ASTM D7392-20

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation:D7392 −20
Standard Practice for
PM Detector and Bag Leak Detector Manufacturers to
Certify Conformance with Design and Performance
Specifications for Cement Plants
This standard is issued under the fixed designation D7392; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
65 mg/dscm at 7 % O (0.028 gr/dscf at 7 % O ) or approximately 30
1. Scope
2 2
mg/acm (0.013 gr/acf) for “existing sources” and (b) 5.3 mg/dscm at 7 %
1.1 This practice covers the procedure for certifying par-
O (0.0023gr/dscfat7 %O )orapproximately2.5mg/acm(0.001gr/acf)
2 2
ticulate matter detectors (PMDs) and bag leak detectors for “new sources.” On March 23, 2006 (71 FR 14665), EPA proposed to
revise the PM standard for new cement plants to 15.9 mg/dscm at 7 % O
(BLDs) that are used to monitor particulate matter (PM)
(0.0069 gr/dscf at 7 % O ), or about 6–9 mg/acm (0.0026–0.0039 gr/acf).
emissions from kiln systems at Portland cement plants that
Theemissionstandardsmaychangeinfuturerulemakings,sousersofthis
burn hazardous waste. It includes design specifications, perfor-
practice should check the current regulations. Some types of monitoring
mance specifications, test procedures, and information require-
instruments are not suitable for use over the range of emissions encoun-
ments to ensure that these continuous monitors meet minimum tered at both new and existing sources.
requirements, necessary in part, to monitor reliably PM con-
1.5 The specifications and test procedures contained in this
centrations to indicate the need for inspection or corrective
practice exceed those of the United States Environmental
action of the types of air pollution control devices that are used
Protection Agency (USEPA). For each monitoring device that
at Portland cement plants that burn hazardous waste.
the manufacturer demonstrates conformance to this practice,
the manufacturer may issue a certificate that states that
1.2 This practice applies specifically to the original
monitoring device conforms with all of the applicable design
manufacturer,ortothoseinvolvedintherepair,remanufacture,
and performance requirements of this practice and also meets
or resale of PMDs or BLDs.
all applicable requirements for PMDs or BLDs at 40 CFR 63,
1.3 This practice applies to (a) wet or dry process cement
Subpart EEE, which apply to Portland cement plants.
kilns equipped with electrostatic precipitators, and (b) dry
process kilns, including pre-heater pre-calciner kiln systems, NOTE 3—40 CFR 63.1206 (c)(8) and (9) requires that BLDs and PMDs
“be certified by the manufacturer to be capable of detecting particulate
equipped with fabric filter controls. Some types of monitoring
matter emissions at concentrations of 1.0 milligrams per actual cubic
instruments are suitable for only certain types of applications.
meter unless you demonstrate under §63.1209(g), that a higher detection
limit would routinely detect particulate matter loadings during normal
NOTE 1—This practice has been developed based on careful consider-
operations.” This practice includes specific procedures for determination
ation of the nature and variability of PM concentrations, effluent
and reporting of the detection limit for each PMD or BLD model.
conditions,andthetype,configuration,andoperatingcharacteristicsofair
pollution control devices used at Portland cement plants that burn
1.6 The values stated in SI units are to be regarded as
hazardous waste.
standard. No other units of measurement are included in this
1.4 This practice applies to Portland cement kiln systems
standard.
subject to PM emission standards contained in 40 CFR 63,
1.7 This standard does not purport to address all of the
Subpart EEE.
safety concerns, if any, associated with its use. It is the
NOTE 2—The level of the PM emission limit is relevant to the design responsibility of the user of this standard to establish appro-
and selection of appropriate PMD and BLD instrumentation. The current
priate safety, health, and environmental practices and deter-
promulgatedPMemissionstandards(70FR59402,Oct.12,2005)are:(a)
mine the applicability of regulatory limitations prior to use.
1.8 This international standard was developed in accor-
dance with internationally recognized principles on standard-
This practice is under the jurisdiction ofASTM Committee D22 on Air Quality
and is the direct responsibility of Subcommittee D22.03 on Ambient Atmospheres
ization established in the Decision on Principles for the
and Source Emissions.
Development of International Standards, Guides and Recom-
Current edition approved Sept. 1, 2020. Published September 2020. Originally
mendations issued by the World Trade Organization Technical
approved in 2007. Last previous edition approved in 2013 as D7392 – 07 (2013).
DOI: 10.1520/D7392-20. Barriers to Trade (TBT) Committee.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D7392−20
2. Referenced Documents changes in PM concentrations using six-hour rolling averages,
2 updated each hour with a new one-hour block average. PMDs
2.1 ASTM Standards:
must also include provisions to activate an alarm and detect
D1356 Terminology Relating to Sampling and Analysis of
faults or malfunctions of the measurement system.
Atmospheres
3.2.2.1 Discussion—PMDs and BLDs are inherently infer-
D6216 Practice for Opacity Monitor Manufacturers to Cer-
ential monitoring devices that sense some parameter which, in
tify Conformance with Design and Performance Specifi-
the absence of interfering effects, is directly related to PM
cations
concentrations.
D6831 Test Method for Sampling and Determining Particu-
3.2.2.2 Discussion—This practice does not discriminate be-
late Matter in Stack Gases Using an In-Stack, Inertial
tween measurement techniques but instead provides design
Microbalance
specifications and performance standards that all devices must
2.2 U.S. Environmental Protection Agency Documents:
satisfy to be acceptable as a PMD or BLD for a cement kiln
40 CFR 63, Subpart EEE National Emission Standards for
that burns hazardous waste. Techniques for continuously mea-
Hazardous Air Pollutants: Final Standards for Hazardous
suring PM include optical transmittance (“opacity”), dynamic
Air Pollutants for Hazardous Waste Combustors
opacity (“scintillation”), optical scatter (side, forward and back
2.3 Other Documents:
scatter), and probe electrification (sensors based on induction,
ISO/DIS 9004 Quality Management and Quality System
contact charge transfer, or combination of effects).
Elements – Guidelines
ANSI/NCSL Z 540-1-1994 Calibration Laboratories and
NOTE 4—Extractive systems using Beta attenuation to sense PM
Measuring Equipment – General Requirements
deposited on filters are used as PM CEMS but can not meet the sampling
and analysis frequency required by EPAregulations for PMDs and BLDs.
3. Terminology
3.2.2.3 Discussion—PMD and BLD instruments that con-
3.1 For terminology relevant to this practice, see Terminol-
form to the requirements of this practice include automated
ogy D1356.
internalmechanismsthatareusedtoverifyproperperformance
3.1.1 Definitions for transmittance measurement equipment
of the measurement device on a daily basis, or more frequent
(that is, opacity monitors) are provided in Practice D6216.
basis if recommended by the manufacturer. PMD instruments
3.2 Definitions of Terms Specific to This Standard: include mechanisms to facilitate external periodic audits of the
measured parameter.
Analyzer Equipment
3.2.3 light-scatter, n—the extent to which a beam of light is
3.2.1 bag leak detector [BLD], n—an instrument installed
reflected, refracted, or diffracted via interaction with PM in a
downstream of a fabric filter control device that interacts with
medium such that a measurable portion of the original beam’s
a PM-laden effluent stream and produces an output signal of
energy is redirected outside the original angle of projection.
sufficient accuracy and repeatability to track changes in PM
3.2.3.1 Discussion—Back-scatter is generically defined as
control device performance and, together with appropriate data
scattering in excess of 150 degrees from the direction of the
analysis, indicates the need to inspect the fabric filter as
original projected beam, side-scatter is generically defined as
referenced in the Federal Register, 40 CFR 63, Subpart EEE.
scattering between 30 degrees and 150 degrees from the
BLDs are used to track rapid changes in PM concentration and
original direction, and forward-scatter is generically defined as
must have sufficient dynamic range to track both “peaks” and
scattering of less than 30 degrees from the projected beam.
baseline PM levels and include provisions for adjusting the
averaging period, alarm delay, and alarm set point appropriate 3.2.3.2 Discussion—Because the correlation between the
for source-specific conditions. BLDs must also include provi- intensity and angular distribution of light scattering and the
sions to detect faults or malfunctions of the measurement actual PM mass concentration is dependent on factors such as
system. particle size, particle shape, wavelength of light, particle
density, etc., this practice is limited to: (a) verification of the
3.2.2 particulate matter detector [PMD], n—an instrument
stability, linearity, and interference rejection of the measure-
that interacts with a PM-laden effluent stream and produces an
ment of scattered light, and (b) verification of the instrument
output signal of significant accuracy and repeatability so as to
sensitivity and detection limit. This practice does not recom-
indicate significant changes in the concentration of particulate
mend any specific light-scattering technology, and leaves the
material entrained in the effluent downstream of an electro-
evaluation of the application to the discretion of the user of a
static precipitator or fabric filter as referenced in the Federal
BLD or PMD.
Register, 40 CFR 63, Subpart EEE. PMDs are used to track
3.2.3.3 Discussion—A light-scatter BLD or PMD may in-
clude the following: (a) sample interface equipment such as
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
filters and purge air blowers to protect the instrument and
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
minimize contamination of exposed optical surfaces, (b) shut-
Standards volume information, refer to the standard’s Document Summary page on
ters or other devices to provide protection during power
the ASTM website.
AvailablefromUnitedStatesEnvironmentalProtectionAgency(EPA),William
outages or failure of the sample interface, and (c) a remote
Jefferson Clinton Bldg., 1200 Pennsylvania Ave., NW, Washington, DC 20004,
control unit to facilitate monitoring the output of the
http://www.epa.gov.
instrument, initiation of zero and upscale calibration checks, or
Available fromAmerican National Standards Institute (ANSI), 25 W. 43rd St.,
4th Floor, New York, NY 10036, http://www.ansi.org. control of other BLD or PMD functions.
D7392−20
3.2.4 dynamic opacity, n—the amount of light variation 3.2.8.2 Discussion—Software installed on external devices,
caused by particles traversing a cross-stack beam of transmit- including external computer systems, and used for processing
ted light. of the PMD or BLD output to generate average values or
activate alarms is not considered part of the PMD or BLD
3.2.4.1 Discussion—Dynamic opacity instruments measure
monitoring device.
the alternating component of the transmitted light and are
sometimes referred to as scintillation instruments. 3.2.8.3 Discussion—For the purposes of this practice, the
BLD or PMD includes the following components which are
3.2.4.2 Discussion—In certain dynamic instruments the
measured alternating signal (light variation) is divided by the described in subsequent sections: (a) internal zero and upscale
performance check devices to evaluate instrument drifts while
average transmitted light intensity signal to provide a ratio
measurement. This ratio is unaffected by optics contamination. installed on a stack or duct; (b) apparatus and means to
quantify, independent of the internal zero and upscale perfor-
3.2.5 probe electrification, n—methods by which the charge
mance check devices, the degree to which the response of the
carried on PM creates a signal in a grounded sensing rod
BLD or PMD has changed over a period of time.
through charge induction, contact, or combination.
3.2.5.1 Discussion—Probe electrification instruments mea-
Analyzer Zero Adjustments and Devices
sure the current produced by charged particles passing or
3.2.9 external zero audit device, n—an external device for
impacting a grounded sensing rod. Certain instruments mea-
checking the zero alignment or performance of the measure-
sure the DC component of the signal, theAC component of the
ment system either by simulating with a surrogate the zero-PM
signal or both the DC and AC components of the signal.
condition for a specific installed BLD or PMD or by creating
3.2.5.2 Discussion—Probeelectrificationinstrumentscanbe
the actual zero-particulate condition.
used after fabric filters where the particle charge is relatively
3.2.10 internal zero performance check device, n—an auto-
constant. The influence of changing velocity should be consid-
mated mechanism within a BLD or PMD that simulates a zero
ered when considering using probe electrification devices in
PM condition while the instrument is installed on a stack or
applications with variable speed fans or variable flow.
duct using a surrogate appropriate to the measurement tech-
3.2.6 BLD or PMD measuring volume, n—thespatialregion
nique.
in which the particles interact with the instrument to produce a
3.2.10.1 Discussion—The internal zero performance check
measurable signal.
device may be used to check zero drift daily, or more
3.2.6.1 Discussion—For light scattering or transmittance
frequently if recommended by the manufacturer, and whenever
instruments, the measuring volume is the spatial region where
necessary (for example, after corrective actions or repairs) to
the projected light and the field of view of the detector optics
assess BLD or PMD performance.
overlap in which the PM concentration can be detected via
3.2.10.2 Discussion—The proper response to either the
scattering of light or reduction of transmittance. For probe
external zero audit device or the internal zero performance
electrification instruments, the measuring volume is the area
check device are established with the PMD set up in a clean
near the sensing probe.
environment and in such a way that no interference or stray
3.2.7 nominal full scale, n—the default, as-shipped full
signal reaches the detector. The internal zero performance
scale calibration of a BLD or PMD, based on standard gains
check device thereby provides the surrogate, simulated zero
and offset settings established during field performance tests
PMconditionwhilethePMDisinserviceandtheexternalzero
under Section 7.
audit device provides a check, which is independent of the
3.2.7.1 Discussion—The nominal full scale (NFS) will be
internal zero performance check, of the proper performance of
determined by the manufacturer by means of data taken as part
the PMD.
of the verification of instrument sensitivity and detection limit
3.2.11 zero alignment, n—the process of establishing the
on at least one representative cement kiln installation.
quantitativerelationshipbetweentheinternalzeroperformance
3.2.8 BLD or PMD model, n—a specific BLD or PMD
check device and the zero PM responses of a PMD.
configuration identified by the specific measurement system
3.2.12 zero compensation, n—an automatic adjustment of
design, including: (a) the use of specific source, detector(s),
theBLDorPMDtoachievethecorrectresponsetotheinternal
lenses, mirrors, and other components, (b) the physical ar-
zero performance check device.
rangement of principal components, (c) the specific electronics
3.2.12.1 Discussion—Zero compensation adjustment is fun-
configuration and signal processing approach, (d) the specific
damentaltotheBLDorPMDdesignandmaybeinherenttoits
calibration check mechanisms and drift/dust compensation
operation (for example, continuous adjustment based on com-
devices and approaches, and (e) the specific software version
parisontoreferencevalues/conditions,useofautomaticcontrol
and data processing algorithms, as implemented by a particular
mechanisms, rapid comparisons with simulated zero and up-
manufacturer and subject to an identifiable quality assurance
scale calibration drift check values, and so forth) or it may
system.
occur each time a control cycle (zero and upscale performance
3.2.8.1 Discussion—Minor changes to software or data
check) is conducted by applying either analog or digital
outputs that do not affect data processing algorithms or status
adjustments within the BLD or PMD.
outputs are not be considered as a model change provided that
the manufacturer documents all such changes and provides a 3.2.13 zero drift, n—the difference between the BLD or
satisfactory explanation in a report. PMD responses to the internal zero performance check device
D7392−20
and its nominal value after a period of normal continuous NFS. Care should be taken to select materials with properties
operation during which no maintenance, repairs, or external that are not affected by aging.
adjustments to the BLD or PMD took place.
3.2.17.2 Discussion—The PMD reference signal source or
3.2.13.1 Discussion—Zero drift may occur as a result of attenuator, components need not be NIST-traceable materials,
changes in the energy source, changes in the detector, varia-
but need to be commercially available and subject to testing
tions in internal scattering, changes in electronic components, and verification for consistency.
or varying environmental conditions such as temperature,
3.2.17.3 Discussion—The PMD external zero audit device
voltage or other external factors. Depending on the design of and the external upscale audit device may be combined into
the BLD or PMD, PM (that is, dust) deposited on optical
one device, where the use of design-appropriate PMD refer-
surfacesorsurfaceofaprobemaycontributetozerodrift.Zero ence signal source are used both to create a zero-PM condition
drift may be positive or negative. The effects (if any) of dust
and to simulate two or more upscale conditions. For light
deposition on optics or deposits on probes will be a monotoni- scattering instruments, the external upscale audit device or
cally increasing or decreasing function depending on the type
combination device may generate the required reference sig-
of instrument. Particular designs may separate dust compensa- nals by utilizing one or more attenuators, reflectance targets, or
tion and other causes of zero drift.
other reference materials in any combination to change the
intensity of the projected light, or the scattered light reaching
3.2.14 light trap, n—A device used to absorb the projected
the detector.
light from a light scattering BLD or PMD, so as to eliminate
3.2.17.4 Discussion—The key attributes of the PMD audit
false optical scattering due to reflections from the inner walls
device are that: (a) it uses the same active components as are
of a duct or stack.
used for making the PM measurement; (b) it is capable of
Analyzer Upscale Calibrations and Adjustments
monitoring any credible change in instrument response not
caused by changes in determinant or stack conditions; and (c)
3.2.15 internal upscale performance check device, n—an
it checks the instruments components in the same physical and
automatedmechanismwithinaBLDorPMDthat(a)simulates
measurement condition as that in making the PM measure-
an upscale value of the parameter sensed by the BLD or PMD
ment.
while the instrument is installed on a stack or duct and (b)
3.2.17.5 Discussion—The reference signals applied to the
provides a means of quantifying consistency or drift in the
BLD must challenge all of the key active components of the
BLD or PMD response.
instrument. They are not necessarily a surrogate for dust (as in
3.2.15.1 Discussion—The internal upscale performance
a PMD), but the reference signals must check the correct
check simulates the parameter sensed by the PMD that is
operation of the instrument.
related to dust concentration and provides a check of all active
analyzer internal components including optics, active elec-
3.2.18 calibration drift, n—the difference between the BLD
tronic circuitry including any light source and detectors,
or PMD responses to the internal upscale performance check
electric or electro-mechanical systems, and hardware, or soft-
device and its nominal value after a period of normal continu-
ware within the nominal operating ranges of the instrument.
ous operation during which no maintenance, repairs, or exter-
3.2.15.2 Discussion—The internal upscale performance
nal adjustments to the BLD or PMD took place.
checkforaBLDmayincludeoneoraseriesofchecksinorder
3.2.18.1 Discussion—Calibration drift may be determined
to evaluate all of the active components of the measurement
either before or after determining and correcting for zero drift.
device and provide for the detection of conditions that ad-
3.2.19 linearity error, n—the differences between the BLD
versely affect the measurement system performance.
or PMD readings and the values of two reference signal
3.2.16 external upscale audit device, n—an external device
sources under zero-PM conditions, using the external zero and
for verifying the stability of the upscale calibration of the BLD
upscale audit device(s).
or PMD by applying a reference signal or condition indepen-
3.2.19.1 Discussion—The linearity error indicates the fun-
dent of the internal simulated upscale calibration device.
damental calibration status of the BLD or PMD.
3.2.17 reference signal source, n—a device that can be used
3.2.20 instrument response time, n—the time required for
to simulate a signal that the PMD measures, corresponding to
the electrical output of a BLD or PMD to achieve greater than
agivenPMconcentration,asestablishedwhentestingtosetup
95 % of a step change in the parameter sensed.
the NFS. In the case of a BLD, the reference signal source may
be one or a combination of test signals/conditions that are
4. Summary of Practice
applied and, taken together, provide a comprehensive test the
4.1 This practice provides a comprehensive series of speci-
correct operation of the instrument.
ficationsandtestproceduresthatBLDandPMDmanufacturers
3.2.17.1 Discussion—For a light scattering instrument, the
must use to certify systems prior to shipment to the end user.
reference signal may be a glass or grid filter that reduces the
The specifications are summarized in Table 1. Certification of
transmittance of light, or a reflective target of defined
conformance with the requirements of this practice requires
reflectivity, such as a photographer’s standard, commercially
providing information or test results, or both, in four parts.
available photo-gray material, or an adjustable iris, or any
combination of such elements, that can be used to simulate a 4.2 To satisfy the certification requirements of Part 1
given intensity of scattered light corresponding to a given “Manufacturer’s Disclosure,” the manufacturer is required to
concentration of PM, as established when testing to set up the provide certain information about the monitoring equipment
D7392−20
TABLE 1 Summary of Manufacturer’s Specifications and Requirements
Specification Requirement
Part 1 Manufacture’s Disclosure PMD BLD
Subsections
Provide written description of monitor principles, internal calibration Provide non-proprietary information for review by users 6.1 6.1
checks procedure and limitations, and external audit procedures
and limitations
Provide written operation, maintenance, and quality assurance Provide information for review and reference by users 6.2 6.2
recommendations
Provide written procedures for setting BLD alarms Provide information for review and reference by users NA 6.3
Part 2 Field Demonstration 90 days field test at cement plant
(Test each model once) PMD BLD
Subsections
Availability (excluding start-up period) $95 % of source operating time 7.3 7.3
Internal Zero Drift #2 % NFS or manufacturer’s specification, whichever is most restrictive 7.4 7.4
Internal Upscale Drift #2 % NFS or manufacturer’s specification, whichever is most restrictive 7.4 7.4
Repeatability (comparison of two instruments) STD of paired differences# 10 % of mean or# 3 % NFS, whichever is 7.5 7.5
least restrictive
External Zero and Upscale Audit Error #3 % NFS or manufacturer’s specification, whichever is most restrictive 7.6 7.6
Analytic Function (comparisons to co-located gravimetric test PMD Correlation Coefficient$0.85 7.7.10 7.7.10
method results during the first and last month of test period) BLD Correlation Coefficient$0.75
Confidence Interval#1%
Tolerance Interval#25 %
Optional Specification 1 (when test concentrations are limited by 7.7.11 7.7.11
operational constraints):
Relative Accuracy#20 %
Optional Specification 2 (when the mean test concentrations are less 7.7.12 7.7.12
than 5 mg/acm [0.002 gr/acf]):
Correlation Coefficient$0.75
Field Detection Limit Determine and report as specified: 7.8 7.8
Noise Limited Detection Limit
Observed Detection Limit
Part 3 Design Specifications
(Test representative instrument once per year for each model) PMD BLD
Subsections
Measurement output resolution $0.5 % NFS 8.2 8.2
Measurement frequency 15 seconds 8.2 8.2
Data recording 60 seconds 8.2 8.2
PMD data averaging 15 minute periods and hourly averages (external devices may be used 8.2 NA
for averaging and recording data)
BLD data averaging Manufacture to specify based on alarm procedure NA 8.2
Internal zero performance check device Automated mechanism required 8.3.1 8.3.3
Internal upscale performance check device Automated mechanism required 8.3.2 8.3.3
External zero audit device Required 8.4 8.4
PMD external upscale audit device Must provide upscale check of parameter sensed by PMD at two levels 8.4 NA
and include source, detector, and all active measurement components
BLD external upscale audit device A check, or series of checks when combined, which test the status of NA 8.4
the upscale response and integrity of measurement device
External audit device repeatability ±2.0 % NFS 8.4 8.4
Status indicators Manufacturer to identify and specify 8.5 8.5
Insensitivity to supply voltage variations ±1.0 % NFS change over specified range of supply voltage variation, or 8.6 8.6
±10 % variation from the nominal supply voltage
Thermal stability ±2.0 % NFS change per 22ºC (40°F) change over specified operational 8.7 8.7
range
Insensitivity to ambient light (optical instruments only) ±2.0 % NFS max. change for solar radiation level of$900 W/m 8.8 8.8
Part 4 Performance Specifications
(Test Each Instrument) PMD BLD
Subsections
PMD instrument response time #15 seconds to 95 % of final value 9.3 NA
BLD instrument response time #1 second to 95 % of final value NA 9.3
Linearity error #3 % NFS for two upscale values 9.4 9.4
Calibration device repeatability #1.5 % NFS 9.5 9.5
“NFS” is nominal full scale as defined 3.2.7.1.
andwrittenproceduresforcertainactivitiestotheenduser.The affect performance) and demonstrate that the BLD or PMD
specific requirements are included in Section 6. monitoring equipment meets the applicable specifications as
provided in Section 7.
4.3 TosatisfythecertificationrequirementsofPart2,“Field
Demonstration” the manufacturer must conduct a one-time 4.4 To satisfy the certification requirements of Part 3,
field test at a Portland cement plant for each model (and “Design Specifications” the manufacturer must certify that the
whenever there is a change in the design that may significantly BLD or PMD design meets the applicable requirements for (a)
D7392−20
measurement output resolution, (b) measurement frequency, 5.3 This practice requires that tests be conducted to verify
(c) data recording and data averaging, (d) internal zero and manufacturer’s published specifications for detection limit,
upscale performance checks, (e) external zero audit device, (f) linearity, thermal stability, insensitivity to supply voltage
external upscale audit capability, and (e) status indicators. In variations and other factors so that purchasers can rely on the
addition, the manufacturer must demonstrate conformance manufacturer’s published specifications. Purchasers are also
with design specifications for thermal stability, insensitivity to assured that the specific instrument has been tested at the point
line voltage variation, and insensitivity to ambient light (opti- of manufacture and shown to meet selected design and
cal systems) by testing a representative instrument annually performance specifications prior to shipment.
(and whenever there is a change in the design, manufacturing
5.4 Thispracticerequiresthatthemanufacturerdevelopand
process, or component that may affect performance) and
provide to the user written procedures for installation start-up,
demonstrate that the BLD or PMD monitoring equipment
operation, maintenance, and quality assurance of the equip-
meets the applicable specifications as provided in Section 8.
ment. This practice requires that these same procedures are
4.5 To satisfy the certification requirements of Part 4 “Per- used for a field performance demonstration of the BLD or
PMD monitoring equipment at a Portland cement plant.
formance Specifications” the manufacturer must demonstrate
conformance with specifications provided in Section 9 for
5.5 The applicable test procedures and specifications of this
instrument response time, linearity error and calibration device
practice are selected to address the equipment and activities
repeatability by testing each BLD or PMD instrument prior to
that are within the control of the manufacturer.
shipment to the end user. The manufacturer must include
5.6 This practice also may serve as the basis for third party
procedures for establishing the value for the PMD internal
independent audits of the certification procedures used by
upscale performance check device.
manufacturers of PMD or BLD equipment.
4.6 Guidance and recommendations for determining PMD
15-minute averages, one-hour block averages, and six-hour
6. Manufacturer’s Disclosure
rolling averages are provided in Appendix X1.
6.1 The equipment manufacturer shall provide a written
4.7 Guidance and recommendations for setting BLD aver-
statement and relevant information for each BLD or PMD
aging period, alarm delay, and alarm levels are provided in model as part of the manufacturer’s certification of confor-
Appendix X2.
mance with this practice in response to the issues identified
below. (In the event the manufacturer has no reliable informa-
4.8 This practice establishes appropriate guidelines for QA
tion about a particular area, the certification shall explicitly
programs for manufacturers of BLDs and PMDs. These guide-
state that it is “unknown” or information is “not available.”)
lines include corrective actions when information provided by
6.1.1 Measurement principle description and specific pa-
the manufacturer is determined to be incorrect or non-
rameter(s) monitored. (For example, a light transmittance
representative based on field applications, or when non-
measurement system may be used and the optical density
conformance with specifications is detected through periodic
output may be monitored.)
tests. Non-conformance with the design or performance speci-
6.1.2 Nominal PM concentration measurement range(s) (in
fications requires corrective action and retesting of the affected
units of mg/acm) over which monitoring device can meet all
model(s)
specifications in this practice and corresponding instrument
output units. The minimum detection limit, minimum practical
5. Significance and Use
quantification level, and nominal maximum PM concentration
5.1 EPA regulations require Portland cement plants that
level should be indicated.
burn hazardous waste to use BLDs or PMDs to provide either
6.1.3 Analytic Function—Linear or other output that can be
a relative or an absolute indication of PM concentration and to
corrected to provide a linear system response.
alert the plant operator of the need to inspect PM control
6.1.4 Description of internal zero and upscale performance
equipment or initiate corrective action. EPA and others have
checks. Identification of components or influences excluded
not established for these applications specific design and
from these checks and explanation of the underlying
performance specifications for these instruments. The design
assumptions, and other relevant limitations.
and performance specifications and test procedures contained
6.1.5 Description of external audit capabilities and audit
in this practice will help ensure that measurement systems are
materials that can be used for periodic independent checks.
capable of providing reliable monitoring data.
Identification of components or influences excluded from such
5.2 This practice identifies relevant information and opera- external audits and explanation of the underlying assumptions,
tional characteristics of BLD and PMD monitoring devices for and other relevant limitations.
Portland cement kiln systems. This practice will assist equip- 6.1.6 Identificationanddescriptionofknownuncontrollable
ment suppliers and users in the evaluation and selection of effluent or PM variables that affect the PMD or BLD response.
appropriate monitoring equipment. Quantitative information should be provided if available from
D7392−20
the manufacturer conducted tests or appropriately referenced droplets or condensed mists are present at the monitoring
based on TUV, MCERTS, or other similar tests or evaluations, location, or (d) other applicable limitations.
if available.
6.2 The manufacturer shall provide written procedures for
6.1.7 A description of cross sensitivities and interferences
installation, start-up, operation and maintenance, and quality
due to changing effluent conditions that are expected to occur
assurance of BLDs and PMDs.The manufacturer shall identify
when monitoring kiln emissions at cement plants burning
those activities, or QAcheck/maintenance intervals, or both, or
hazardous waste. This shall include statements regarding the
otherfactorsthatmayneedtobeadjustedbasedonsite-specific
PMD or BLD response to changes in effluent (a ) flow rate or
conditions.
velocity at the point of measurement, (b) effluent temperature,
6.3 BLD manufacturers shall provide detailed written pro-
(c) effluent moisture content, (d) effluent gas composition, and
cedures for establishing alarm levels for BLDs including
(e) other known factors, if any. Table 2 provides nominal
provisions for adjustment of the averaging period, alarm delay,
measurements and effluent values and ranges of variation for
and alarm set point, and any other parameters appropriate for
several representative applications at Portland cement plants.
source-specific conditions. The manufacturer shall specify the
6.1.8 Explicit statements regarding the applicability of the
minimum (or range) BLD monitoring period necessary to
monitoring device (a) downstream of electrostatic
establish the alarm set point. The manufacturer shall provide
precipitators, (b) downstream of fabric filters, (c) where water
criteria for re-setting the alarm point.
5 7. Field Demonstration
(Note: TÜV (Technischer Überwachungs Verin) is an internationally recog-
nized certification and testing organization in the Federal Republic of Germany
7.1 Representative Instrument—Perform the field perfor-
(with offices word wide) that performs laboratory and field tests of environmental
mance specification verification procedures in this section for
monitoring instrumentation for TUV approaval. MCERTS is the Monitoring and
Certification Scheme of the United Kingdom and includes laboratory and field each representative model or configuration involving substan-
testing of environmental monitoring systems.)
tially different sources, detectors, active components,
electronics, or software and include the results in a report.
TABLE 2 Typical Portland Cement Effluent Characteristics
Perform the tests on a representative instrument installed to
Wet process cement kiln with ESP control
monitor kiln emissions at a Portland cement plant.
PM concentrations 10–40 mg/acm
(0.004–0.017 gr/acf) with 7.2 Operational Period—Operate the BLD or PMD for a
short term variability due
period of at least 90 days in accordance with the manufactur-
to rapping in ESP
er’s written installation, operation and maintenance
Six-Minute Opacity 4–20 % opacity
Moisture Content 30 % (water droplets procedures, as provided in response to the requirement in 6.2
may be present during
during the test program.
start-up or while shutting
down)
7.3 Monitor Availability—Report all malfunctions or
Effluent Temperature (at 180–232ºC (350–450°F)
breakdowns, maintenance and corrective actions performed
stack testing location)
Flow Rate 80 000–100 000 acfm during the test period. After completing all BLD or PMD
Varying ±10 % and
start-up activities (not to exceed 14 days), calculate and report
proportional to production
the percent monitor availability achieved (excluding, all in-
rate (except for start-up
and shut down, or waste valid data, monitor downtime, monitor maintenance time, etc.)
fuel cut off transients)
as a fraction of source operating hours during the test period.
SO 300–800 ppm
Percent monitor availability ≥95 % is acceptable.
(2–10 ppm H SO )
2 4
NO 300–1200 ppm
x
7.4 Drift Test—Perform internal zero and upscale perfor-
HCl 1 to 13 ppm
NH 1–10 ppm mance check cycles daily, or more frequently if recommended
by the manufacturer’s written procedures, for at least seven
Contemporary pre-heater pre-calciner kiln system with in-line raw mill
consecutivedaysandverifythattheinstrumentdrift(difference
Mill On Mill Off
(90 % of operating time) (10 % of operating time) between current value and reference value) is within 62%
PM concentrations 3–8 mg/acm 4–10 mg/acm
NFS or the manufacturer’s published specification, whichever
(0.0013–0.0034 gr/acf) (0.0017–0.0043 gr/acf)
is more restrictive. Intrinsic and automatic adjustments may be
6-Minute Opacity 2–20 % opacity 2–20 % opacity
Moisture Content 12–18 % May decrease 1–2 % performed at any time, and prescribed maintenance may be
H O
performed in accordance with the manufacturer’s written
Effluent Temperature (at 120–180ºC (250–350°F) May increase 30ºC
procedures.
stack testing location) (50°F)
Flow Rate 400 000 acfm May increase 5–15 %
7.5 Repeatability Test—Perform a repeatability test by in-
SO 200–300 ppm May increase 50–100
stallingtwoPMDsortwoBLDsofthesamemodelatsampling
(2–3 ppm H SO ) ppm
2 4
NO 200–400 ppm 200–400 ppm
x
locations expected to provide comparable results. Summarize
HCl 2–50 ppm 10–60 ppm
the concurrent one-hour average outputs (or other representa-
NH 1–10 ppm May have five fold
transient increase when tive period) of the two instruments recorded at approximately
mill shuts down
eight-hourintervals(threetimesperday)foraperiodincluding
May have co-mingled emissions from coal mill, alkali bypass, or clinker cooler
at least 60 days of concurrent operation. Reject non-
PM control systems at kiln system test location.
representative data, missing pairs of data during maintenance
D7392−20
or other downtime. The repeatability is acceptable if the composition, dust re-injection, etc.) as selected by the plant
standard deviation of the differences between the monitor operator. For plants with ESP controls, conduct tests at two or
responses is less than 10 % of the average of the two more ESP power settings. For plants with in-line raw mills,
instruments, or 3 % of NFS, whichever is less restrictive. conduct testing under both “mill on” and “mill off” conditions.
7.7.5 Select sample run durations to provide representative
7.6 External Audit—Conduct audits of the installed BLD(s)
measurement results as indicated by the variability of emis-
orPMD(s)usingtheexternalauditdevicetwoormoretimesat
sions on the Test Method D6831 instrument’s real-time output.
least 30 days apart during the field test.Verify that the linearity
Typically, sample run durations range from 5 to 20 minutes.
error at zero and two upscale levels during the external audits
Multiple consecutive test runs can be performed without
is ≤3 % NFS or the manufacturer’s published specification,
removalofthemicrobalancefromtheductorstackandwithout
whichever is more restrictive.
filter replacement. For high level emissions, sample periods
7.7 Analytic Function Testing—Conduct independent PM
may range from 1 to 3 hours before filter replacement is
concentration tests to verify the ability of the BLD or PMD to
necessary. For low level emissions, sampling may be per-
indicate PM Concentrations. Using Test Method D6831 is
formed for 8 hours, or longer before filter replacement is
strongly recommended, especially for sources with low PM
necessary.
concentrationsandsourceswithsignificanttemporalvariability
7.7.6 If upset or transient conditions occur during a particu-
as indicated by the PMD or BLD. Other in-stack filtration
lar test period, discard the Test Method D6831 data and the
manual test methods may be used, such as 40 CFR 60,
concurrentBLDorPMDdataforthosesamplerunsorperiods,
Appendix A, Method 17, or EN 13284-1, etc. These methods
or adjust the run start and stop times to avoid including the
may provide acceptable comparisons for sources with emis-
emission anomaly in the comparison.
sions above 20 mg/acm (0.0086 gr/acf). However, the apparent
7.7.7 For sources without water droplets, perform the com-
acceptability of the monitoring instrument may be adversely
parison of the Test Method D6831 results and BLD or PMD
affected by the test method limitations, including poor preci-
datawithoutdesiccationofthefilter.Performfilterstabilization
sion at low concentrations and as well as actual PM concen-
and nozzle recovery procedures only between consecutive
tration variability during the sample run. Out-of-stack filtration
samplingperiodswhenitisnecessarytochangefiltersorwhen
methods, such as 40 CFR 60,AppendixA, Method 5 or 5I may
testsareperformedatsourceswithwaterdroplets.Ifthenozzle
also be used. However, these methods are subject to the same
recovery is greater than 3 % of the total mass collected,
limitations as Method 17 and may also result in the measure-
apportion the mass evenly over the sampling time. Otherwise,
ment of condensable or reactive compounds that are not
ignore the nozzle recovery results.
present in the effluent stream as PM. For example, gaseous
7.7.8 Continuetestinguntilsufficientdatahasbeenacquired
ammonia may react with HCl or sulfur compounds and form
to achieve satisfactory results. (Typically, sufficient data can be
PM that is not present in the effluent stream and thus not seen
obtained by Test Method D6831 testing for three hours at each
by the PMD or BLD.
test condition under two or more operating conditions.)
7.7.1 Discussion—Test Method D6831 can resolve in-situ
7.7.9 Reduce the test data to concurrent sets ofTest Method
PMconcentrationsof0.5mg/acm(0.0002gr/acf).IfactualPM
D6831 concentration measurement data reported at actual
concentrations during the test are below 5 mg/acm (0.002
conditions and BLD or PMD output data.
gr/acf), it is very likely that measurement error will adversely
affect any attempt to establish a statistical correlation. In these 7.7.10 If data are available over a sufficient range, calculate
cases, extra care is required in performing the tests. the correlation coefficient, confidence interval, and tolerance
7.7.2 Filter Temperature—Operate the Test Method D6831 interval for the data sets using a linear function. Acceptable
results are obtained for a PMD if (a) correlation coefficient
with the filter temperature 5ºC (9ºF) above the effluent tem-
perature. ≥0.85,(b)confiden
...