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Function of Reactor Multi-Point Temperature Sensing PowerPoint Presentation
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Function of Reactor Multi-Point Temperature Sensing

Function of Reactor Multi-Point Temperature Sensing

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Function of Reactor Multi-Point Temperature Sensing

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  1. 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

  2. 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 14.03 Sections E230, E585, E608 & E780

  3. 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

  4. Cased Multi-Point With Heat Transfer Blocks and Pointed tip

  5. Cased Multi-Point With Expansion Sleeve and Secondary Pressure Containment

  6. Cased Multi-Point With Mechanical Reinforcement Attachments

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

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

  9. 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

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

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

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

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

  14. 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

  15. 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

  16. 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

  17. 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

  18. 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

  19. 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

  20. 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

  21. 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

  22. 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

  23. 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

  24. 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)

  25. Sensor Routing Example

  26. Free-Hanging Multi-Point Support Bracket

  27. Base Support Structure Example

  28. Reactor Vessel - Typical Point Locations

  29. Reactor Vessel – Typical Routing and attachment with Expansion Loop

  30. North American Sales Offices Deer Park, TX Tel: (713) 475-0022 Fax: (713) 475-0011 Edmonton, AB* (Head Office) Tel: (780) 463-7035 Fax: (780) 462-0017 Calgary, AB Tel: (403) 237-5960 Fax: (403) 264-0095 Burnaby, BC Tel: (604) 299-3855 Fax: (604) 299-4566 Montreal, QC Tel: (514) 332-0330 Fax: (514) 332-4292 Fort McMurray, AB Tel: (780) 791-9995 Fax: (780) 743-2296 Oakville, ON Tel: (905) 337-1611 Fax: (905) 337-2716 Quebec City, QC Tel: (418) 952-7779 Fax: (514) 332-4292 Saskatoon, SK Tel: (306) 664-1105 Fax: (306) 244-4084 Grande Prairie, AB Tel: (780) 357-0386 Fax: (780) 357-0389 Sarnia, ON Tel: (519) 344-1339 Fax: (519) 344-3824 Website:www.wika.comEmail:infoUSA@wika.com * WIKA flexible multi-point manufacturing facilities