant velocity required outside this range

  •  After process dryers

  • Non-condensing / dry flue gases*

  • Explosive atmosphere zones 2, 20, 21 and 22

  • Not suitable for electrostatic precipitators or applications with water droplets*

* For wet / condensing flue gas applications see PCME STACK 181 WS

Typical Applications

The PCME STACK 990 is used to monitor emissions from the following types of processes:

  • Quarrying (eg. Rotary Dryers, Roller Mills)

  • Carbon Black filter plant

  • HEPA filters (eg. pharmaceutical/biomedical plant)

  • Coal Mill / Cement Mill / Cement Kiln arrestment plant

  • Humid application eg Dryers, Calcinators

  • Wood cutting & chipping plant

Performance

Approvals

Identical PCME technology to the PCME STACK 990 is used in the PCME STACK 991 instrument which can be used to be MACT compliant.

TUV (BlmSchV 17, 13)

Certification Range

0-15 mg/m3 (TUV)

Measurement Capability

0-500 mg/m3

Long Term Zero Drift

< 0.1 mg/m3

Air Purge Requirement

May be required on some applications (consult PCME), 5-10 liters/min of dry, clean, oil free instrument air

Inspection Frequency

6 months (dependant on application)

Stack Diameters

100mm - 6m (flow profile dependant on large stacks)

Stack Temperatures

0-250°C (option to 800°C)

Automatic Functionality and Quality Assurance Checks

The PCME STACK 990 features comprehensive automatic self-checks to ensure regulatory compliance and to provide plant operators with a preemptive warning of potential sensor issues to allow preventative maintenance scheduling, lower process down times and confidence of data integrity:

  • Automated Zero and Span drift checks to enable a simplified process for operators to meet regulatory standards

  • Patented probe rod contamination check, measures, and reports condition of probe-to-stack insulation ring for maintenance scheduling, before short circuit can occur

  • Probe rod short circuit check enables operator to know when the sensing rod may be electrically shorted to the stack and avoid associated errors

Advanced Signal Processing and Diagnostics

Accurate emission measurement with rapid dynamic ranging allows plant operators to locate the position of leaking bags in multi-compartment bag filters. When integrated with PCME's Predict PC software this provides ultimate arrestment plant fault finding capability:

  • Rapid dynamic ranging of 10,000:1 permits bag cleaning pulses to be accurately monitored while maintaining high accuracy in background emission measurement. Sufficient dynamic ranging is provided to follow "on-line" and "off-line" bag cleaning cycles for predictive filter failure and faulty bag location detection

  • Rolling ('walking window') digital average calculations for accurate emission measurement

Durable Sensor Options for Varied Applications

Standard sensors for probe electrification instruments will only perform under certain process conditions. For example, conductive particulate matter, high levels of humidity, explosive and corrosive atmospheres will present different challenges to probe electrification technologies, can cause errors in measurement or potentially damage the instrument. The PCME STACK 990 offers a range of rugged, durable sensor options to address challenging stack conditions:

  • Patented insulted sensing rod option, significantly increases the maintenance interval required for probe electrification type instruments used in humid flue gases or where conductive dust is present, and provides unrivaled performance in process dryer applications

  • Active/passive design - sensor is available with passive section between active sensing probe and stack connection stub, eliminating concerns over potential short circuits by bridging in the connection stub caused by condensation

  • Optional Hastelloy® stack connection to provide enhanced galvanic corrosion protection, preserves the integrity of the electrical ground through stack connection

  • ATEX/IECEx certified for gas zone 2, dust zones 20, 21, 22

Sensor

  • 316 stainless or fully insulated PTFE coated option for conductive dust or humid flue gas application

  • Stack temperature ranges 0-250°C, 0-400°C, 0-800°C

  • Standard, or with Passive section (for short circuit prevention by creating clearance between active section of sensor and potential contamination 'bridging' sites)

  • RS485 (Modbus) output to control unit

  • Local 4-20mA and Alarm Relays for DCS integration

  • 24VDC power supplied via control unit

  • IP65 die-cast aluminum enclosure

  • ATEX/IECEx category 3G/1D/2D/3D for gas zone 2 and dust zones 20, 21, 22

  • Air Filter and Regulator Assembly for plant instrument air (air purge typically not required for most applications)

Control Unit

  • Controller Type

    • Interface module

    • PRO Controller

  • # of Sensor Channels

    • 1

    • PRO 1-32

  • ICON Driven Multilingual Menus

    • Emission and Alarm levels

    • Quality Assurance results

    • Calibration screens

    • Review data logs

    • Show graph and bar chart

    • Set up and password

    • Advanced calculations (Mass, normalization)

  • Bagfilter Optimization Diagnostics

    • Pulse log review for diagnosing location of leaking bags

  • Emission Data Logs
      Long (averages for reporting)
      Short (process trends)
      Pulse data
      Alarms

    • Capacity stated for one sensor
         12 months @ 15 minutes
         7 days @ 1 minute
         2 hours @ 1 second
         500 entries

    • PRO Capacity stated for four 990 sensors
         24 months @ 15 minutes
         7 days @ 1 minute
         8 hours @ 1 second
         500 entries

  • Ethernet Option Available

  • Outputs

    • 1 x RS-485 (Modbus RTU)
      1 x 4-20mA (500 ohm)
      2 x Relay (2A@250V, user selectable)

    • PRO 2x RS-485 (Modbus RTU or ASC11)
      4 x 4-20mA (500 ohm)
      4 x Alarm Relays (4.5A@250V)

  • Inputs

    • 1 input for plant off indication, bag cleaning reference and multiple calibrations

  • Enclosure Size (DxWxH)

    • 3.1 x 8.7 x 4.8 in.

    • PRO 4.6 x 15.4 x 8.7 in.

  • Power Supply

    • 90 to 260 VAC (50/60Hz), 1A


To contact us:

Corporate Office
2623 Kaneville Court
Geneva, IL 60134

Phone: 630-262-4400
Fax: 630-262-6220
Sales E-mail: sales@altechusa.com
Service E-mail: service@altechusa.com