Reactor Multipoint Brochure - Engineered Products, LLC · The Cased multipoint design utilizes an external protection tube that protects the sensors from the process. ... 11 Reactor

Temperature Measurement

WIKA Reactor Multipoint ThermocouplesWIKA Reactor Multipoints allow for temperature measurement at a number of different locations utilizing only a single process connection. These points can either be aligned along a single path or as individual sensors for vessel routing. Depending on the size of the process connection, WIKA can produce Multipoints with up to 60 sensing points. These points are strategically placed to ensure the best possible temperature profiling.

WIKA Multipoint Functions:

• Measure catalyst bed inlet differential temperature 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.

ContentsWhat is a Chemical Reactor ................................................................................ Page 2Cased Style Multipoints ........................................................................................ Page 3 Cased Sensor Styles ................................................................................ Page 4 Cased Data Sheet ........................................................................................ Page 5Free-Hanging Multipoints ................................................................................ Page 7 Mineral Insulated Cable ................................................................................ Page 8 Free-Hanging Data Sheet ........................................................................ Page 9 Handling and Installation................................................................................ Page 11 Sensor Routing ........................................................................................ Page 12Secondary Pressure Containment ........................................................................ Page 14Testing and Certifications ................................................................................ Page 15Junction Boxes ................................................................................................ Page 16

Reactor Multipoints

What is a Chemical Reactor A Chemical Reactor is a vessel designed to contain and control chemical reactions.

The reactions are monitored and controlled for safety and efficiency.

Operating Temperatures ranging from 400-600°C

Example: Hydrocracker (5000 kPa)

(THERMOCOUPLE POINT LOCATIONS)

2

VESSEL

Cased (Protection Tube) Style MultipointThe Cased multipoint design utilizes an external protection tube that protects the sensors from the process. They are used to measure temperatures at various intervals along a single plane. They give indication of longitudinal and/or cross sectional temperature measurement.

If the protection tube already exists as part of the vessel, the multipoint can be coiled for shipping and, once at site, uncoiled and installed.

3

Options:

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 multipoint sensor removal from tube)

Sleeve design allowing for multipoint tube movement

without deformation of tube

Advantages:

Protection of the MI-cable from the process

Rigid construction offering superior protection when

turbulence is present in vessel

Depending on the design, the individual

thermocouples can be removed if process

maintenance or sensor replacement is required

MULTIPOINT ASSEMBLY

Reactor Multipoints

CATALYST BED

SECONDARY CONTAINMENT OPTION

Cased Sensor Styles

4

Bimetallic or high temperature steel spring loading.

This design consists of a spring loaded device attached to

each individual sensor which creates positive contact of the

sensor tip to the protection tube inner wall.

The bimetallic design is inserted into the protection tube in the

relaxed position, contact with the inside wall of the protection

tube is achieved when heat is applied to the process. This

style will function at temperatures up to 538 degrees C.

The high temperature steel spring design has a maximum

temperature rating of 650 degrees C.

Heat transfer block.

This design allows for individual removal and replacement

of the sensors during operation if required.

It has the advantage of a primary and secondary pressure

boundary within the process.

The heat transfer block is welded to the wall of the protection

tube and to an inner guide tube. The sensor is located inside

the inner guide tube and rests against the heat transfer block.

Bimetallic or high temperature steel spring loading with

support strap

The support strap is fitted inside the total length of the

protection tube and has the sensors fastened to it. The spring

loading is from the strap to the inside wall of the protection

tube.

Spring loading mechanism provides a positive contact to

protection tube increasing accuracy and response time to

process temperature changes.

HeatTransferBlocks

BimetallicSpring Loaded

withSupport Strap

BimetallicSpringLoaded

Reactor Multipoints

5

Customer Detail:

Type of Vessel:

Name and Model of Vessel:

Vessel Dimensions:

Vessel Material:

Vessel Condition:

Temperatures:

Pressure:

Process Connection:

Type of Sensor:

Number of Points:

Sensor Style:

MI Cable Material:

MI Cable Diameter:

Protection Tube:

Protection Tube Diameter:

Protection Tube Material:

Removable Sensors:

Secondary Containment:

Visual Indication:

Additional Notes:

Height:

Material:

Type J Thermocouple:

Type N Thermocouple: Single (N) Dual (NN)

Junction:

RTD (Consult Factory)

Single (E)

Grounded

Other (Specify in notes)

Dual (EE)

Ungrounded

No

NoYesComplete

Yes

Yes

No

No

Individually

Yes

OD: ID:

Existing New

See next page for point details

Spring Loaded Spring Loaded with Strap Heat Transfer Block

Type K Thermocouple: Single (K)

Dual (JJ)

Type: Size:

Dual (KK)

Type E Thermocouple:

Single (J)

Used (In service) New

Ambient: Process:

Process:

WIKA Instruments - Reactor Multipoint Data Sheet (Cased)Company Name: Contact:

Diameter:

Rating:

Phone: Fax: Email:

Address:

Schedule (Nozzle): ID of Nozzle:

6

POINT LENGTH FROM PROCESS CONNECTION TRANSMITTER RANGE (IF REQ'D) TAG NUMBER

'U' N/A N/A

P1

P2

P3

P4

P5

P6

P7

P8

P9

P10

P11

P12

P13

P14

P15

P16

P17

P18

P19

P20

P21

P22

P23

P24

P25

*Consult factory if additional points are required.

Free-Hanging Style MultipointFree-Hanging reactor multipoints are flexible and offer greater area coverage for cross sectional and radial temperature measurement. They are designed to be routed around the circumference of the vessel and then inwards to the sensing point. Free-Hanging multipoints are supplied without an outer protection tube and can be coiled for shipment.

7

Options:

Close coupled or remote mounted terminations

Heavy or double wall MI-cable for extra resistance to process medium

Top or side mount

Secondary Pressure Containment in the event of a primary pressure boundary failure

VESSEL

MULTIPOINT ASSEMBLY

Reactor Multipoints

Advantages:

Resistance to extensive pressure build-up in

hydrocracking applications (more temperature

measuring points available)

Mirror image thermocouple patterns allow operator to

see channeling, coke balls or improper temperature

distribution

Fast response to temperature changes

Coiled units result in less shipping

and handling costs

Better tip sensitivity

Multiple locations throughout

the total area of the vessel

Applicable for severe service in both

Hydrocrackers and Hydrotreater service

Redundant system with multiple

mutually independent sensors

Easy removal for access during catalyst changes

Flexible routing: can overcome last minute reactor

tray and beam changes

Mineral Insulated Cable Multiple MI cable sizes available to meet application requirements

1/4″ (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 added durability in severe applications Variety of other diameters available upon request Available in various alloys, such as 347SS, to meet the specifications of the reactor process Special tools not required for large radius bends Tube-bending tool advisable for final 90° bend and any other tight radius bending required

Reactor Multipoints

For standard 5/16” MI Cable 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 in severe applications Standard 0.040″ (1.0 mm) wall thickness with a second 0.040″ (1.0 mm) sheath

Standard Wall

Heavy Wall

Double Wall

8

Single Junction

Number of cablesper sensor diameter

NPS Schedule 5/16" [8mm]

40 2580 [XS] 22

160 16XXS 1340 55

80 [XS] 49160 40XXS 3140 95

80 [XS] 86160 69XXS 58

NozzleSize

2"

3"

4"

9

Customer Detail:

Type of Vessel:

Name and Model of Vessel:

Vessel Dimensions:

Vessel Material:

Vessel Condition:

Temperatures:

Pressure:

Process Connection:

Type of Sensor:

Number of Points:

MI Cable Material:

MI Cable Diameter:

Protection Tube Diameter:

Secondary Containment:

Visual Indication:

Additional Notes:

Junction: Grounded Ungrounded

RTD (Consult Factory) Other (Specify in notes)

Type E Thermocouple: Single (E) Dual (EE)

Type N Thermocouple: Single (N) Dual (NN)

Type K Thermocouple: Single (K) Dual (KK)

Type J Thermocouple: Single (J) Dual (JJ)

Yes No

Yes No

OD: ID:

See next page for point details

Rating:

Schedule (Nozzle): ID of Nozzle:

Type: Size:

Material:

Used (In service) New

Ambient: Process:

Process:

WIKA Instruments - Reactor Multipoint Data Sheet (Free-Hanging)Company Name: Contact:

Phone: Fax: Email:

Address:

Diameter: Height:

*Consult factory if additional points are required.

10

POINT LENGTH FROM PROCESS CONNECTION TRANSMITTER RANGE (IF REQ'D) TAG NUMBER

P1

P2

P3

P4

P5

P6

P7

P8

P9

P10

P11

P12

P13

P14

P15

P16

P17

P18

P19

P20

P21

P22

P23

P24

P25

Handling and Installation Procedures forFree-Hanging MultipointsUpon receipt of assembly the multipoint should be stored laying down and protected from the elements if removed from its sealed shipping container.

Note: Sidewall Brackets and Weld Clips are to be incorporated into vessel manufacturing and should be in place prior to installation.

Installation procedure:

1) Review with the client the proposed thermocouple locations with reference to trays, struts, and any other vessel obstructions. These locations are usually determined during the drawing/design review procedure.

2) From drawing data, mark thermocouple point locations inside the vessel.

3) Hang support cables and set clip locations (location of the sensing points).

4) Using the upper flange assembly, lift and lower the thermocouple assembly into the vessel.

5) Route the thermocouples to their positions (see page 12).

6) After install is complete, test sensors for function.

This is a standard install once WIKA Technicians are at site and have completed the plant safety training and site orientation.

To save costs we ask that all scaffolding, required equipment and personnel be in place upon completion of the training. This will reduce unnecessary waiting and costs to the client.

The personnel required to install the cables and thermocouples is to be determined by the client. Generally these are instrument technicians and fitters.

11

Reactor Multipoints

Expansion loop inside vessel Installation using craneTypical point layout

12

Sensor Routing ExampleUsing the Base Support, Sidewall Bracket and Weld Clips (see page 13), route the thermocouples along the designated path to their sensing locations. Utilize a vertical weld clip when routing MI-cable to required elevations and the horizontal clip when bending around the vessel circumference.

Reactor Multipoints

Note: the sensors are routed along side the clips, not through.

VESSELHORIZONTALWELD CLIP

VESSELVERTICALWELD CLIP

13

Installation Accessories

Sidewall Bracket

Base Support Styles

Weld Clip

Reactor Multipoints

Secondary Pressure Containment Engineered to suppress process in the unlikely event of a primary pressure boundary failure

Indication provided to operator regarding breech either AROUND or THROUGH the MI-cable

Optional WIKA pressure gauge/transmitter for visible indication of containment chamber

Optional double-flanged design allows for access to safety containment chamber during

reactor shutdowns

Excess lead wire is added to allow for seperation of double flange

14

WELD

WELD

PRESSURE GAUGE

‘DOUBLE FLANGE’

Reactor Multipoints

Pressure Feed Thru

REDUCING ADAPTER

Testing and Certifications

The following testing and inspections can be performed upon request:

Hydrostatic Pressure testing up to 10,000 psi Pneumatic Pressure testing Liquid penetrant inspection (LPI) Positive Material Identification (PMI) Radiography (RT) Ultrasonic (UT) Sensor calibration (As per NIST) ASME Pressure Calculations

Most designs can be offered with local certifications such as ATEX, CSA, INMETRO and GOST. Canadian Registration Numbers (CRN) are also avilable upon completion of pressure calculations.

Reactor Multipoints

15

Right: a hydrostatic pressure test is being

monitored using a custom vessel and

specialized software.

PMI Gun Hydrostatic Test Vessel

Junction Box Stainless Steel - Weather Proof / Corrosion resistant

Direct or remote mount

Cable entry connection to suit customer requirements

Available as Explosion Proof (EEx-d) or General Purpose (NEMA/IP Rating)

Easy access to terminals or transmitters

Terminal strips or DIN rail mounting options available

16

Reactor Multipoints

mA +-- +

21

34

mA +-- +

21

34

mA +-- +

21

34

mA +-- +

21

34

mA +-- +

21

34

mA +-- +

21

34

POINT 1 POINT 2 POINT 3

POINT 6POINT 5POINT 4

POINT NUMBER LABEL

DIN RAIL TERMINALS

TRANSMITTER

SERIAL NUMBERCUSTOMER INFORMATION

NAME PLATE OPTION

Right: sample junction box with

SAK terminals.

WIKA worldwideNorth America

Canada (COE Multipoints)WIKA Instruments Canada Ltd.Edmonton, AlbertaTel.: (+1) 780 463 7035Fax: (+1) 780 462 0017E-mail: [email protected]

MexicoInstrumentos WIKA México,S.A. de C.V.Álvaro ObregónTel.: (+52) 55 5020 5300 Fax: (+52) 55 5020 5301 E-mail: [email protected] www.wika.com.mx

USAWIKA Instrument CorporationLawrenceville, GeorgiaTel.: (+1) 770 513 8200 Fax: (+1) 770 338 5118 E-mail: [email protected] www.wika.com

USA (COE Multipoints)WIKA Instrument CorporationHouston FacilityDeer Park, TexasTel.: (+1) 713 475 0022 Fax: (+1) 713 475 0011 E-mail: [email protected] www.wika.com

South America

ArgentinaWIKA Argentina S.A. Buenos Aires Tel.: (+54) 11 4730-1800 Fax: (+54) 11 4761-0050 E-mail: [email protected] www.wika.com.ar

BrazilWIKA DO BRASIL Iperó - SP Tel.: (+55) 15 3459 9700 Fax: (+55) 15 3266 1650 E-mail: [email protected] www.wika.com.br

Europe

AustriaWIKA Meßgerätevertrieb Ursula Wiegand GmbH & Co. KG Wien Tel.: (+43) 1-8 69 16 31 Fax: (+43) 1-8 69 16 34 E-mail: [email protected] www.wika.at

BeneluxWIKA Benelux EchtTel.: (+31) 475 53 55 00 Fax: (+31) 475 53 54 46 E-mail: [email protected] www.wika.nl

BulgariaWIKA Bulgaria EOOD Sofia Tel.: (+359) 2 82138-10 Fax: (+359) 2 82138-13 E-mail: [email protected]

FinlandWIKA Finland Oy Helsinki Tel.: (+358) 9-682 49 20 Fax: (+358) 9-682 49 270 E-mail: [email protected] www.wika.fi

FranceWIKA Instruments s.a.r.l.Eragny-sur-OiseTel.: (+33) 1/34 30 84 84 Fax: (+33) 1/34 30 84 94 E-mail: [email protected] www.wika.fr

Germany - Head Office(COE Multipoints)WIKA Alexander WiegandGmbH & Co. KG Klingenberg Tel.: (+49) 9372 132-0 Fax: (+49) 9372 132-406 E-mail: [email protected] www.wika.de

ItalyWIKA Italiana SRL Arese (Milano) Tel.: (+39) 02-93 86 11 Fax: (+39) 02-93 86 174 E-mail: [email protected] www.wika.it

PolandKujawska Fabryka Manometrow Wloclawek Tel.: (+48) 54230 11 00 Fax: (+48) 54230 11 01 E-mail: [email protected] www.manometry.com.pl

RomaniaWIKA Instruments Romania S.R.L. BucurestiTel.: (+40) 21-456 31 38 Fax: (+40) 21-456 31 37 E-mail: [email protected]

RussiaZAO “WIKA MERA” Moskau Tel.: (+7) 495-648 01 80 Fax: (+7) 495-648 01 81 E-mail: [email protected] www.wika.ru

SerbiaWIKA Merna Tehnika d.o.o. Beograd Tel.: (+381) 11 2763 722 Fax: (+381) 11-753 674 E-mail: [email protected] www.wika.co.yu

SpainInstrumentos WIKA, S.A. Sabadell (Barcelona) Tel.: (+34) 902 902 577 Fax: (+34) 933 938 666 E-mail: [email protected] www.wika.es

SwitzerlandMANOMETER AG Hitzkirch Tel.: (+41) 41 919 72 72 Fax: (+41) 41 919 72 73 E-mail: [email protected] www.manometer.ch

UkraineWIKA Pribor GmbH Donetsk Tel.: (+38) 062 345-34-16 Fax: (+38) 062 345-34-17 E-mail: [email protected] www.wika.donetsk.ua

United KingdomWIKA Instruments Limited Merstham, RedhillTel.: (+44) (0) 1737 644 008 Fax: (+44) (0) 1737 644 403 E-mail: [email protected] www.wika.co.uk

Asia

ChinaWIKA International Trading(Shanghai) Co., Ltd. Shanghai Tel.: (+86) 21 53 85 25 72 Fax: (+86) 21 53 85 25 75 E-mail: [email protected]

IndiaWIKA Instruments India Pvt. Ltd. Wagholi, PuneTel.: (+91) 20-66293200 Fax: (+91) 20-66293325 E-mail: [email protected] www.wika.co.in

JapanWIKA Japan K.K. Minato-ku, Tokyo Tel.: (+81) 3-5439-6673 Fax: (+81) 3-5439-6674 E-mail: [email protected]

KazakhstanTOO WIKA Kasachstan Almaty Tel.: (+7) 3272 33 08 48 Fax: (+7) 3272 78 99 05 E-mail: [email protected]

KoreaWIKA Korea Ltd. SeoulTel.: (+82) 2-869 05 05 Fax: (+82) 2-869 05 25 E-mail: [email protected] www.wika.co.kr

MalaysiaWIKA Instrumentation (M) Sdn Bhd Puchong, Selangor Tel.: (+03) 80631080 Fax: (+03) 80631070 E-mail: [email protected] www.wika.com.my

SingaporeWIKA Instrumentation PTE. LTD. Singapore Tel.: (+65) 6844 55 06 Fax: (+65) 6844 55 07 E-mail: [email protected] www.wika.com.sg

TaiwanWIKA Instrumentation Taiwan Ltd. Pinjen, Taoyuan Tel.: (+886) 3 420 6052 Fax: (+886) 3 490 0080 E-mail: [email protected] www.wika.com.tw

Africa/Middle East

EgyptWIKA Alexander WiegandGmbH & Co. KG Nasr City, Cairo Tel.: (+20) 2-227 33 140 Fax: (+20) 2-227 33 140 E-mail: [email protected]

IranWIKA Instrumentation ParsKish Ltd. Tehran Tel.: (+98) 21- 8852 6730 3 Fax: (+98) 21- 8875 7413 E-mail: [email protected] www.wika.ir

South AfricaWIKA Instruments (Pty.) Ltd. Gardenview, JohannesburgTel.: (+27) 11-621 00 00 Fax: (+27) 11-621 00 59 E-mail: [email protected] www.wika.co.za

United Arab EmiratesWIKA Middle East FZE Jebel Ali, Dubai Tel.: (+971) 4-883 90 90 Fax: (+971) 4-883 91 98 E-mail: [email protected]

Australia

AustraliaWIKA Australia Pty. Ltd. Rydalmere NSW Tel.: (+61) 2 8845 5222 Fax: (+61) 2 9684 4767 E-mail: [email protected] www.wika.com.au