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Function of Reactor Multi-Point Temperature Sensing

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Presentation on theme: "Function of Reactor Multi-Point Temperature Sensing"— Presentation transcript:

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2 Function of Reactor Multi-Point Temperature Sensing
Measure catalyst bed inlet differential temperature (CT) to ensure proper distribution Maintain precise process temperature for optimal conversion Ensure proper quench in conversion reactions similar to hydro-cracking operations and severe hydro-treating units Indicate temperature excursions in high temperature / high pressure reactors Protect reactor vessel wall integrity Protect catalyst integrity

3 WIKA Multi-Point Designs
Cased (Protection Tube) Bi-metallic/Steel Alloy spring loaded Heat transfer block Bi-metallic spring/Steel Alloy spring loaded with support strap Free-Hanging With or without guide tubes Mi Cable primary pressure boundary Fast response Design Codes of Conformance For temperature and pressure: ASME Section VIII Division 1 for category H fittings ASME B31.3 Piping Code For thermocouple integrity and conformance: ASTM Sections E230, E585, E608 & E780

4 Bi-Metallic Spring Loaded Spring Loaded with Support Strap
Cased Multi-Point Designs Options Include: Pointed tip machined from bar stock Variety of alloy steels to suit process conditions Cooling fins to dissipate convected and conducted heat from terminations Secondary Pressure containment in the event of a primary pressure boundary failure Individual sensor replacement during production with heat transfer block design (Spring loaded designs involve complete multi-point sensor removal from tube) Sleeve design allowing for multi-point tube movement without deformation of tube Bi-Metallic Spring Loaded Heat Transfer Block Spring Loaded with Support Strap

5 Cased Multi-Point With Heat Transfer Blocks and Pointed tip

6 Cased Multi-Point With Expansion Sleeve and Secondary Pressure Containment

7 Cased Multi-Point With Mechanical Reinforcement Attachments

8 Cased Multi-Point With Mechanical Support Tube, Vented for Fast Response Including Secondary Pressure Containment

9 Cased Multi-Point With Cooling Fins and Pointed Tip, External to Protection Tube for Faster Response to Temperature Changes

10 Free-Hanging Multi-Point Designs
Flexible for longitudinal & cross sectional temperature measurement Options include: Close coupled or remote mounted terminations Heavy or double-wall MI Cable for extra resistance to process medium Secondary pressure containment Top or side mount

11 Free-Hanging Multi-Point
With Secondary Pressure Containment with Visual Indication

12 Includes reducing adaptor to suit vessel nozzle
Free-Hanging Multi-Point With Secondary Pressure Containment with Block & Bleed Includes reducing adaptor to suit vessel nozzle

13 Designed for top or side mounting where space restrictions apply.
Free-Hanging Multi-Point With Angled Secondary Pressure Containment Designed for top or side mounting where space restrictions apply.

14 Free-Hanging Multi-Point
With Guide Tubes for Extra Mechanical/Corrosion Protection

15 Free-Hanging Multi-Point Thermocouple Advantages
Reduces the number of external skin thermocouples Resistance to extensive pressure build-up in hydro-cracking applications Fast response Multiple locations Mirror image thermocouple patterns allow operator to see channelling, coke balls or improper temperature distribution Optional secondary pressure containment Greater number of thermocouples for multi-point assembly reduces number of nozzles required for identical number of sensing points

16 Thermocouple with 90° Bend
Mineral Insulated (MI) Cable for Free-Hanging Multi-Point Designs Multiple MI cable sizes available to meet application requirements 0.236″ (6 mm) – greatest number of thermocouples through a single flange 5/16″ (7.5 mm) – industry standard for free-hanging design 3/8″ (10 mm) – for most severe service when reliability is a premium Variety of other diameters available upon request Available in various alloys to meet the specifications of the reactor process Special tools not required for large radius bends Tube-bending tool advisable for final 90 degree bend and any other tight radius bending required Thermocouple with 90° Bend

17 Mineral Insulated (MI) Cable Sheath & Conductors
Standard wall 0.040″ (1.0 mm) Reactor heavy wall 0.050″ (1.3 mm) sheath with 16 AWG conductors also available Optional double-wall sheath available for additional safety, durability and reliability Standard 0.040″ (1.0 mm) wall thickness with a second 0.040″ (1.0 mm) sheath Standard Wall Heavy Wall Double Wall

18 Free-Hanging Multi-Point Design Features
Pressure Feed-Through Sleeve Design Eliminates localized heat build-up during welding process preventing distortion of fittings Heat transferred away from thermocouple sheath during welding procedure Eliminates possible damage through overheating to MI cable sheath during construction of assembly

19 Free-Hanging Multi-Point Design Features
Secondary Pressure Containment Secondary Pressure Containment engineered to suppress process in unlikely event of primary pressure boundary failure Indication provided to operator regarding breech either AROUND or THROUGH the Mineral Insulated (MI) cable sheath Optional WIKA pressure gauge/transmitter for visible identification on containment chamber Optional double-flange design allows for access to safety containment chamber during reactor shutdowns

20 Safety Features Include: Eliminates exposure risk
Process fluids unable to migrate to junction box Block & Bleed valve designed to bleed-off trapped hydrogen or process fluids Compromised thermocouples do not require capping with a pressure fitting Localized indication of primary pressure boundary failure

21 Junction Box Features Include:
Stainless steel, weatherproof/corrosion resistant Direct or remote mounted Easy access to terminals or transmitters All thermocouple terminal connections individually identified Cable entry connection to suit customer requirements Available as explosion proof (EExd) or general purpose (NEMA/IP Rating) Other materials available including cast steel and cast aluminum Terminal strips or din rail mounting options available

22 Reactor Design Considerations with Free-Hanging Style Multi-points
Fewer penetrations into the reactor vessel for thermometry Fewer nozzles translates into reduced thermometry expense Ease of vessel design Greater structural integrity of the vessel Nozzles can be top or side mounted to the vessel Superior process information for enhanced design operations Reduced exposure risk

23 Measurement Design Considerations with Free-Hanging Style Multi-points
Significant increase of thermocouple points results in a lower cost than using traditional cased style designs Total number of thermocouple points determined by nozzle size and thermocouple diameter All designs and thermocouple locations are reviewed with the customer to ensure optimum efficiency

24 Testing of Multi-Points
Include: Pressure testing (hydrostatic & pneumatic) up to 10,000 psi Liquid penetrant inspection (LPI) Positive Material Identification (PMI) Radiography (RT) Ultrasonic (UT) Sensor calibration

25 Installation Designed to be routed around the inner circumference of the vessel, then projected inward to the sensing positions Reduces both channelling effects and interference with nozzle flow patterns Base support Hanging support (sidewall bracket)

26 Sensor Routing Example

27 Free-Hanging Multi-Point Support Bracket

28 Base Support Structure Example

29 Reactor Vessel - Typical Point Locations

30 Reactor Vessel – Typical Routing and attachment with Expansion Loop

31 North American Sales Offices
Deer Park, TX Tel: (713) Fax: (713) Edmonton, AB* (Head Office) Tel: (780) Fax: (780) Calgary, AB Tel: (403) Fax: (403) Burnaby, BC Tel: (604) Fax: (604) Montreal, QC Tel: (514) Fax: (514) Fort McMurray, AB Tel: (780) Fax: (780) Oakville, ON Tel: (905) Fax: (905) Quebec City, QC Tel: (418) Fax: (514) Grande Prairie, AB Tel: (780) Fax: (780) Sarnia, ON Tel: (519) Fax: (519) Saskatoon, SK Tel: (306) Fax: (306) Website: * WIKA flexible multi-point manufacturing facilities

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