ppc technical spec revc - process...

Process Metrix, LLC. 6622 Owens Drive, Pleasanton, CA 94588-3334 Phone (925) 460-0385 | Fax (925) 460-0728 www.processmetrix.com

Technical Specification Description The Process Particle Counter (PPC) is a powerful instrument designed to produce particle size and concentration information in a wide range of environments. As such, there are several possible PPC hardware configurations, each designed to function in specific environmental conditions. The software remains the same for all PPC models, although specific application requirements define the setup. The PPC system is an optical single particle counter consisting of an optical sensor head, an electronics interface/signal processing enclosure, and a computer to run the data collection and display software. The sensor requires compressed instrument quality air and power,. The in-situ probe form of the optical head requires water flow to cool the sensor at high temperatures. The PPC instrument has an extensive history in combustion research, and has been used to measure burning coal particles in small scale reactors up to 500 megawatt boilers. Other applications include filtration measurements upstream and downstream of electrostatic precipitators, bag houses, mist eliminators, cyclone separators, and paint booths. The PPC is available in fixed or semi-portable installations, and provides an optimal answer for in-process particle characterization of dilute process streams in hostile environments. The PPC has been proven in the following industry applications:

• Fossil Energy Combustors • Pulp and Paper Recovery Boilers • Powder & Materials Process Streams • Refining Flue Gas Streams • Gas Transmission Lines

Table 1: Benefits and Advantages

Improved Reliability

-Prevent unplanned shutdowns from fouling of equipment by tracking particle size, mass concentration, and velocity of particulate flow in process gas streams. -Monitor filters, cyclones, separators, electro-static precipitators and other filtration equipment performance ongoing.

Improved Energy Optimization

Minimize fouling and downtime in energy recovery systems by measuring mass concentration over time.

Improved Regulatory Compliance

Monitor regulatory compliance in real time by tracking particulate size, concentration, and velocity in gas streams prior to, and following filtration equipment.

Improved Cost of Operations

Prevent damage of sensitive measuring and metering devices by tracking particle size, concentration, and velocity in real time.


Wide Versatility and Durability

-Available in fixed or semi-portable installations -High temperature probe available -High pressure probe available -Control PC to signal processor/optical probe: 1,000 meters through Ethernet connection -Enclosures available to meet explosion proof, waterproof or laboratory environment requirements

Minimal Energy Consumption 100-240 VAC, 2A, 50-60 Hz

Reliable System Configuration

PPC is calibrated via ASTM reticle analysis and confirmed by wind tunnel measurements of known cement dust. PPC measurements can be obtained in situ at atmospheric pressure or by iso-kinetic sampling at high pressure (up to 200 bar). Optimal measurement configurations is provided for process monitoring and control for each client application. Calibration verification services provided according to customer needs (generally yearly).

Features Two different interface packages are available, an atmospheric pressure- high temperature probe, which can be inserted into the flow stream, or a high pressure and variable temperature cell combined with an iso-kinetic sampling system. The optical parameters can be customized to suit user's specific particle size and concentration requirements. Particle measurements are based on analysis of light scattered by single particles passing through one or two focused laser beams. The Process Particle Counter is provided in two primary configurations: Configuration A: In situ or extractive sampling at atmospheric pressure and temperatures ranging from 200 to 1000 oC. Requires water-cooled jacket for high temperatures. Configuration B: Extractive (iso-kinetic) high pressure flow cell. (3-200 bar and temperatures up to 1000 C.

Process Particle Counter System Figure 1: PPC standard system: 1) PPC probe with standard flow window configuration (center section) 2) Laptop computer for data collection and processing 3) Ethernet cable (max. length 300 ft.) 4) PPC probe signal and power cables (max. length 20 ft) 5) Signal Processor enclosure


PPC Dimensional Drawings

Figure 2: Configuration A: In-situ or extractive sampling PPC. Dimensions shown are in inches.

Figure 3: Configuration B: High pressure extractive sampling PPC. Dimensions in inches

PPC System Schematic Diagram Figure 4 shows an overall layout of the PPC instrument system, with all the major components. For configuration (A), the Flow Control Box is also shown, monitoring air purge and water cooling of the instrument probe and water cooling jacket.


Figure 4: Schematic layout of PPC Instrument System, (configuration A), showing basic components and connections.

Figure 5: Schematic Layout of High Pressure PPC Instrument System (configuration B), with basic components and connections. Flow inlet is at center of flange.

Table 2: Physical Specifications Standard Extractive Sampling Probe

Machined from 6061-T6 aluminum and anodized. See above figure 2 for dimensions

High Pressure Probe

Machined from 304/304L or 316/316L stainless steel. See above figure 3 for dimensions. See section “High Pressure/High Temperature Flow Cell” for additional specifications.


High Temperature Probe-Cooling Jacket

The water-cooled jacket has a 3.25 inch I.D. into which the PPC instrument is inserted. Standard cooling jacket lengths are 4 or 10 ft, and can be fully inserted in the process flow. Lightweight design fabricated from aluminum. See section “High Temperature Cooling Jacket” for additional specifications.

Signal Processor Enclosure

Purged, weatherproof enclosure 20” x 16” x 8”. NEMA 4, IP 66. Composed of 16 gauge powder-coated sheet steel. Laboratory version is 9” x 12” x 5” and IP 54. See section “PPC Signal Processor” for additional specifications.

Flow Control Box Hard laminated plywood case, 24” x 15” x 17” Typical ¼” service connections provided. See section “PPC Flow Control Box” for additional specifications.

Laptop Computer Recommended Panasonic Toughbook CF-29 (512 MB RAM, 1.6GHz, 80GB Hard Drive). See section “Laptop Computer” for additional specifications.

Table 3: Operating Parameters Measurement parameters are the same for all PPC models including ambient, high pressure and high temperature models. Additional PPC measurement variables are included in the “PPC Variables” Table at the end of this section.

Particle Size General capability from 0.3 to 200 microns Typical configuration is 0.4 to 80 microns

Particle Concentration

Submicron: up to 107/cm3 (typical up to 106/cm3) Supermicron: to 10 PPM by volume

Flow Velocity General capability 0.1 to 400 m/s Typical configuration 1 to 100 m/s up to 500,000 measurements/second

Accuracy Accuracy: ±5% of indicated size Precision: ±3% of indicated size Verification via ASTM reference standard reticle

Pressure Ambient up to 200 bar

Temperature Up to 1000oC

Table 4: Software Specifications

Environment Windows XP based color graphics program for data acquisition, processing, and display. Continuous real-time display of a wide range of particle distribution parameters. Flexible data formatting is available and determined at startup according to client preferences.


PPC Program Process Metrix, LLC proprietary software receives data from signal processor and provides real time data streams as noted in “PPC Variables” section

DCS Compatibility PPC software can be customized to provide up to 6 discreet analog inputs per I/O card.

Table 5: Electrical Specifications

PPC Power Supply Power input from signal processor

PPC Data Supply Control PC to signal processor: 1,000 meters through ethernet connection. Signal processor is connected to PPC instrument by 20ft. shielded cable.

Signal Processor Power Supply 100-240VAC, 2A, 50-60 Hz.

Flow Control Power Supply No power inputs required

Laptop Computer Standard 100-240VAC, 50-60 Hz. Includes 7+ hr battery

Table 6: PPC Variables {NOTE: x1 and x2 are user input values in the range of 0 – 100.} Variable Title Name Units Description Standard Variables Cn Number Concentration #/cc Total number of particles per unit volume of

gas flow through instrument sample volumeCm Mass Concentration mg/m^3 Total mass of particles per unit volume of

gas flow through instrument sample volumeCv Volumetric Concentration PPM Total volume of particles per unit volume of

gas flow D(x1) Characteristic Diameter µm Particle diameter at x1 % (where x1 is a

user-defined percentage) of either the total number concentration or total mass concentration. E.g. Dm(50) gives the mean size by mass, that is, size at 50% of the mass.

%< x1 Percent Less Than % Percent of total number or mass concentration less than size x1


%>x1 Percent Greater Than % Percent of total number or mass concentration greater than size x1

x1 < % <x2 Percent Between % Percent of total number or mass concentration between sizes x1 and x2

V(x1) Average Velocity m/s Particle velocity of module x1 (user picks 1,2,3, or All), averaged over the accumulation period set in the software

v(x1) Instantaneous Velocity m/s Instantaneous Velocity of module x1. Velocity of module over one update period (several update periods make up one accumulation period)

N Number Flux #/s Total number of particles flowing through entire flow cross section (specified by user), per second. User specifies cross-sectional area of pipe from which sample is taken, and software calculates total particle flow rate through that cross section.

M Mass Flux mg/s Total mass of particles flowing through entire flow cross section (specified by user), per second. See above.

R(x1) Accumulated Data Rate Hz Number of pulses detected per second, averaged over the accumulation period set in the software. Used to determine if instrument discriminator is properly configured

r(x1) Instantaneous Data Rate Hz Number of pulses detected per second, averaged over the update period set in the software. Used to determine if instrument discriminator is properly configured

Variables that may be used depending on analytical need T[x1] Temperature °F Temperature at specified point. Only

available for points inside the instrument, not the particle flow. Used as safety indicator

SSA Specific Surface Area m^2/cc Average surface area per unit volume of the particle distribution. This is a characteristic surface area of the distribution that is related to Blaine number (used in cement industry) by a constant.

[D(x1)-D(x2)]/D(50.0)

Span (none) Diameter width between x1 and x2, normalized by D50. Indication of width of distribution. This number increases as the top size of the distribution increases, and will indicate when there is a greater number of large particles.


D[x1][x2] Diameter Moment µm^(x1-x2)

Σn(d)*d^x1/Σn(d)*d^x2. E.g. Sauter mean diameter, D[3][2]. This gives the equivalent diameter of a particle that has the same volume to surface area ratio as the average particle in the distribution.

D(x1)/D(x2) Diameter Ratio (none) Diameter Ratio at x1 and x2 More variables available at client request.


High Pressure/High Temperature PPC Flow Cell Description The high pressure and temperature flow cell is applied to installations requiring sampling of high pressure gas streams. The high pressure probe has specially engineered purge and cooling systems to handle this hostile configuration.

The High Pressure Cell Figure 6: High pressure flow cell for PPC. Instrument transmitter and receiver attach to front and back face. Process connections at right and left, high pressure purge connections at top and bottom, water cooling connections diagonal.

The following diagram shows a cutaway view of the High Pressure Process Particle Counter (HP PPC) flow cell. Particle flow passes through the flow cell from left to right. The particle flow is directed through the laser sample volume by the purple nozzle. The lasers from the transmitter travel along the optical path, scatter off of the particles in the sample volume, and are detected by the receiver (not shown) on the far side of the flow cell. Figure 7: Section view of High Press/High Temperature Flow Cell. Orange and red areas indicate air pockets.


Table 7: Physical Specifications

Housing 304, 304L, 316, 316L SS

Nozzle and Liner 304, 304L, 316, 316L SS

Figure 8: Dimensional Drawing

Table 8: Operating Parameters

Pressure Up to 200 bar



High Temperature Cooling Jacket Description High Temperature Probe (up to 1000 C): The water-cooled jacket measures 3.75 inches OD and has a standard length of 10 ft. This probe is ideal for measurement through an access port of 4 inches or larger.

Figure 9: Layout of water jacket and PPC probe for in situ high temperature applications. PPC probe (3” dia.) is inserted into 4” dia. water jacket and their flow ports are lined up using the probe positioning nuts. Maximum insertion distance into the flow is 9 feet for 10 ft. long water-cooled jacket.

Figure 10: Cooling Jacket Diagram


Table 9: Physical Specification Housing Machined and welded from 6061-T6 aluminum tube.

Table 10: Operating Parameters Pressure Up to 50 psig



PPC Signal Processor Description This enclosure contains modules for processing of signals from the sensor probe, and interfacing with the computer. Communication between the computer (typically a laptop) and the signal processor is by Ethernet. The signal processor must be within 7 meters (about 20 ft) of the sensor, while the distance between computer and signal processor is unlimited via Ethernet. Enclosures can be provided for standard laboratory environments (IP 54) or to meet explosion/waterproof requirements (NEMA 4, IP 66). The enclosure requires input power of 100-240VAC, 50-60Hz

Figure 11: Front of standard signal processor box, showing power button in off position, and analog signal BNC connector (to oscilloscope).

Figure 12: Back of signal processor box, showing Ethernet, power, probe control, signal cable, and purge connections.

Table 11: Electrical Specifications

Power Supply Powered by external brick power supply that requires 100-240VAC, 2A, 50-60 Hz. Connects to signal processor “power in” connection.

Data Supply Connects to PPC instrument via shielded “probe control” cable and signal cable, 20 ft. Control PC connected to signal processor by up to 1,000 meters of crossover Ethernet cable, or through a network. Cables installed according to client Area Classification.


PPC Flow Control Box Description The Flow Control Box regulates to flow of cooling water supply and return, instrument air and nitrogen to the PPC. Hoses to and from the PPC and water cooling jacket are provided. Connections to the jacket and instrument are quick connect, and plant air and water connections the flow control system are standard ¼” NPT, with quick connects. Other connections are available by customer request. Figure 13: Back Panel of Flow Control System.

Table 12: Operating Parameters Flow Control Front Panel Operating Ranges:

AIR OUT TO PPC Typical Flow Rate = 100-200 SCFH

WATER OUT TO PPC Typical Flow Rate = 10 GPH

WATER IN FROM PPC

Typical Flow Rate = 10 GPH, which should correspond to flow rate of water out, above.


WATER OUT TO COOLING JACKET

Flow Rate = 1 – 100 GPH, depending on temperature outside cooling jacket.

WATER IN FROM COOLING JACKET Flow Rate = 1 – 100 GPH, corresponding to water out.

Figure 14: Front of Flow Control Box


Laptop Computer Process Metrix recommends using the Panasonic Toughbook CF-29, with:

• PM 1.6GHz Centrino Processor • 13.3" XGA TOUCH Display • HI-BRIGHT Outdoor Readable Display • 80GB Hard Drive • CD-RW/DVD Drive • 802.11abg • Windows XP SP2 • 7+ Hour Battery • MS Office

PPC Software can be installed on any Windows XP based system. The software can be installed on multiple computers for data sharing and post-processing.


Standard Warranty Information Valid from one year after system commissioning at customer facility, Limited Product Warranty: Process Metrix Company (PMC) warrants that this product will be free from defects in materials and workmanship during the warranty period, and will perform according to product documentation. This warranty is expressly limited to product repair or replacement, at the sole direction of PMC. Except for the express warranty expressed above, PMC grants no other warranty. All implied warranties of merchantability and fitness for a particular purpose are expressly disclaimed and are not applicable to the product. This warranty is contingent upon proper use of the product in the application for which it is intended and does not cover any product that was modified or subjected to unusual mechanical stress. PMC’s maximum liability for breach of, or resulting from, this warranty will be limited to an amount not exceeding the original product purchase price, in no event will PMC be liable to any party for any special, consequential, or incidental damages, or for damages for personal injury or property.

ppc technical spec revc - process...

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