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Monitoring Catalytic Reaction Efficiency with Advanced Temperature Measurement System Upgrades
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Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
Eric Heidt, Senior Technology Manager
Daily Thermetrics
a division of Daily Instruments Corp.
CATTRACKER Catalyst Tracking Technology
Monitoring Catalytic Reaction Efficiency with Advanced Temperature Measurement System Upgrades
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
Advanced Process Control for the Process Industry
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
DAILY THERMETRICS
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
Since 1973
PresenterPresentation NotesFirst, a little about who we are.
Who here is familiar with Daily Thermetrics, or has worked with us in the past?
(probe anyone that answers in the affirmative to see what products they may have used and how their experience with us was. If they have CatTrackers or other products in service, ask how they are working. Take advantage if you have someone that is already happy with Daily products.)
Daily Thermetrics specializes in the design, engineering, and manufacture of temperature instrumentation for the refining and petrochemical industry. We are recognized global leaders in this field, and offer a full portfolio of products and services to meet your needs. We have been specializing in this industry since 1973, and bring an enormous accumulation of knowledge and experience to utilize as a resource for our customers.
High Quality Instrumentation
Industry Leading Technologies
Demanding Applications
Specialized Industries
Highly Engineered
DAILY INSTRUMENTS
ISO : 9001 CERTIFIED QUALITY ASSURANCE
DAILY THERMETRICS
DAILY THERMOCONTROL
L
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
PresenterPresentation NotesThermocontrol is a small but very high-end aerospace thermometry manufacturer. Since the early 1980s it has supplied thousands of very highly technical thermocouples on about 100 different engines and engine versions.
At its founding, the major supplier of aerospace thermometry took a different business focus, and Thermocontrol hired several of their top people, including several engineers, the head of quality, and the head of manufacturing. These people were relocated from the east coast of the US to California. They also hired several top aerospace engineers and manufacturing heads from the then vey large California aerospace market. From this they built a very high quality technically superior aerospace thermometry company. The company was acquired by Daily Instruments in 1989.
I would also like to point out that we are an ISO 9001:2008 Certified company. As we discuss Daily Thermetrics commitment to quality products, I want you to realize that our high level of quality is neither by accident, nor by random.
Reactor Accessories
Vessel Skin Sensors
HEATERS & FURNACES
Thermowells & Sensors
Technical Services
Design & Field Engineering
DAILY THERMETRICS
Product Offerings, Advanced Solutions
REACTOR THERMOMETRY
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
PresenterPresentation NotesProper degin intstall is needed we have filed engineersTube skin engineers specialized on thisDifferent business units specialized on their areathermowell sensors even there we have key differentiatorsOutside of the reactor industry leading ideas innovative solutions for this
PROCESS LICENSOR RECOGNITION
Which PROCESS LICENSORS recognize Daily Thermetrics as specialists in downstream thermometry?
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
VESSEL SURFACES
Vessel Skin Sensors
HEATERS & FURNACES
Thermowells & Sensors
Technical Services
Design & Field Engineering
DAILY THERMETRICS
UPGRADE & REVAMP SOLUTIONS
FRACTIONATOR & REACTOR THERMOMETRY
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
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
WORLD WIDE EXPERIENCE
REACTOR & FRACTIONATOR THERMOMETRY
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
IDENTIFYING REACTOR ASSETS
Catalytic Processing Units: Key Investments
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
VESSEL /
ASSOCIATED COMPONENTS
INTERNALS,
MECHANICAL
CATALYST
WHICH INVESTMENTS REQUIRE
ADVANCED MONITORING?
(Concepts we already know.)
IDENTIFYING REACTOR ASSETS
Catalyst Investment
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
CATALYST
REOCCURING INVESTMENT Significant Consumable Investment
PERFORMANCE Reduce / Increase Production depending on Utilization and Condition
3 Critical Components for Properly Operating Reactors
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
REACTOR
Internals THERMOMETRY Catalyst
DAILY THERMETRICS
Reactor Components
OFTEN TIMES MINIMALIZED
3 Critical Components for REACTOR THERMOMETRY
SENSOR AVAILABILITY Is there sufficient quantity of sensors to properly troubleshoot, plan, and justify future investment?
SENSOR ACCURACY Does the sensor provide the highest level of confidence of the actual reaction temperature? SENSOR RELIABILITY Does the sensors life represent a maintenance cost or a long term investment?
PresenterPresentation NotesYour reactor is like a three-legged stool. For it to work to its best ability, you have to have all three critical components working together for maximum benefit.
Get agreement regarding the important decision making made in INTERNALS and CATALYST.
Get agreement that THERMOMETRY is the key 3rd leg.
EVOLUTION: REACTOR THERMOMETRY
MEASUREMENT: INLET, OUTLET, & WABT
Single INLET Temperature Measurement
Single OUTLET Temperature Measurement
Weighted Average Bed Temperature
EVOLUTION: REACTOR THERMOMETRY
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
EVOLUTION: REACTOR THERMOMETRY
MEASUREMENT: PIPE WELL/THERMOBAR MULTI-POINT
TEMPERATURE VISIBILITY at Measurement Elevations
EVOLUTION: REACTOR THERMOMETRY
MEASUREMENT: RADIAL PROFILING
RADIAL TEMPERATURE PROFILING
Process Licensor Specifications for NEW Reactors
EVOLUTION: REACTOR THERMOMETRY
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
YEAR 1987: MEETING RADIAL SPECIFICATIONS
IMPROVEMENTS
AVAILABILITY IMPROVED
ACCURACY NO IMPROVEMENT
RELIABILITY NO IMPROVEMENT
1st GENERATION RADIAL PROFILING
TECHNOLOGY LIMITATIONS: SIGNIFICANT HARDWARE
1st GENERATION FLEXIBE SENSORS
YEAR 1987: MEETING RADIAL SPECIFICATIONS
IMPROVEMENTS
AVAILABILITY IMPROVED
ACCURACY NO IMPROVEMENT
RELIABILITY NO IMPROVEMENT
EVOLUTION: REACTOR THERMOMETRY
MEASUREMENT: 2nd GENERATION RADIAL PROFILING
NEWEST GENERATION FLEXIBE SENSORS YEAR 2001: MEETING RADIAL SPECIFICATIONS
PATENT # 6,550,963 & 6,599,011 / CANADA & EU PATENT PENDING
IMPROVEMENTS
AVAILABILITY IMPROVED
ACCURACY IMPROVED
RELIABILITY IMPROVED
v.2012 CatTracker
1. Ultra High Accuracy 2. Ultra High Precision 3. Maintenance-Free, Repair-Free Technology 4. Extended Life 5. Patented, aerospace-derived technology
with up to nine (9) measurement locations along each sheath/probe
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
PresenterPresentation NotesWe have patented techPatented technology directly relative to our aerospace
The CatTracker is a thermocouple that combines the performance of aerospace technology and the efficiency of nine points per tube.
WHAT IS THE CATTRACKER?
MEASUREMENT: 2nd GENERATION RADIAL PROFILING
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
IMPROVEMENTS
AVAILABILITY IMPROVED
ACCURACY IMPROVED
RELIABILITY IMPROVED
PresenterPresentation NotesSubstantial improvement in reactor performanceConsiderable mechanical and safety advantagesLower total operating costs
Aerospace Technology
WHAT IS THE CATTRACKER?
MEASUREMENT: 2nd GENERATION RADIAL PROFILING
IMPROVEMENTS
AVAILABILITY IMPROVED
ACCURACY IMPROVED
RELIABILITY IMPROVED
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
PresenterPresentation NotesOne point per engine keeping the plane in the air.
Aerospace Technology
9 Points Per Tube
PresenterPresentation NotesThe advantages I have outlined today are only available with by using 2012 CatTracker technology. These advantages include combining the performance of aerospace technology with the efficiency of nine points per tube, thus achieving substantial performance improvements, and considerable mechanical advantages. As an added benefit, the service and engineering exceptionalism that I have pointed out during this presentation is only available from Daily Thermetrics.
PATENT # 6,550,963 & 6,599,011 / CANADA & EU PATENT PENDING Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
WHAT IS THE CATTRACKER?
MEASUREMENT: 2nd GENERATION RADIAL PROFILING
PresenterPresentation NotesI am here to discuss the SUPERIOR TECHNOLOGY in the market today.the CatTracker.
Resolves:Decreases hardware usage for both measurement sensors and support
2.Significantly increases sensor reliability
3.Creates a new standard relating to an aspect of temperature measurement never approached before:
Precision of any one sensor in relation to all sensors used to monitor the catalyst bed
Number of Tubes Required: 45 Sensing Points
Out -Dated Technology
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
IMPROVEMENTS
AVAILABILITY IMPROVED
ACCURACY IMPROVED
RELIABILITY IMPROVED
PresenterPresentation Notes As you can see from the picture, the CatTracker requires a minimal number of tubes/sheaths to achieve the desired point density.
This means you can get a much more comprehensive sensing profile through a much smaller nozzle. In fact, we can get as many as 72 sensing points through a 3-inch ID nozzle. No other technology can accomplish this and still provide the robustness required for hydrocracking or hydrotreating operations . And we will still have our process seal at the flange face where it belongsan important feature that we will discuss in a moment.
REDUCING NOZZLES
REDUCING COSTS
Reactor Optimization
PATENT # 6,550,963 & 6,599,011 / CANADA & EU PATENT PENDING
$20,000-$65,000 Cost Savings per Nozzle
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
PresenterPresentation NotesNEW reactor vessel cost savings!! $$$$
-Engineering hours-Manufacturing labor-Material cost (wiring, nozzles, platforms, etc)
Safety-More nozzles = more leak points
Daily has engineers to assist and help recommend in your reactor design, at no cost
ONLY DTC is authorized by Axens & CLG to reduce the number of nozzles in the engineering/design phase.
Case Study: Recent Hydrocracker project, Foster Wheeler Houston stated the savings on reducing one nozzle near $50,000.
2nd GENERATION RADIAL PROFILING
CatTracker Catalyst Tracking Solutions
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
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.
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
PresenterPresentation NotesSAFETY for starters!
All of the live process stays inside the reactor ALWAYS with the CatTracker. We will NEVER bring live process outside the reactor before making our primary process seal. Our primary pressure boundary will ALWAYS be at the flange face, where it belongs.
We have fewer obstructions in the reactor to interfere with catalyst loading and unloading. Less for workers to step on, or trip on. Fewer fragile components inside the reactor to be broken during maintenance.
And we have fewer potential leak paths. Every tube means a seal weld, which is a potential leak path. Bringing live process outside the reactor flange , with the ensuing weight of the apparatus required to do so, places additional strain on the area around the flange and increases potential for failure.
The heavy-wall design of each of our tubes provides much better protection against sheath failure inside the reactor, and our MUCH higher insulation compaction, which we will discuss in a moment, provides a FAR superior migration barrier if there should be an actual sheath failure.
There is no Reactor Thermometry system available that offers such comprehensive mechanical protection against failure.
World Class Manufacturing Facility
Over 260 feet of vacuum, baking and annealing ovens 140 foot continuous baking oven
Extensive CNC and Swiss machines
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
PresenterPresentation NotesGet better pictures
with automated welding equipment
All CatTracker thermocouple tube welds are made with computer controlled automatic welders
All CatTracker measuring junctions are made with computer controlled equipment
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
IMPROVEMENTS
AVAILABILITY IMPROVED
ACCURACY IMPROVED
RELIABILITY IMPROVED
Concentric Live Micro-Focus X-Ray High-Definition Digital X-Ray Display
(Hot Junction)
Pass
Reject Porosity - Not Visible to the
Naked Eye
and state of the art calibration and test equipment.
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
IMPROVEMENTS
AVAILABILITY IMPROVED
ACCURACY IMPROVED
RELIABILITY IMPROVED
PresenterPresentation NotesDaily Instruments has an on-site X-Ray Facility and implements 360 concentric live feed X-Rays on ALL hot and cold junctions.
Note:X-Ray performed AFTER swaging
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.
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
PresenterPresentation NotesYour reactor is like a three-legged stool. For it to work to its best ability, you have to have all three critical components working together for maximum benefit.
Get agreement regarding the important decision making made in INTERNALS and CATALYST.
Get agreement that THERMOMETRY is the key 3rd leg.
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
PresenterPresentation NotesYour reactor is like a three-legged stool. For it to work to its best ability, you have to have all three critical components working together for maximum benefit.
Get agreement regarding the important decision making made in INTERNALS and CATALYST.
Get agreement that THERMOMETRY is the key 3rd leg.
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
PresenterPresentation NotesTransition housing from our senior engineers for moisture barriers
Silver braze, two stage epoxy, first epoxy test it , epoxy injuction under vacuum eleminate voids..dryness noone can offer.
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.
0
5
10
Industry Standard Daily
Thermetrics
1
10 IR Pass/Fail Criteria
Gigaohms at 500V at ambient temperature
1 G at 500V at ambient temperature
10 G at 500V at ambient temperature AFTER a water submersion period of
10 minutes is performed
IMPROVEMENTS
AVAILABILITY IMPROVED
ACCURACY IMPROVED
RELIABILITY IMPROVED
PresenterPresentation NotesMinimum cut off is 10 times than competitors 10 yrars///
360
365
370
375
380
385
390
395
700
710
720
730
740
750
760
770
780
790
800
Tem
pera
ture
(C)
Tem
pera
ture
(F)
Time
Too Hot Coking
Overproduction of Lights Reduced Yield Value
Exotherms Upset Propensity
Too Cold Below Optimum Conversion
Optimum Temperature
REACTOR THERMOCOUPLES
Whats the importance?
Accurate Measurement allows for Accurate Inlet Temperature Control Decisions
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
Standard Accuracy +/- 3.2 C at 427C
Special Limits +/- 1.6C at 427C
Daily Thermetrics Accuracy +/- .80C at 427C
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
ULTRA HIGH ACCURACY
Daily Thermetrics Corporation (EXCLUSIVE OFFERING)
Up to 4X MORE ACCURATE than previous generation sensors
Normal Thermocouple
Normal Thermocouple
Special Limits of Error
Special Limits of Error CatTracker
+3/4% TOLERANCE
+3/8% TOLERANCE
SPECIAL LIMITS
STANDARD LIMITS
1C MAX
At 427C:
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
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
PresenterPresentation NotesThis is how we achieve that.
Aerospace Proven Technology
Type K thermocouple (beyond 530F)Standard Limits of Error = +/- %Special Limits of Error = +/- 3/8%
CatTracker will always be in the Special Limits of Error tolerance. But we dont stop there.
The CatTracker is engineered & designed such that the temperature readings are within 1C at 427C and verified using calibration testing per ASTM E 220.-100% Special Limits of Error-100% Matched Lot TCs for each reactor (all Chromel from same lot, all Alumel from same lot)-Proprietary Manufacturing Processes
Our design criteria is 1C, but our calibration data is seeing 1F.
DTC calibrates 100% of our CatTrackers as part of our Quality Management system, regardless if client requests it.
Note: Typical TC type is K, but Daily can use ANY type.
Background Info:Per ASTM E 839-03:Type E and K thermoelements will have changes in thermoelectric homogeneity produced by exposure to temperatures in the 320 to540C (608F-1004F) temperature range. Calibration of Types E and K thermocouple assemblies should be regarded as a (possibly) destructive test for subsequent use of the thermocouple assembly. Type E or K thermocouple calibrations should be used only to characterize a production run.
Actual results for every CatTracker produced:1 One sigma: degree F (one sigma is 68.3% of all items produced)Two sigma: 1 degree F (two sigma is 95.4%) (About 1/2 degree C)Three sigma 1.6 degree F (three sigma is 99.7%Four is 99.993666Five is 99.999942Six is 99.9999998We are still gathering and analysis. The current results are heavily loaded in the better than degree F at three sigma due to improved manufacturing processes and procedures and more accurate testing. This is twice as good as the degree C number shown above.1 degree F equals .55 F at 800 F1 degree C equals 1.8 degrees F at 427 C (800.6 F)
SENSOR AVAILABILITY Is there sufficient quantity of sensors to properly troubleshoot, plan, and justify future investment?
SENSOR ACCURACY Does the sensor provide the highest level of confidence of the actual reaction temperature? SENSOR RELIABILITY Does the sensors life represent a maintenance cost or a long term investment?
Daily Instruments Corporation. All Rights Reserved. Any unauthorized distribution or disclosure is prohibited.
THERMOMETRY
DAILY THERMETRICS
Revisited: Reactor Thermometry Components
3 Critical Components for REACTOR THERMOMETRY
2ND GEN. CatTracker OFFERS: As much as NINE TIMES (9X) MORE sensors using the same quantity of equipment as 1ST GENERATION systems.
Up to FOUR TIMES (4X) MORE accurate than standard 1ST GENERATION systems. REPAIR FREE, maintenance free operation backed by an industry leading 10 year warranty.
PresenterPresentation NotesYour reactor is like a three-legged stool. For it to work to its best ability, you have to have all three critical components working together for maximum benefit.
Get agreement regarding the important decision making made in INTERNALS and CATALYST.
Get agreement that THERMOMETRY is the key 3rd leg.
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.
Slide Number 1Slide Number 2Slide Number 4Slide Number 5Slide Number 6Slide Number 7Slide Number 8Slide Number 9Slide Number 103 Critical Components for Properly Operating ReactorsSlide Number 12Slide Number 13Slide Number 14Slide Number 15Slide Number 16Slide Number 17Slide Number 18Slide Number 19v.2012 CatTrackerSlide Number 21Aerospace TechnologySlide Number 23Slide Number 24Number of Tubes Required:45 Sensing PointsSlide Number 26Slide Number 27Slide Number 28SafetyWorld Class Manufacturing Facilitywith automated welding equipmentSlide Number 32Slide Number 33Slide Number 34New for 2012:Ralexian Transition DesignSlide Number 36Slide Number 37Standard Accuracy+/- 3.2 C at 427CSlide Number 39Slide Number 40Slide Number 41