PCME STACKFLOW 400

Flue Gas Flow

Measurement System
PROCESS & EMISSIONS MONITORING SYSTEMS

SPECIFIC FEATURES:
 Unique extended measurement path (400mm) permits accurate and increased
representative measurement
 Robust flow measurement for industrial applications

 Inbuilt automatic reference self-checks for regulatory compliance (QAL3)

 Facilitates stack velocity, volumetric flow and pollutant mass release calculations
when linked to gas and dust CEMS
 Angled probe version to fit existing perpendicular ports
QAL1 Certified to EN 16911
US EPA PS-6 capable

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 TECHNOLOGY / APPLICATION
SYSTEM DESCRIPTION
The PCME STACKFLOW 400 is an advanced flue gas flow

© Lühr Filter. Biomass Combustion plant. Reproduced with kind permission.

measurement system for continuously monitoring releases from
industrial sources. This instrument complies with European
monitoring standards EN 16911-2 and 15267-3 for QAL1.

The PCME STACKFLOW 400 sensor satisfies the need for high
quality assurance on emission release data, reporting mass
emissions (kg/year) as well as concentration monitoring.

It uses ENVEA’s unique Fluesonic ® technology and mathematical

measurement algorithm (patent pending) that allows the transit
time of the signal to be measured accurately in real stack
conditions, hence permitting:
• An extended measurement path of 400mm in a single,
stack-mounted probe design
• Capability to deal with flow profiles across the extended
measurement path
• Tolerance to contamination and flow eddies

PRINCIPLE OF OPERATION
The instrument uses ENVEA’s innovative FlueSonic ® Ultrasonic
Techno-logy, measuring the time of flight of ultrasonic signals
between two transducers (see Figure 1). Each transducer emits an
ultrasonic pulse that is detected by the other. The sensor is mounted in
the stack at an angle (typically 45 degrees), such that the transducers
lie upstream and downstream of each other.

The time of flight of an ultrasonic pulse travelling between the two

transducers depends on the distance it has to travel, the speed of
sound in the gas and the velocity of the gas. The time of flight of
a pulse travelling in the same direction as the gas (downstream)
is shorter than the time of flight of the pulse travelling against the
direction of the flow (upstream).

The difference in these flight times is directly proportional to the

velocity of the flue gas.
The stack flow velocity in the measurement path is calculated from the
upstream and downstream transit time in a way that is independent
of the speed of sound in the gas, flue gas temperature or pressure of
flue gas composition. The flow rate is calculated by multiplication of
average flue gas velocity by the stack cross-section area. Figure 1: Principle of Operation of the PCME STACKFLOW 400

CALIBRATION AND INBUILT SELF-CHECKS

The PCME STACKFLOW 400 measures the average velocity in the stack Probe insertion length 1.36 m
across a measurement path length of 400 mm. It is important to locate
this measurement path in a representative location across the stack flow
profile and as such the instrument is provided with a 900 mm extension
tube with movable flange so that the measurement path can be located in Movable flange
the optimum position (probe insertion length: approx. 1.4 m), see Figure 2.
Figure 2: PCME STACKFLOW 400 sensor with movable
As with all flow measurement devices, the relationship between instrument flange to locate the optimum measurement path
output and average flow across the full cross-sectional area of the stack
is calibrated by comparison to measurements made using a Standard
Reference Method (such as Pitot traverses or tracer methods pursuant to
EN ISO 16911-2).
Automated Reference Checks
The PCME STACKFLOW 400 performs Lower and Upper Reference (Zero
and Span) sensor self-checks (a requirement of EN 16911-2), see Figure 3.
These self-checks assess not only the performance of the electronics
and measurement algorithm, but also the performance and correct
operation of the transducers, including their ability to transmit, receive
and discriminate actual ultrasonic signals from noise and offsets in the
stack environment.
These automatic Quality Assurance features provide outputs which can be
used for QAL3 reporting requirements (as defined in EN ISO 16911-2) and Figure 3: PCME STACKFLOW 400
provide feedback to the user on the correct operation of the instrument. Lower and Upper Reference Self-Checks
PRODUCT FEATURES
TYPICAL APPLICATIONS
The PCME STACKFLOW 400 is suitable for measuring the flue
gas flow rate after both bag-filter and electrostatic precipitator
(ESP) arrestment plant and satifies the need for high quality
measurement on emission release data. From a regulatory
perspective its high quality assurance features make the sensor
suitable as a compliance device.

Typical application areas are:

• Waste-to-Energy and Incineration plants
• Emissions from Steel, Chemical and Mineral processing
applications
• Gas Turbines and Coal-fired Power plants
• Industrial stacks (before or after final arrestment plant)

© Lühr Filter. Integrated Steel plant. Reproduced with kind permission.

ADDED VALUE FEATURES AND BENEFITS

Application Conditions Specification

Stack Temperature -20°C to 200°C (-4°F to 392°F)

Stack Diameter ≥0.5 m (1.6 ft)
Stack Pressure ±100 mbar Dust Monitor Flow Monitor

Ambient Temperature* -20°C to 50°C (-4°F to 122°F)

*at monitoring point

Measurement Specifications
Measurement Path 400 mm (16”, nom.)
Response Time 40 s
Gas Velocity ±(0–50) m/s
±(0–30) m/s (Certification Range)
Resolution: 0.1 m/s
Minimum Detection Velocity 0.0 m/s

S e n s o r C o mm o n S p e c i f i c a t i o n s

Sensor Material Sensor body: 316 SS, Transducers: Hastelloy ®

Enclosure Dimensions W 148 x H 192 x D 106 mm (5.8 x 7.6 x 4.2 in.)
Enclosure Rating IP65
Power Supply Voltage 24V DC (via the control unit or PSR)
Current Consumption Average load: 120mA (24V), max. load: 140mA (24V)
RS-485 Comms Ethernet
RS-232/USB
Outputs 1x RS-485 Modbus, 2x Relays, 1x 4-20mA 4-20 mA

Input 1x Digital Input Figure 4: PCME STACKFLOW 400 combined with a PCME dust
monitor for integrated concentration and mass emissions reporting
Flange 3”/4” ASME // DN80/100 PN10/16 (combined
flange), also DN40 PN6 106 454 473

Straight Sensor
Installation Angle 45° to stack wall
Sensor Options Horizontal stack orientation
Vertical stack orientation
Angled Sensor
Insertion Length max. 1360 mm (53.5”)
Weight 8.6 kg (19 lb)
40
0

Angled Sensor

Installation Angle 90° to stack wall

400
Flange Option: 4” BSP Adaptor
Straight Sensor
Sensor Options Horizontal stack orientation
Vertical stack orientation
192

Insertion Length max. 805 mm (32”, nom.)

Weight 6.2 kg (13.5 lb) 106 910 573

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SPECIFICATIONS PCME STACKFLOW 400
Network Controllers and accessories
Number of sensors/channels 1 1–32
Display Two-tone grey, backlit graphical LCD High-contrast, anti-glare 7” (viewable) TFT LCD
Multiple Data Viewing PC or RS-485 PC/RS-485/Ethernet simultaneously

Overview Dimensions W220 x H124 x D80 mm W390 x H221 x D118 mm

Power supply voltage 100–240V AC (50/60 Hz) 85–265V AC (50/60 Hz)
Protection Rating IP65 IP66
Ambient Temperature Range -20°C to 50°C -20°C to 50°C
Up /Dow n /Le ft/Rig h t/Ente r
Navigation keys Up /Dow n /Le ft/Rig h t/Ente r plus 5 function keys: 3x short-cut keys
and 2 user-programmable keys
Icon-driven, multilingual menus n/a 
Secure password protection  
Features and Sensor system setup and configuration
Functions options  
Configurable emission alarm levels  
Sensor calibration screens  
Seamless integration with existing
PCME control units and sensors
n/a 
Long-term Log 12 months @ 15 minutes 48 months @ 15 minutes
Short-term Log 7 days @1 minute 28 days @ 1 minute
Data Logging*
Pulse Log 8 hours @ 1 seconds 32 hours @ 1 second
Alarm Log 500 entries 500 entries

Ethernet (RJ45) n/a 

Connection type: 100Base-T/Tx 100 Mb/s

USB 2.0 n/a 

System Outputs Suitable for connecting to a local PC or laptop
Relays 2 off (programmable) 4 off (programmable)
4–20 mA 1 off (programmable) 4 off (programmable)
RS-485 1 1
Digital
User selectable for: PLANT OFF indication,
1 4
System Inputs Bag-filter cleaning sequences, multiple
calibrations
4–20 mA 0 2

*Data logging capacity for one sensor. Data stored varies per sensor type. Please consult ENVEA for specific data.

Analogue Output Module (AOM)

1 1–8
provides 8 additional 4–20 mA outputs definable to sensors/channels
Network Modules
Auxiliary Input Module (AIM)
(can be connected to 1 1–8
provides 4 additional digital inputs, plus 4 additional relay outputs
Controller Network
Relay Output Module (ROM)
systems to provide 1 1–8
provides 8 additional relay outputs
additional Inputs and
Outputs) SPUR
1 1–32
provides sensor network connection and local isolation during maintenance
Power Supply Repeater (PSR)
1 1–8
provides voltage and signal boost for extended cable runs and large sensor networks
Publication Part No. 496006 V6 (10/20)

ABOUT ENVEA
As a progressive environmental Company, ENVEA specialises in particulate measurement for industrial processes.
With a worldwide reputation for reliability, innovation and technological excellence, the Company produces under
the trademark envea™ equipment for concentration and mass monitoring for regulatory, environmental and process
control requirements. A dedicated team of qualified application and sales engineers is always on hand and should be
consulted in the selection and usage of the most suitable equipment for any particulate application.
ENVEA UK
ENVEA House Rose and Crown Road
Swavesey / Cambridge - UK CB24 4RB
+44 (0)1480 468200
[email protected]

Part of the ENVEA Group

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