Thermocouple Documentation TEMP-PRO Inc.

Project Name: Yura S A - Yura Cement Plant Contract No. 0820208 FLS Equip No: 851.IP851

Attachments:
STW-1217 A48 B20-FLS 990309 Sheet 1 Sheet 1-11 Cement Kiln T/C ASM Instruction & Installation Manual

FLSmidth Inc. Document Number: 60072687 Ver. 1.0

TEMP-PRO Inc.
An ISO 9001 CERTIFIED Company

Instruction Manual

INSTRUCTION AND INSTALLATION FLS PO NO.: 4-0820208-263317A MANUAL CONTRACT NO.: 25-08-20208-910
EQUIPMENT NO.: 851.IP851

TEMP-PRO Inc. 200 Industrial Drive Northampton, MA 01060 Telephone: (413) 584-3165 Toll Free: (800) 991-9093 Fax: (413) 586-3625 E-Mail: sales@temp-pro.com Web Site: www.temp-pro.com

TEMP-PRO Inc.
An ISO 9001 CERTIFIED Company

Instruction Manual

INSTRUCTION MANUAL
Operation And Maintenance Instructions
1. General Information
The Temp-Pro Thermocouple assembly you have selected is a precision temperature sensing unit which offers accurate readings under your specified industrial field conditions. Reasonable care, however, must be exercised in handling these sensors. Specified operating limits (see Table 1 on page 2) must not be exceeded. Rough handling, bending, or dropping of the sensor must be avoided.

2. Unpacking and Inspection

Immediately upon receipt, the sensors should be examined for possible in-transit damage and for physical conformance to specifications, In the case of damage, file a claim with the carrier and notify Temp-Pro Inc. without delay.

3.

Thermocouple Assemblies and Technical Requirements

3.1. EMF Values: Each thermocouple has been manufactured to meet the EMF vs. Temperature characteristics specified by NIST (National Institute of Standards and Technologies). These tables are available at Temp-Pro and can be supplied to you upon request. 3.2. Calibration: Temp-Pro has a calibration Laboratory for calibration and verification of Temperature vs. EMF of the thermocouples supplied to the customers and provides calibration data when requested by the customer. 3.3. General Information: General information related to commonly used thermocouples in industries are shown in Table 1 (page 2) including the temperature range, color coding, tolerances, etc. 3.4. Insulation Resistance (IR) Test of the Thermocouples: This is the most common test done on UNGROUNDED Thermocouples (and RTDs). See test method under MEASURING IR on page 6 of this manual.

TEMP-PRO Inc. 200 Industrial Drive Northampton, MA 01060 Telephone: (413) 584-3165 Toll Free: (800) 991-9093 Fax: (413) 586-3625 E-Mail: sales@temp-pro.com Web Site: www.temp-pro.com

TEMP-PRO Inc.
An ISO 9001 CERTIFIED Company

Instruction Manual

TABLE 1
INITIAL CALIBRATION TOLERANCES TO THERMOCOUPLE THERMOCOUPLE TYPE WIRE ALLOYS COLOR CODE Blue Red White Red Yellow Red ANSI TYPE SYMBOL T TEMPERATURE RANGE -200 to -650 -65 to +130 +130 to +350 0 to +285 +285 to +750 -200 to -170 -170 to +250 +250 to +340 +340 to +900 -200 to -110 -110 to 0 0 to +285 +285 to +1250 0 to 285 +285 to +1250 0 to +600 +600 to +1450 0 to +600 +600 to +1450 C STANDARD LIMITS 1.5% 1 0.75% 2.2 0.75% 1% 1.7 1.7 0.5% 2% 2.2 2.2 0.75% 2.2 0.75% 1.5 0.25% 1.5 0.25% SPECIAL LIMITS 0.8% 0.5 0.4% 1.1 0.4% 1 1 0.4% 0.4% TEMPERTURE RANGE -330 to -85 -85 to +270 +270 to +660 +32 to +545 +545 to +1400 -330 to -270 -270 to +480 +480 to +640 +640 to +1600 -330 to -165 -165 to +32 +32 to +545 +545 to +2300 +32 to +545 +545 to +2300 +32 to +1110 +1110 to +2650 +32 to +1110 +1110 to +2650 F STANDARD LIMITS 1.5% 1.8 0.75% 4 0.75% 1% 3 3 0.5% 2% 4 4 0.75% 4 0.75% 2.7 0.25% 2.7 0.25% SPECIAL LIMITS 0.8% 0.9 0.4% 2 0.4% 1.8 1.8 0.4% 0.4% 2 0.4% 2 0.4% 1.1 0.1% 1.1 0.1%

Copper (+) vs. Constantan (-) *Iron (+) vs. Constantan (-) Chromel (+) vs. Constantan (-)

Chromel (+) vs. *Alumel (-) Nicrosil (+) vs. Nisil (-) Platinum 10% Rhodium (+) vs. Platinum (-) Platinum 13% Rhodium (+) vs. Platinum Platinum 30% Rhodium (+) vs. Platinum 6% Rhodium (-) Tungsten (+) vs. Tungsten -26% Rhenium (-) Tungsten 3% Rhenium (+) vs. Tungsten 25% Rhenium (-) Tungsten 5% Rhenium (+) vs. Tungsten 26% Rhenium (-)

Yellow Red

1.1 0.4% 1.1 0.4% 0.6 0.1% 0.6 0.1%

+870 to +1700

0.5%

0.25%

+1600 to +3100

0.5%

0.25%

WR

+400 to 2300

1%

+800 to +4200

1%

W3

+400 to 2300

1%

+800 to +4200

1%

W5

+400 to +2300

1%

+800 to +4200

1%

* Magnetic Trademark, Hoskins Manufacturing Co. T not ANSI type symbol NOTE: Percent limits apply directly to temperature in degrees Celsius, but for degrees Fahrenheit equivalents are applied to the number of degrees Fahrenheit above or below the ice point (+32 degrees Fahrenheit). [i.e., Limit (degrees F) = (Temperature (degrees F) - 32 (degrees F)) * Percentage]

TEMP-PRO Inc. 200 Industrial Drive Northampton, MA 01060 Telephone: (413) 584-3165 Toll Free: (800) 991-9093 Fax: (413) 586-3625 E-Mail: sales@temp-pro.com Web Site: www.temp-pro.com

TEMP-PRO Inc.
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Instruction Manual

4. Resistance Thermometer Detector (RTD) Assembly and Technical Requirements

4.1. Outputs and Measurements: The output of RTD is resistance and can be measured with a Digital Multimeter. 4.2. General Information: General Information about different types of RTDs are shown in Table 2 below. TABLE 2
RESISTANCE TEST READING ELEMENT TYPE Platinum (DIN) Platinum Nickel Nickel C opper Nickel - Iron TEMP. COEF. (TCR) .00385 .00392 .00426 .006720 .004274 .005188 OHMS AT 0 C 100.00 100.00 90.38 120.00 9.04 604.00 OHMS AT 25 C 109.73 109.91 99.11 140.20 10.00 676.00

4.3. Temperature vs. Resistance: Temperature vs. Resistance of the most commonly used RTDs are shown in Table 3 on page 5. 4.4. Insulation Resistance of the RTDs: The Insulation Resistance Test of RTD is similar to Thermocouple except, use maximum 100 VDC as an applied voltage when using a megohmmeter (see Measuring IR on page 6) 4.5. Maintenance of RTDs, including Platinum RTDs: Normally, RTDs do not require maintenance. Should there be any apparent change in response time or drift in signal output, remove sensor from the assembly (or thermowell) and check for any deposits of foreign materials on the tip of the probe, or on the terminal screws inside the enclosure. 4.6. Checking Failure Conditions: If any failure occurred during the operation, check operating conditions against sensor specifications (verify the output against those in Table 3, on page 5, for the RTD type).

TEMP-PRO Inc. 200 Industrial Drive Northampton, MA 01060 Telephone: (413) 584-3165 Toll Free: (800) 991-9093 Fax: (413) 586-3625 E-Mail: sales@temp-pro.com Web Site: www.temp-pro.com

TEMP-PRO Inc.
An ISO 9001 CERTIFIED Company

Instruction Manual

4.7. Calibration of RTD: To determine the Resistance vs. Temperature characteristic of an RTD, the unit must be calibrated at a fixed temperature. The most commonly used fixed calibration environment is the ICE BATH. For instructions and the calibration method, see Figure 1 below:
Figure 1: RTD Resistance Measurement Calibration Method

4.8. Bench Test of RTD. Use a Digital Multimeter for resistance measurement and a megohmmeter for Insulation Resistance Measurement. 4.8.1. Wipe dry external surfaces of sensor. 4.8.2. Refer to wiring diagram on the drawing and connect Digital Multimeter leads across opposite terminals of the platinum resistance winding extension wires. Resistance should read approximately 110 ohms at room temperature and 100 ohms in the ice bath. See the RTD calibration set-up and instruction, Figure 1 on page 4. 4.8.3. Test Insulation Resistance by connecting one megohmmeter lead to wires on terminal (all wires shorted together) and the other to the external sheath (metal protection casing) of the sensor. Resistance reading should exceed 5 megohms unless otherwise specified (applied voltage should not exceed 100 VDC). See also Insulation Resistance Test of the Thermocouples, Measuring IR, on page 7 of this instruction manual.
TEMP-PRO Inc. 200 Industrial Drive Northampton, MA 01060 Telephone: (413) 584-3165 Toll Free: (800) 991-9093 Fax: (413) 586-3625 E-Mail: sales@temp-pro.com Web Site: www.temp-pro.com

TEMP-PRO Inc.
An ISO 9001 CERTIFIED Company

Instruction Manual

TABLE 3
T EMPERAT URE RESISTANCE CHARACT ERIST ICS T EMPERAT URE DEGREES C -130 -110 -90 -70 -60 -50 -40 -30 -20 -10 +-0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140 +150 +160 +170 +180 +190 +200 +210 +220 +230 +240 +250 +260 +280 +300 +320 +340 +360 +380 +400 +420 +440 +460 +480 +500 +520 +540 +560 +580 +600 +620 +640 +660 +680 +700 +720 +740 +760 +780 +800 +820 +840 F -202 -166 -130 -94 -76 -58 -40 -22 -4 +14 +32 +50 +68 +86 +104 +122 +140 +158 +176 +194 +212 +230 +248 +266 +284 +302 +320 +338 +356 +374 +392 +410 +428 +446 +464 +482 +500 +536 +572 +608 +644 +680 +716 +752 +788 +824 +860 +896 +932 +968 +1004 +1040 +1076 +1112 +1148 +1184 +1220 +1256 +1292 +1328 +1364 +1400 +1436 +1472 +1508 +1544 RESISTANCE IN OHMS PLAT INUM WINDINGS *ALPHA .00385 47.93 56.13 64.25 72.29 76.28 80.25 84.21 88.17 92.13 96.07 100.00 103.90 107.79 111.67 115.54 119.40 123.24 127.07 130.89 134.70 138.50 142.28 146.06 149.82 153.57 157.32 161.04 164.76 168.47 172.16 175.84 179.51 183.17 186.82 190.46 194.06 197.70 204.88 212.03 219.13 226.18 233.19 240.15 247.06 253.93 260.75 267.52 274.25 280.93 287.57 294.16 300.70 307.20 313.65 320.05 326.41 332.72 338.99 345.21 351.38 357.51 363.59 369.62 375.61 381.55 387.45 *ALPHA .00392 47.28 55.52 63.71 71.86 75.92 79.96 83.99 88.01 92.02 96.02 100.00 103.97 107.93 111.88 115.82 119.75 123.66 127.56 131.45 135.33 139.20 143.06 146.90 150.73 154.55 158.36 162.16 165.94 169.71 173.47 177.22 180.96 184.69 188.40 192.10 195.80 199.47 206.80 214.07 221.30 228.48 235.62 242.70 249.74 256.74 263.68 270.58 277.43 284.24 291.00 297.71 304.37 310.99 317.56 324.08 330.56 336.99 343.37 349.70 355.99 362.23 NICKEL WINDINGS *ALPHA .00426 *ALPHA .006720 COPPER WINDINGS *ALPHA .004274

68.27 71.19 74.24 77.39 80.56 83.77 87.04 90.38 93.80 97.31 100.91 104.60 108.39 112.28 116.27 120.36 124.55 128.85 133.26 137.78 142.40 147.11 151.91 156.79 161.89 167.13 172.46 177.95 183.55 189.40 195.35 201.55 208.00 214.60 228.45 242.70

73.10 79.62 86.17 92.76 99.41 106.15 113.00 120.00 127.17 134.52 142.06 149.79 157.74 165.90 174.27 182.85 191.64 200.64 209.86 219.30 228.96 238.85 248.97 259.37 269.92 280.79 291.96 303.46 315.31 327.53 340.14 353.14 366.53 380.31 409.07 439.43

7.10 7.49 7.88 8.26 8.65 9.04 9.42 9.81 10.19 10.58 10.97 11.35 11.74 12.12 12.51 12.90 13.28 13.67 14.06 14.44 14.83 15.22 15.61 16.00 16.39 16.78 17.17 17.56 17.95 18.34 18.73

* TCR = Temperature Coefficient of Resistance = Ohm / Ohm / Degree Celsius

TEMP-PRO Inc. 200 Industrial Drive Northampton, MA 01060 Telephone: (413) 584-3165 Toll Free: (800) 991-9093 Fax: (413) 586-3625 E-Mail: sales@temp-pro.com Web Site: www.temp-pro.com

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Instruction Manual

Measuring IR
T/C TERMINAL HEAD TERMINAL (POST)

MEASURING SHEATH
JCT. (TIP)

INDICATING SCALE SHOWS INSULATION RESISTANCE

MEGGER INSULATION TESTER

Insulation Resistance may be performed to test ungrounded thermocouples or RTD's. Measuring IR need not be of the highest precision, in that low IR should be grounds for rejection. Precision instrumentation is not therefore required, although calibration must be dependable, and any recognized megohmmeter is satisfactory. To measure IR, you would use an IR tester, which is a portable instrument that's essentially a resistance meter, or ohmmeter, with a built in hand cranked or line-operated DC generator that develops high DC voltage. This voltage (usually 500V or more) causes a small current to flow through and over the insulation's surface. The tester provides a direct reading of IR in ohms or megohms. Test is made with clips connected to the sheath and to all leads tied together. Insulation resistance may be expected to be in excess of 1000 megohms at room temperature and not less than 20 megohms at 200 degrees Celsius. The above picture shows a typical megohmmeter test instrument hook-up to measure insulation resistance. You can use an IR meter and obtain measurements. A high resistance value would indicate a "good" insulation, while a relatively low resistance value would point to a "poor" insulation. In actual applications, resistance values can be higher or lower due to the effects of factors such as temperature, humidity, the moisture content of the insulation, and even the person doing the testing. Therefore, the IR reading can be very different for the same wire tested on different days.

TEMP-PRO Inc. 200 Industrial Drive Northampton, MA 01060 Telephone: (413) 584-3165 Toll Free: (800) 991-9093 Fax: (413) 586-3625 E-Mail: sales@temp-pro.com Web Site: www.temp-pro.com

TEMP-PRO Inc.
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Instruction Manual

Installation of Thermocouples or RTDs

5. Installation Instruction
5.1. Complete unit: Complete unit may be secured into process location without sensor disassembly, in the case of those with threaded or flanged thermowells or fittings. 5.2. Weld-in Thermowell Assembly: On a weld-in thermowell assembly, the sensor inset must be removed before welding in place, to prevent possible damage by overheating during welding.

6. RTD Spring-Loaded: Removal And Assembly Instructions Into Thermowell

(Refer to Figure 2 on page 8) 6.1. To remove RTD inset, take off connection head cover and loosen the two terminal block retaining screws until they are disengaged from the connection head. 6.2. Withdraw inset from connection head without further disassembly, and place in a safe location to prevent bending and possible damage. 6.3. With an ohmmeter, check and verify resistance of the unit. A 100 ohm platinum RTD should have a resistance of about 110 ohms at room temperature between red and blue and/or black and white respectively. There should be no continuity between the leadwires and the sheath of the probe. 6.4. Screw the RTD connection head and extension into the existing thermowell. 6.5. Replace the RTD inset (reverse of 6.1). 6.6. Connect extension leads to the terminal block. Be careful to observe color coding polarity. 6.7. Tighten terminal block retaining screws in the terminal block. Spring should be compressed about 3/16". Spring may be repositioned as required.

TEMP-PRO Inc. 200 Industrial Drive Northampton, MA 01060 Telephone: (413) 584-3165 Toll Free: (800) 991-9093 Fax: (413) 586-3625 E-Mail: sales@temp-pro.com Web Site: www.temp-pro.com

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Figure 2: Removal and Assembly Instructions into Thermowell

Retaining Screws

Option 1 Option 2 Option 3

Terminal Block

7. Thermocouple Spring-Loaded: Removal and Assembly Instructions into Thermowell

(Refer to Figure 2 above) 7.1. To remove the thermocouple inset, open the cover of the thermocouple connection head and loosen the two terminal block retaining screws, until they are disengaged from the connection head. 7.2. Carefully remove the terminal block and thermocouple inset. Avoid bending or straining the thermocouple bare wires. Close cover. 7.3. Screw the thermocouple head and extension with the extension into the existing thermowell. 7.4. Replace the thermocouple inset. 7.5. Insert the thermocouple block into the head allowing the bare thermocouple wires to pass through the 5/16" diameter hole in the terminal block. The negative leg of the thermocouple wire is color coded red and is to match with the brass post next to the stamped negative sign in the terminal block. 7.6. Connect extension wires through the head conduit connection port and into the brass post. Close cover.
Figure 3: Thermocouple Inset

TEMP-PRO Inc. 200 Industrial Drive Northampton, MA 01060 Telephone: (413) 584-3165 Toll Free: (800) 991-9093 Fax: (413) 586-3625 E-Mail: sales@temp-pro.com Web Site: www.temp-pro.com

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8.

Screw-In Thermowell Installation

8.1. If necessary, remove sensor assembly from thermowell by unscrewing nipple from well or by breaking the extension at the union. (Refer to 6 and 7). Use care whenever removing or replacing the sensor element. 8.2. Insert thermowell into process connection and screw in until snug. Apply additional torque until the threads are well engaged. The following chart (see Table 4) indicates the approximate length of thread engagement of various pipe sizes: TABLE 4
PROCESS 1/2" NPT 3/4" NPT 1" NPT 1-1/4" NPT 1-1/2" NPT 2" NPT 2-1/2" NPT 3" NPT ENGAGEMENT 1/2" 1/2"
"U" "L

5/8" 5/8" 5/8"

MAX. DIA.

SENSOR CONNECTION

5/8" 3/4" 3/4"

PROCESS CONNECTION MIN. DIA.

TEMP-PRO Inc. 200 Industrial Drive Northampton, MA 01060 Telephone: (413) 584-3165 Toll Free: (800) 991-9093 Fax: (413) 586-3625 E-Mail: sales@temp-pro.com Web Site: www.temp-pro.com

TEMP-PRO Inc.
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Instruction Manual

PRODUCTS
Thermocouple's Sub-Zero up to 5,000 F. Gas Turbine T/C Multipoint Specials Plastics Industry Platinum RTD's Copper Platinum Nickel Ni-Iron Flat Strip (Stator) Immersion Custom Thermistors All Applications, Including Compressor Thermowells Industrial Glass Thermometers Limited Space Threaded Raised Face Flanged Sanitary Thermowells Socket-Weld Steam Sampling Nozzles Threaded Van Stone Weld-In Electrical Accessories Junction Boxes Turning Gear Boxes Wiring Harnesses Cable Assemblies Gauge Panels Control Panels Circuit Boards Liquid Level Detectors Remote Terminal Units (RTU's) Remote Sensing Swamping (Averaging) T/C Boards Logistics Management Purchasing Warehousing Assembling/Kitting Shipping Services Research & Development in Temperature Sensing Products

Thermocouple & RTD Wire Compensated Terminal Blocks Plugs, Jacks, and Fittings Selector Switches Reference Junctions Transmitters/Controllers/Scanners Thermometers Bimetal Thermometers Filled System Thermometers Hydrogen Activity Probes

Reg. No. 950 98 0142

Form 990309

TEMP-PRO Inc. 200 Industrial Drive Northampton, MA 01060 Telephone: (413) 584-3165 Toll Free: (800) 991-9093 Fax: (413) 586-3625 E-Mail: sales@temp-pro.com Web Site: www.temp-pro.com