REACTOR TEMPERATURE PROFILING REACTOR TEMPERATURE PROFILING PRODUCT CATALOGstan INTRODUCTION In the refining, chemical and petrochemical industries there are increasing needs for accurate and complete temperature data for proper operation of reactors. These industries continue to see increasing regulatory requirements, emerging competition and the need to operate older units or reactors. Profitable operation often demands maximizing yields and increasing catalyst run time. Having the flexibility to take advantage of new process operating schemes and catalysts becomes imperative. Since there are significant differences in: + Operating conditions * Reactor designs * Process parameters * Mechanical conditions and stresses * Catalyst reactivity itis critical that the proper design of temperature measuring system be specified and implemented. By property selecting, or designing the temperature measuring system, itis possible to: + Optimize process safety + Extend catalyst life + Enhance operations + Decrease maintenance costs * Increase yields + Improve product quality The following sections of the "Reactor Temperature Profiling” catalog gives five general categories of technology: + Flex-R® (Radial Multipoint Reactor Thermometry) * Gayesco Single Sheath * Hybrid Solutions + Flex-O™ (Multipoint Pipewell Reactor Thermometry Systems) i-Multipoint Assemblies Gayesco specializes in unique solutions to difficult applications. If the categories listed above do not address the specific needs of your reactor / process, please contact the Gayesco representative cof your area, which can be located from our website at www.gayesco.com, or contact our corporate headquarters at U.S. (713) 941-8540 for more information,kgs TABLE OF CONTENTS FLEX-R® (Radial Multipoint Reactor Thermometry) .. Gayesco Single Sheath Radial Reactor Thermometry ... Hybrid Solutions for Radial Multipoint Reactor Thermometry ..... 13 FLEX-O™ (Multipoint Pipewell Reactor Thermometry Systems) ...|5 Mini-Multipoint Assemblies ...............-..-.0.++ iz i 27kan FLEX-R® Radial Multipoint Reactor Thermometryakg THE FLEX-R® General Conventional temperature measurment designs limit or mislead operators due to design or location. In response to these industry needs Gayesco has developed a “RADIAL" temperature measurment system called the FLEX-R®. This technology features advancement in several major areas of process temperature measurment and is a commercially proven success since 1987. Advantages + Real Time Temperature Readings * Higher Point Density Potential * Secondary Containment * Adaptability to Existing Reactor Nozzles * Greater Process Control * Increased Operator Confidence * Process can be Run More Efficiently Operations/Process Enhancement + Fast Response Time (4 to 8 seconds) igh Point Density per nozzle * Unlimited Point Location in reactor + Powerful Diagnostic Tool that identifies maldistribution, hot spot formation and channeling + Improves Product Selectivity System Pays For Itself * Eliminates Pipewell Costs and Limitations * Survivability through catalyst dump & turnaround * Possible Elimination of External Skin Points * Ability to Push Operation of Unit with Confidence * Possibility of Eliminating Nozzles * Enhanced Through-put Potential * Lower Shipping, Storage and Handing Cost Safety * Fast Response to a Temperature Excursion * Hot Spot Identification * Thorough Coverage for Vessel Protection * High Redundancy Capability makes in idual measurement point less critical. 44am Pipewell Technology The Flex-R°® Top Entry SHHet Top Entry 1 POINTS PER NOZZLE I.D. NOZZLE] NOZZLEI.D. | POSSIBLE NO] SIZE OF POINTS* 2" | Sch.. 80 (1.939") 2 | ‘Sch . 160 (1.689") 18 ‘Sch . XXS (1.503") 14 3" — | Sch. 80 (2.90") 50+ ‘Sch . 160 (2.62) 48. Sch . XXS (2.30") 38. 4" | Sch. 80 (3.83" 50+ Sch . 160 (3.44) 50+ ‘Sch . XXS (3.15") 50+ * Number of points is determined by primary seal design and/or customer requirements Side Entry — © _penotes possible temperature Side Entry measurement locationskal TIME vs. TEMPERATURE RESPONSE TEST This test represents an instantaneous temperature rise from 32°F/0°C to 212°F/100°C. Response time is shown for two designs of thermometry: A) Pipewell with heat transfer block B) Gayesco Flex-R® technology RESPONSE TIME TESTING 200 40 120 100 Temperature (°F) | 0 % 0 2 . Flex-R® si Heat Transfer Block 0 0 ws oO eo 10 120 100 veo 100200 azo Time(Seconds)kama CHANNELING EFFECT CONVENTIONAL FLEX-R® — = CHANNELING EFFECT ae —— INTENDED FLOW PATH PIPEWELL. T/C PT. We PT. Wert. FLOWkam Gayesco Single Sheath Radial Reactor Thermometrykage Gayesco Enhanced Multipoint Assemblies Specification Sheet Gayesco Enhanced Multipoint (GEM) Assemblies are used all over the world for temperature measurement solutions. Gayesco offers the ability to choose the independent, reliable, and repositionable, Flex - R®, or to maximize information points with the Gayesco Single Sheath with multiple junctions in a single sheath, or to combined both technologies into a single assembly for a tailor made solution. GEM assemblies include © All welded construction ©. Primary and Secondary seals © Instrument connection for checking integrity of seals and seal chamber ° Safety Tra Flex - R™ Gss—4 GSS - 9) Sheath O. D. he 1g we # of Measuring Junctions Possible Single or Duplex Upto4* Upto9* Sheath Thickness 060 070 070 Conductor Size 054 032 032, Insulator MgO. MgO MgO. + iis posbe omnia he GSS —4 upto 16 measuring junctions and maximize the GSS ~9 yp to 36 messing jnctions. This eques certain rae of in desig whch your erecettive can ast you wih, ‘A variety of metallurgies are available for both the flange assemblies and the thermocouple sheaths. ‘Thermocouples are available in a variety of thermocouple types. Flex - R™ GSS -4 GSS - 4 GSS -9 GSS -9 Points ina | Sheaths ina | Points ina | Sheaths ina | Points ina GEM GEM GEM GEM GEM System System System System System Size __| Schedule Assembl Assembly | Assembly | _Assembl Assembl) i= 80 4 | 4 1 9 2 80. 26 28 6 34 mz 160 48 76 13 17 a8 80 50 92 19 i a" 160 50+ 132 30 270 a 80 50+ 172 37 333 mn request Gayesco is an ASME U and R manufacturer, Other inspections are provided For more information contact Gayesco LLC: 2859 Westside Drive Pasadena, TX 77502 Ph 713 941 8540" Fax 713 9443715 virserson@eavesco.com Gayesco Enhanced Multipoint Assemblies-ations include but not limited too: 000000000 Hydroprocessing ( including Hydrocracking, Hydrotreating, and Low Sulfur Fuels) Isomersization Reactors Catalytic Reforming Regenerators Fractionation Columns (including Crude, FC Contactor Columns ( Including Amine) Fixed Bed Reactors Syngas Reactors (Shift and Methanation) ‘Cumene Styrene ind Petrochemical) Connection Nozzle Type (Flanged / Other) Size, Schedule, and Rating Facing Metallurgy Thermocouple Options Flex—R® Seal Chamber = eae =H \ 2. Ther yocouple Sheath 1, Measuring EP asteee t — Flange Safety Transition $$ Lead Wires ween ISA Type___Thermocouple (Single/ Duplex), (grounded/ ungrounded) Sheath Metallurgy Stainless Steel Epoxy — Potted, Safety Transition GA., Thermocouple leads dimension to be determined in conjunction with Gayesco Project Services Staff. Tfheigl Lead Wires Thermocouple Sheath + Flange + Seal Chamber =F) HF “~~ ——_ 43 — oe | Common Safety Trau t— Measuring Junctions (up to4)__ISA Type _Thermocouple (ungrounded) Sheath Metallurgy Stainless Steel Epoxy — Potted, Safety Transition __GA., Thermocouple leads “L” dimensions to be determined in conjunction with Gayesco Project Services Staff, yaeneGss—9 Lead ye Wires tH A + Flange Thermocouple Sheath ft a” Seal Chamber 7 nL * tr ss — 16" — — 47 "Le" Common Safety 9 ‘ arene Measuring Junctions (# up 0 9) ISA Type __ Thermocouples (ungrounded) Stain weeNe Sheath Metallurgy nless Steel Epoxy ~ Potted, Safety Transition GA., Thermocouple leads dimensions to be determined in conjunction with Gayesco Project Services Staff.Hybrid Solutions for Radial Multipoint Reactor ThermometryGayesco Enhanced Multipoints Hybrid Options The Flex — R", Gayesco Single Sheath, and Flex -O™ Pipewell systems are custom designed for your application by the experienced design staff at Gayesco. An additional level of customization can be a hybrid assembly, blending two or more of the options to create the best solution for your application, Standard Hybrid Options include; + Flex —R", flexible, independent thermocouples. + Gayesco Single Sheath with multiple junctions in a single sheath + Pipewells with Flex - O™ multipoint pipewell assemblies. Depending on the application, other hybrid options maybe available as well. Consult your representative for additional information. All Gayesco Enhanced Multipoints include; + All welded construction: + Primary and Secondary Seals * Leak detection chambers ‘The Gayesco design team is the most experienced team in the industry at designing moder temperature measurement systems to fit a variety of needs. From simple low pressure, low temperature applications to demanding, complex, high temperature, high pressure processes, Gayesco can design a system for you.kal FLEX-O™ and Purge Tube FLEX-O™ Multipoint Pipewell Reactor Thermometry Systems4am The Flex-O™ Thermocouple Assembly4am INHERENT DESIGN CHARACTERISTICS OF THE PATENTED FLEX-O™ THERMOCOUPLE SYSTEMS Flexibility ‘Traditional long, non-flexible multipoints present problems in shipping, storage and installation. They must be shipped on large trucks, stored in sizeable spaces, and installed using a crane with a boom at least twice the height of the vessel. The FLEX-O™, on the other hand, may be coiled due to it’s spiral construction. It can also be installed with ease because of the bimetal strips at each point. Shipping and storage are no problem with the FLEX-O™, which is coiled in crates measuring 7’x7'x2’. More importantly, handling is easy: two men may conveniently uncoil and insert a FLEX-O™ into either top or bottom entry vessels without the use of heavy equipment. Replaceability The bimetal strip design allows removal and replacement of the thermocouples during operation, ‘The strip produces a pressure of § p.s.i between the thermocouple tip and thermowell wall at process temperatures. This pressure is adequate for accurate temperature measurement without impeding removal during vessel operation, should this become necessary.BIMETALLIC STRIP The FLEX-O™ multipoint thermocouple assembly mounts an individual thermocouple on a birhetallic strip composed of two dissimilar metals with different coefficients of expansion. The strip remains flat at ambient temperature, but bends outward as the process temperature rises. The thermocouple is thus forced against the pipewell wall when the reactor is operational, but they retract during shutdown.akg RESPONSE TIME Due to the low mass at the sensor tip, the FLEX-O™ has a substantially faster response time than other pipewell multipoint designs. The data below illustrates this point. RESPONSE TIME TEST THERMOCOUPLE - |/8" OD RESPONSE - 63.2% OF STEP CHANGE FROM 32°F TO 212°F PIPEWELL SCHEDULE WALL THERMOCOUPLE | RESPONSE TIME SIZE IN NO. IN. ARRANGEMENT | nny SEC 3/8 OD 0.120 NOTE A 0 15 11/4 PIPE 10 0.109 NOTE B o 42 11/4 PIPE 40 0.140 NOTE B It 03 11/4 PIPE 80 0.191 NOTE B 1 38 11/4 PIPE 10 0.109 NOTE C 2 7 11/4 PIPE 40 0.140 NOTE C 2 48 11/4 PIPE 80 0.191 NOTE C 3 23 NOTEA — THERMOCOUPLE IS BOTTOMED IN TUBING WELL. NOTEB — GAYESCO FLEX-O™ DESIGN, WITH THERMOCOUPLE FORCED. AGAINST THE INNER WALL OF THE WELL BY A BIMETALLIC STRIP NOTEC — THERMOCOUPLE IS BOTTOMED IN A GUIDE TUBE, THE END OF WHICH IS WELDED TO A HEAT-SINK BLOCK, WHICH IS IN TURN WELDED INTO THE WALL OF THE PIPEskein THE FLEX-O™ THERMOCOUPLE ASSEMBLY Secondary Seal A special, patented secondary seal can be designed into each FLEX-O" assembly. This design prevents contact of the process with the atmosphere in the event of thermowell failure, resulting in protection for both the process and the operators. EXTENSION WIRE TRANSITION THERMOCOUPLE THIS PRODUCT I5 COVERED BY ONE OR MORE OF THE FOLLOWING PATENT NUMBERS: ‘ADDITIONAL PATENTS PENDING 20+k.gapt THE FLEX-O™ THERMOCOUPLE ASSEMBLY Warpage Problems Mit ized Pipewell warpage is, unfortunately, a common occurrence in reactors. High process temperatures and shifts in the catalyst bed are the usual causes of well warpage. Occasionally, design requirements even necessitate the installation of a curved pipewell. The performance of the FLEX-O™ in these situations is unparalleled. The small diameter, spiral arrangement, bimetallic strips, and flexibility all contribute to easy installation in all but the most severely damaged wells. This saves the expense and trouble of well replacement and reactor shutdown by making usable wells out of those that would otherwise have to be replaced. 21ASSUME: TEST DATA: TOTAL DRAG FORCE TOTAL WT OF ASSY BELOW SEAL PLATE TOTAL FORCE TO REMOVE AREA OF 3/16” CENTER POST STRESS WHEN STARTING TO. REMOVE FLEX-O™ CONCLUSION: kgs DRAG FORCE STRESS ON FLEX-O™ WHEN REMOVING FROM A PIPEWELL OPERATING AT 950°F 2 A 20-point | 3/8” FLEX-O™, 100’ long in a | 1/2” Sch. 80 pipewell Takes 90 seconds (average of five tests all about the same) for T/C to begin to initiate a drag force. After 2 1/2 minutes, the ultimate drag resulted in a force of 7Ibs to pull out or remove from pipewell. 7x20 = 140 Ibs 50 Ibs 190 Ibs 0.028 sqin 190 O02 = 6786PS! A100" long FLEX-O™, in operation at 950°F, could be removed from its well with a pull force of 190 Ibs. This would result in a stress on the center post of 6800 psi, assuming that the center post took all the force. Even so, sucha stress is less than 1/2 of the yield point 950°F. Insertion of the same assembly at an average rate of | ft/sec would be accomplished with no discernible resistance. After a total insertion time of about 2 min., 15 sec., the drag would equal the weight, and the remainder of the FLEX-O™ would require downward push to move any remaining length into thermowell. n(aT wale ~ a zi EEO EE] WN ow oly ASSY TIEN3éld ® O-HS “id ~~ Be ar ‘unvamao Sr1¥s® aNnezaNroNT 479 me a le ar 2 = wanna i EOPEvEDpE sdeuces i i ee loc % i easTHE PURGE TUBE FLEX-O™ DESIGN HISTORY The Flex-O™ design allows for temperature measurement at various levels throughout.a reactor with the use of multiple sensing points; and it does so while offering a flexibility feature that makes installation easier, Additionally, the flexibility ensures that the bimetallic activated Multipoint design remains in continuous contact with the ID of the pipe well. These characteristics, as well as Flex-O"'s replaceabilty, speed of response, bimetallic actuation, and point density, have made this design a standard used throughout the industry. PURGE TUBE DESIGN The Purge Tube Flex-O™ incorporates a purge system into Gayesco's patented Flex-O™ Multipoint thermocouple design. The result is a unique product offering superior reliability, utility and safety. (Refer to Figure |, Page 19) .€ incorporation of a purge system within the Flex-O™ provides four design factors packaged into a single assembly: ‘+ Multipoint multilevel temperature sensit Maximum flexibility; ‘+ Purging of well contaminants; + Internal pipe well pressure relief. The typical multipoint design usually encapsulates the thermocouples into a protective pipe well installed into the vessel. In the interest of safety, the Flex-O™ thermocouples are pressure sealed as they exit the protective well to contain any pressure leakage due to pipe well failure. 1) One disadvantage of using a secondary sealed or partially sealed well, however, is that accumulations of corrosive elements may, in time, form at certain locations within the well. These usually reach highest eoncentration levels in areas where the temperature « dient is the highest (such as in primary nozzle area out side the reactor). If this situation occurs, the result could be deterioration of thermocouple sheaths (due to chloride stress corrosion as an example) or premature failure of the pipe well ey) 2) An additional safety concern involves migration of the hydrogen, from the process into the pipe well, resulting in the internal pipewell pressure build up. Because the pipewellisa sealed system which remains at the pressure even when the reactor is down for maintenance, a risk of an accident is high if personnel in the area are not aware of this phenomenon. Placement of a purge tube directly within the Flex-O"’s protective well minimizes these problems by allowing safe venting of this explosive gas. The additional employment of check valves in the system enhances the advantages of the secondary seal system. The incorporation of the purge system directly into the Flex-O™ posed a two-fold design challenge: it had to be such that it would not add limitations to the flexibility of the system; and it could not decrease the number of thermocouples that could be supplied in the bundle. In short, the systems designers wanted all the advantages of the internal purge systems without sacrificing the flexibility, accuracy, or response characteristics of the Flex-O™ temperature measurements system. ‘To accomplish this, the center support member used as the “flexible backbone” of the Flex-O™ system was replaced with a single, heavy wall center support tube. This tube not only effectively provided a conduit for introduction of a purge gas into the well, but it succeeded in doing so without inhibiting the desired flexibility characteristics. It was also important in designing the Purge Tube Flex-O™ that the purge gas to be introduced near the bottom of the well, and then exit through a purge outlet outside the vessel. The spent purge gas could then be vented to atmosphere or a suitable disposal area. CONCLUSION With the enhanced design features of the Purge Tube Flex-O™ users of pipe well based, temperature ‘measurement systems have a effective tool for improving temperature measurement while increasing safety and life of the sensors.lk gral PURGE TUBE FLEX-O™ fee OYE CVO rT Eel at eerie ser) FIGURE | 25kg INSTALLATION INSTRUCTIONS FOR THE FLEX-O™ AND PURGE TUBE FLEX-O™ THERMOCOUPLE ASSEMBLIES GENERAL These assemblies are normally designed in such a manner that the thrust weight of the assembly is carried through center post to a support plate or seal plate between flanges on the outer end of the pipewell. For details of the method of securing the support plate or seal plate, refer to the drawing specifically certified for your own installation, Because of the nature of bimetallic support member provided for each thermocouple tip, at a normal ambient temperatures each thermocouple tip will be retracted. Normally, contact is made between the thermocouple tip and the inner wall of the well at an operating temperature of 200 °F to 250 °F I INSTALLATION OF THE ASSEMBLY From the foregoing, it follows that insertion of the assembly into the well at a normal ambient temperatures causes no rubbing between the thermocouple tips and the well. On occasions when insertion must be made at operating temperatures, the bimetallic support members will rapidly move out to cause contact of the thermocouple's tips with the inner wall of the well as the assembly is being inserted, Therefore, the assembly should be inserted as rapidly as possible while avoiding jamming the individual “spider” assemblies as they enter the well. If sudden resistance is encountered, slow rotation of the entire assembly while maintaining length wise thrust will often allow the bundle to pass beyond the internal obstruction. Il, REMOVAL OF THE ASSEMBLY As in the case of installation, removal of the assembly should be accomplished whenever possible under normal ambient conditions, If the removal must be done under operating temperatures, it should be withdrawn slowly. If sudden obstructions are encountered, slowly rotate the entire assembly while continuing to maintain a moderate pull 2%4am Mini-Multipoint Thermocouple Assemblieskann MINIMULTIPOINT THERMOCOUPLE ASSEMBLY Minimultipoint thermocouple assemblies are generally small diameter, individual sensing probes which measure temperature at different positions or elevations. Each individual probe is protected with a stainless steel (or other alloy) sheath, These probes may then be contained in a protective tube, These assemblies are used when a temperature profile is desired and mass, or size, of the probe is a limitation. These assemblies can be constructed in a wide variety of configurations. Foyer sven i é ere ITEM|QTY DESCRIPTION NZ [TEMPERATURE SENSORS (THERMOCOUPLES) N/A [COMMON HOUSING. N/A [PROTECTIVE TUBING N/A [FLEXIBLE LEADWIRE N/A [STABILIZING TUBE Jon] feo fro || APPLICATIONS: Minimulipoint thermocouple assemblies are used in a number of different applications. Some of the more common uses are: a“ ‘Tube Sheet Reactors * Pilot Plant Temperature Measurement . Food Preparation dition it is possible in some applications to add a traversing ability to the temperature measurement assembly. This allows for continuous data to be collected over the distance of the traverse stroke, This feature can help gather important information relating to catalyst or process activity. These traversing units can be electrically driven with precise feedback on position. 28ami Tube Sheet Reactor: This application requires vertical profiles within one or more catalyst filed tubes through which a process stream flows. During the passage through the tube a temperature gradient is produced. This temperature gradient dataiis often critical information for optimum performance of the process. This data can help maximize throughput and insure product quality. Important design features include: ‘+ Minimize catalyst loading problems + Maintenance problems can be minimized with use of designs which allow removal of temperature assembly without disturbing catalyst or process. + Low mass designed to avoid influencing process conversion and temperatures. + Proper centering in catalyst tube for accurate process temperatures. lot Plant Temperature Measurement: This application includes process demonstration units and research. Since temperature data is critical to understanding a new or modified process the sensor system must be carefully desigr and manufactured. In pilot plant operation the sensors must also be scaled down in order to not influence the reactions taking place. At the same time it is important that the data taken be accurate. These important factors which must be taken into account during design. Important Design features include: + Low mass * Accurate temperature readings-Sensors can be comparison tested with N.I.S.T. traceable standards. + Low cost Food Preparation: This application requires flexibility in point placement and consistency of readings. This allows even temperatures in baking or chilling operations to be monitored for product uniformity. 29For More Information call Gayesco® Phone (713) 941-8540 or Fax (713) 944-3715 Web Site: www.gayesco.com e-mail : gayesco@gayesco.com Gayesco® © All Rights reserved Published January 2007