Daily Thermetrics - Reactor Temperature Measurement - January 28 2013

CATTRACKER Catalyst Tracking Technology
Monitoring Catalytic Reaction Efficiency

with Advanced Temperature Measurement System Upgrades
. Heidt, Senior Technology Manager
Eric
Daily Thermetrics
a division of Daily Instruments Corp.
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
DAILY THERMETRICS
Advanced Process Control for the Process Industry
Its not the cost of the equipment, rather,

its the cost of replacing the equipment.
Where to direct low cost investments in

temperature monitoring upgrades which
produce high value returns in
profitability, safety and time.
DAILY THERMETRICS
Since 1973
DAILY INSTRUMENTS
DAILY
THERMETRICS
ISO : 9001 CERTIFIED

QUALITY ASSURANCE
DAILY
THERMOCONTROL
L
High Quality Instrumentation

Industry Leading Technologies
Demanding Applications
Specialized Industries
Highly Engineered
DAILY THERMETRICS
Product Offerings, Advanced Solutions
Technical Services
REACTOR THERMOMETRY
Design & Field Engineering
Thermowells & Sensors
HEATERS & FURNACES

Reactor Accessories
Vessel Skin Sensors
PROCESS LICENSOR RECOGNITION

Which PROCESS LICENSORS recognize Daily Thermetrics
as specialists in downstream thermometry?
DAILY THERMETRICS
UPGRADE & REVAMP SOLUTIONS
Technical Services
FRACTIONATOR &
REACTOR THERMOMETRY
Design & Field Engineering
Thermowells & Sensors
HEATERS & FURNACES
VESSEL SURFACES
Vessel Skin Sensors
WORLD WIDE EXPERIENCE

REACTOR & FRACTIONATOR THERMOMETRY
SINCE 2001:
REACTOR EXPERIENCE:
500+ Catalytic Vessels Profiled
OPERATIONAL SENSORS:
24,000+ Sensors in Operation
COMMON APPLICATIONS:
HydroCRACKING
80+ Reactors
HydroTREATING
200+ Reactors
Reforming
35+ Reactors/Regenerators
Hydrogen Generation
20+ Reactors
IDENTIFYING REACTOR ASSETS

Catalytic Processing Units: Key Investments
CATALYST
WHICH INVESTMENTS
REQUIRE
ADVANCED
MONITORING?
INTERNALS,
MECHANICAL
(Concepts we already know.)

VESSEL /
ASSOCIATED
COMPONENTS
IDENTIFYING REACTOR ASSETS

Catalyst Investment
CATALYST
REOCCURING INVESTMENT
Significant Consumable Investment
PERFORMANCE
Reduce / Increase Production

depending on Utilization and Condition
DAILY THERMETRICS
Reactor Components
3 Critical Components for

Properly
REACTOR
Operating
THERMOMETRY
Reactors
SENSOR AVAILABILITY
Is there sufficient quantity of sensors to
REACTOR
properly troubleshoot, plan, and justify
future investment? OFTEN TIMES
MINIMALIZED
SENSOR ACCURACY
Does the sensor provide the highest
level of confidence of the actual
reaction temperature?
Internals
SENSOR RELIABILITY
THERMOMETRY
Does the sensors
life represent a
maintenance cost or a long term
Catalyst
investment?
EVOLUTION: REACTOR THERMOMETRY

MEASUREMENT: INLET, OUTLET, & WABT
Single INLET Temperature

Measurement
Weighted Average Bed Temperature
Single OUTLET Temperature

Measurement

MEASUREMENT: INLET, OUTLET, & WABT
Weighted Average Bed Temperature

WABT = SINGLE VALUE FOR CATALYST
CAN NOT EFFECTIVELY DETECT:

PROCESS FLOW & CHANNELING ISSUES
TEMPERATURE EXCURSIONS & HOT SPOTS
PROCESS MAL-DISTRIBUTION
DISTRIBUTOR / TRAY FOULING

MEASUREMENT: PIPE WELL/THERMOBAR MULTI-POINT
TEMPERATURE VISIBILITY
at Measurement Elevations

MEASUREMENT: RADIAL PROFILING
RADIAL TEMPERATURE PROFILING

Process Licensor Specifications
for NEW Reactors

MEASUREMENT: 1st GENERATION RADIAL PROFILING
1st GENERATION FLEXIBLE SENSORS

YEAR 1987: MEETING RADIAL SPECIFICATIONS
Industrial Refinery
Thermocouple
IMPROVEMENTS
AVAILABILITY
IMPROVED
ACCURACY
NO IMPROVEMENT
RELIABILITY
NO IMPROVEMENT
1st GENERATION RADIAL PROFILING

TECHNOLOGY LIMITATIONS: SIGNIFICANT HARDWARE
1st GENERATION FLEXIBLE SENSORS

IMPROVEMENTS
AVAILABILITY
IMPROVED
ACCURACY
NO IMPROVEMENT
RELIABILITY
NO IMPROVEMENT
1st GENERATION RADIAL PROFILING

TECHNOLOGY LIMITATIONS: SIGNIFICANT HARDWARE
1st GENERATION FLEXIBE SENSORS

IMPROVEMENTS
AVAILABILITY
IMPROVED
ACCURACY
NO IMPROVEMENT
RELIABILITY
NO IMPROVEMENT

MEASUREMENT: 2nd GENERATION RADIAL PROFILING
NEWEST GENERATION FLEXIBE SENSORS

IMPROVEMENTS
AVAILABILITY
IMPROVED
ACCURACY
IMPROVED
RELIABILITY
IMPROVED
PATENT # 6,550,963 & 6,599,011 / CANADA & EU PATENT PENDING
v.2012 CatTracker
1.
2.
3.
4.
5.
Ultra High Accuracy

Ultra High Precision
Maintenance-Free, Repair-Free Technology
Extended Life
Patented, aerospace-derived technology
with up to nine (9) measurement locations
along each sheath/probe
WHAT IS THE CATTRACKER?

The CatTracker is a thermocouple that combines the

performance of aerospace technology and the efficiency
of nine points per tube.
IMPROVEMENTS
AVAILABILITY
IMPROVED
ACCURACY
IMPROVED
RELIABILITY
IMPROVED

Aerospace Technology
IMPROVEMENTS
AVAILABILITY
IMPROVED
ACCURACY
IMPROVED
RELIABILITY
IMPROVED
Aerospace
Technology
9 Points
Per Tube

Number of Tubes Required:

45 Sensing Points
Out -Dated Technology
IMPROVEMENTS
AVAILABILITY
IMPROVED
ACCURACY
IMPROVED
RELIABILITY
IMPROVED
Reactor Optimization
REDUCING
NOZZLES
REDUCING
COSTS
$20,000-$65,000
Cost Savings per Nozzle
2nd GENERATION RADIAL PROFILING

CatTracker Catalyst Tracking Solutions
CatTracker Catalyst Tracking Solutions
Safety
Never any live process beyond the
flange face.
Fewer obstructions inside the reactor to
create hazards during catalyst changes
and turnarounds.
Fewer potential leak paths.
World Class Manufacturing

Facility
Over 260 feet of vacuum, baking and annealing ovens

140 foot continuous baking oven
Extensive CNC and Swiss machines
with automated welding

equipment
All CatTracker thermocouple tube welds are made with computer

controlled automatic welders
IMPROVEMENTS
AVAILABILITY
IMPROVED
All CatTracker measuring junctions
are made with
computer
ACCURACY
IMPROVED
controlled equipment
RELIABILITY
IMPROVED
and state of the art calibration

and test equipment.
Concentric Live
Micro-Focus X-Ray
High-Definition Digital X-Ray Display

(Hot Junction)
Pass
IMPROVEMENTS
AVAILABILITY
IMPROVED
Reject
ACCURACY
Porosity - IMPROVED
Not Visible to the
Naked
Eye
RELIABILITY
IMPROVED
ADVANCED TOPIC: Thermocouple Moisture

Understanding Thermocouple Performance
ASTM E780
Significance and Use
Thermocouples fabricated from thermocouple cable that
has been contaminated by moisture or by other
impurities may undergo large changes in thermoelectric
properties or may fail catastrophically when exposed to
high temperatures. Since such contamination usually lowers
the electrical resistance between the thermoelements and the
sheath substantially, measurement of the insulation resistance
can provide a valuable check of insulation quality and
cleanliness, and can serve as a basis for rejection of unsuitable
material and unreliable components.
ADVANCED: Thermocouple Moisture

Understanding Thermocouple Performance
Moisture in contact with thermocouple wires and

insulation cause:
WIRE CORROSION
Changes in composition of wire
metallurgy also changes known
voltage
GHOST JUNCTIONS & SHORTS
Moisture creates resistance drops
and if localized, will short out a
thermocouple or create multiple low
output junctions
Corroded Type K, E, and J wires do

not carry the same temperature
gradient/voltage at a given
temperature as non-corroded clean
thermocouple wire
Resistance drops, especially

between thermocouple wires
between designated hot and
cold junctions create
unintended junctions that
disrupt the EMF and output
voltage resulting in poor
measurement
New for 2012:

Ralexian Transition Design
Developed and offered
exclusively by Daily
Thermetrics
Moisture-tight Seal
Multiple Epoxies with
different curing
temperatures used
Function tested multiple
times to ensure moisture
resistance
Water Submersion Test
IMPROVEMENTS
AVAILABILITY
IMPROVED
ACCURACY
IMPROVED
RELIABILITY
IMPROVED
ADVANCED: Thermocouple Moisture

CatTracker Sets a NEW World Standard
Measuring Moisture in Thermocouples:

Insulation Resistance (IR) Test
This test is performed by testing the resistance between any single ungrounded
thermocouple wire and the external thermocouple sheath.
IR Pass/Fail Criteria
10
10
5
10 G at 500V at ambient temperature

AFTER a water submersion period of
10 minutes is performed
Gigaohms at
500V at ambient
temperature
0
Industry
Standard
1 G at 500V
at ambient temperature
Daily
Thermetrics
IMPROVEMENTS
AVAILABILITY
IMPROVED
ACCURACY
IMPROVED
RELIABILITY
IMPROVED
REACTOR THERMOCOUPLES
Whats the importance?
Accurate Measurement allows for

Accurate Inlet Temperature Control Decisions
800
780
Temperature (F)
770
Too Hot
Coking
Overproduction of Lights
Reduced Yield Value
Exotherms
Upset Propensity
760
750
390
385
380
Optimum Temperature
375
740
730
Too Cold
Below Optimum Conversion
720
Temperature (C)
790
395
370
365
710
700
Time
360
ULTRA HIGH ACCURACY

Daily Thermetrics Corporation (EXCLUSIVE OFFERING)
Accuracy
DailyStandard
Thermetrics
Special Limits
Accuracy
+/- 1.6C
.80C
427C
3.2 Catat
at427C
427C
Up to 4X MORE ACCURATE than

previous generation sensors
ULTRA HIGH PRECISION

Daily Thermetrics Corporation (EXCLUSIVE OFFERING)
Guarantee: Every sensor in the entire reactor is designed and
manufactured to achieve a 1C maximum delta-T at 427C
+3/4% TOLERANCE
Normal Thermocouple
+3/8% TOLERANCE
At 427C:
1C
MAX
Special Limits of Error
CatTracker
SPECIAL LIMITS
Special Limits of Error
STANDARD LIMITS
Normal Thermocouple
DAILY THERMETRICS
Revisited: Reactor Thermometry Components
3 Critical Components for

REACTOR THERMOMETRY
THERMOMETRY
2ND
GEN. CatTracker OFFERS:
SENSOR
AVAILABILITY
much as NINE
TIMESof(9X)
MORE
Is thereAssufficient
quantity
sensors
sensors
using the same
quantity
to properly
troubleshoot,
plan,
and of
equipment
as 1ST GENERATION
justify future
investment?
systems.
SENSOR ACCURACY
Does the sensor provide the highest
Up to FOUR TIMES (4X) MORE
level ofaccurate
confidence
the actual
than of
standard
1ST
reaction
temperature?
GENERATION
systems.
SENSOR RELIABILITY
Does the
sensors
representfree
a
REPAIR
FREE,life
maintenance
maintenance
cost
or a long
operation
backed
by anterm
industry
leading 10 year warranty.
investment?
Conclusion: Precise Temperature Management

1.
Temperature Measurement & Temperature Management

Measurement All Monitor/Control Equipment is not the
same
Management Data management capabilities can hurt or
help catalyst utilization & condition
2.
Identifying Unit Assets should include the Process Control

Temperature Equipment as this equipment may or may not
have an adverse effect on the unit and catalyst performance
depending on equipment used.
3.
Daily Thermetrics offers INCREASED MEASUREMENT DENSITY to

provide the most complete profile without interrupting process
flow.
4.
CatTracker Technologies provide upgraded performance

(accuracy and precision via ULTRA HIGH GRADE components)
and upgraded reliability compared to previous generation
equipment.

Daily Thermetrics - Reactor Temperature Measurement - January 28 2013

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Daily Thermetrics - Reactor Temperature Measurement - January 28 2013

Загружено:

Авторское право:

Доступные форматы

CATTRACKER Catalyst Tracking Technology

Monitoring Catalytic Reaction Efficiency

Its not the cost of the equipment, rather,

Where to direct low cost investments in

ISO : 9001 CERTIFIED

High Quality Instrumentation

HEATERS & FURNACES

PROCESS LICENSOR RECOGNITION

HEATERS & FURNACES

WORLD WIDE EXPERIENCE

500+ Catalytic Vessels Profiled

24,000+ Sensors in Operation

IDENTIFYING REACTOR ASSETS

(Concepts we already know.)

IDENTIFYING REACTOR ASSETS

Significant Consumable Investment

Reduce / Increase Production

3 Critical Components for

EVOLUTION: REACTOR THERMOMETRY

Single INLET Temperature

Weighted Average Bed Temperature

Single OUTLET Temperature

EVOLUTION: REACTOR THERMOMETRY

Weighted Average Bed Temperature

CAN NOT EFFECTIVELY DETECT:

EVOLUTION: REACTOR THERMOMETRY

EVOLUTION: REACTOR THERMOMETRY

RADIAL TEMPERATURE PROFILING

EVOLUTION: REACTOR THERMOMETRY

1st GENERATION FLEXIBLE SENSORS

1st GENERATION RADIAL PROFILING

1st GENERATION FLEXIBLE SENSORS

1st GENERATION RADIAL PROFILING

1st GENERATION FLEXIBE SENSORS

EVOLUTION: REACTOR THERMOMETRY

NEWEST GENERATION FLEXIBE SENSORS

PATENT # 6,550,963 & 6,599,011 / CANADA & EU PATENT PENDING

Ultra High Accuracy

WHAT IS THE CATTRACKER?

The CatTracker is a thermocouple that combines the

WHAT IS THE CATTRACKER?

WHAT IS THE CATTRACKER?

PATENT # 6,550,963 & 6,599,011 / CANADA & EU PATENT PENDING

Number of Tubes Required:

2nd GENERATION RADIAL PROFILING

PATENT # 6,550,963 & 6,599,011 / CANADA & EU PATENT PENDING

CatTracker Catalyst Tracking Solutions

PATENT # 6,550,963 & 6,599,011 / CANADA & EU PATENT PENDING

World Class Manufacturing

Over 260 feet of vacuum, baking and annealing ovens

with automated welding

All CatTracker thermocouple tube welds are made with computer

and state of the art calibration

High-Definition Digital X-Ray Display

ADVANCED TOPIC: Thermocouple Moisture

ADVANCED: Thermocouple Moisture

Moisture in contact with thermocouple wires and

Corroded Type K, E, and J wires do

Resistance drops, especially

New for 2012:

ADVANCED: Thermocouple Moisture

Measuring Moisture in Thermocouples:

10 G at 500V at ambient temperature