WIKA TC82 Operating instructions
EN
DE
Additional operating instructions
Zusatz-Betriebsanleitung
Additional operating instructions for installation of models TC82,
TC83 Calitum®
Zusatz-Betriebsanleitung für die Montage der Typen TC82,
TC83 Calitum®
Models TC82-F Models TC83-F
EN
DE
2
14486176.01 07/2021 EN/DE
WIKA additional operating instructions for installation of models TC82, TC83 Calitum®
Additional operating instructions models TC82,
TC83 Calitum®
Page
3 - 14
Zusatz-Betriebsanleitung Typen TC82, TC83 Calitum®
Seite
15 - 26
© 07/2021 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
WIKA®is a registered trademark in various countries.
WIKA®ist eine geschützte Marke in verschiedenen Ländern.
Prior to starting any work, read the operating instructions!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!
1. Mounting of the thermocouple in the reactor nozzle 4
2. Mounting of the primary protection tube 5
3. Integrity check 9
4. Horizontal installation 10
5. Purge gas connection 13
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WIKA additional operating instructions for installation of models TC82, TC83 Calitum®3
Contents
Contents
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4
1. Mounting of the thermocouple in the reactor nozzle
For the correct mounting of the thermocouple in the reactor nozzle, please observe the
following instructions and carry out the following steps:
The reactor nozzle must be clean of debris, deposits, welding cinder, etc. The cut-out in
the reactor wall at the bottom of the nozzle must have a diameter of at least 90 mm [3.5 in].
The visible refractory brick lining at the bottom of the nozzle must be level and free of
major damage.The bore through the refractory brick lining with a diameter of 80 ... 82 mm
[3.15 ... 3.23 in] must be clean, centric to the nozzle and at right angles to the flange nozzle.
Attention:
If the bore does not meet the
aforementioned criteria, when the reactor
is starting up, the movement of the
refractory brick lining can lead to a break
in the thermocouple.
The sum of the height of the reactor nozzle and the thickness of the entire refractory brick
lining to the inside of the reactor must correspond to the insertion length of the
thermometer. Deviations can lead to incorrect measurements or damage to the
thermocouple or the model TW83 primary protection tube (first process-side protection
tube).
Insertion length
Insertion
length
1. Mounting of the thermocouple in the reactor nozzle
Supplementary documentation:
▶
This additional operating instructions applies in conjunction with the operating
instructions “High-temperature thermocouples, models TC80, TC82, TC83 Calitum®,
TC84“ (article number 14486177).
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WIKA additional operating instructions for installation of models TC82, TC83 Calitum®5
The total thickness of the refractory brick lining and the length of the straight part of the
primary protection tube must match.
Deviations can lead to damage to the thermocouple or primary protection tube during
operation. If the dimensional deviations exceed 12 mm [0.5 in], the thermometer must not
be installed. In this case, please contact your WIKA contact person to find a solution.
2. Mounting of the primary protection tube
1. Carefully insert the primary protection tube into the hole of the refractory brick lining. The
stop collar of the primary protection tube must lie flat on the refractory brick lining. The
tip of the primary protection tube must protrude approx. 25 mm [1 in] into the
combustion chamber while the sensor is roughly flush with the refractory brick lining.
If any material from the refractory brick
lining has found its way into the nozzle
and there is therefore no flat surface
at the bottom of the nozzle, this must
be removed before fitting the primary
protection tube.
Protection tube length
Thickness of
the brick lining
1. Mounting of ... / 2. Mounting of the primary protection tube
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6
2. Before inserting the thermocouple, check the correct insertion length of the sensor and
insertion depth of the primary protection tube by measuring from the bottom of the
primary protection tube to the flange sealing surface.This length must be
approx. 25 mm [1 in] longer than the insertion length of the thermocouple.
3. Fill the gap between the stop collar and the inner side of the flange nozzle with the
sealing disc or alternatively with the mineral sealing cord.
4. Fill approx. 2/3 of the nozzle with the soft sealing discs.
Insertion length
Insertion length +
approx. 25 mm [1 in]
primary
protection tube
secondary
protection
tube
Sealing discs
soft sealing
discs
{
2. Mounting of the primary protection tube
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5. Now fill the remaining 1/3 of the nozzle with the hard sealing discs, so that the
uppermost hard sealing disc protrudes about halfway above the flange sealing surface
of the nozzle. If necessary, adjust the filling height by removing or adding additional soft
sealing discs.
If the inner diameter of the nozzle is smaller than specified, the hard sealing discs will
not fit and it must be reworked. For this purpose, we recommend using a lathe, making
sure that the dust produced is extracted.
6. Centre the matching flange sealing to the nozzle.
Flange sealing
2. Mounting of the primary protection tube
hard sealing
discs
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8
7. Now, preferably with the help of another person, carefully insert the thermocouple
protection tube into the sealing discs. Make sure that no lateral forces act on the
ceramic protection tube, otherwise the thermocouple could break.
8. The soft sealing discs are pressed together as the thermocouple is installed.
Flange sealing
soft sealing
discs
{
2. Mounting of the primary protection tube
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2. Mounting of the primary protection tube / 3. Integrity check
9. Once the thermocouple is mounted centrally on the flange nozzle, it can be carefully
aligned for the electrical connections and, if necessary, purge gas connections by
turning it. Now fit and tighten the flange bolts using skilled personnel.
10. Now the electrical connections and, if necessary, the purge gas connections can be
made.
3. Integrity check
We recommend carrying out the integrity check of the installed thermocouple after
installation and before commissioning the reactor.This will ensure that no damage has
occurred to the measuring instrument and that the purge gas connection has been made
correctly.
This test should be carried out as soon as possible after the installation of the
thermocouple so that, in the event of a damaged measuring instrument, a replacement
measuring instrument can be supplied before the reactor is commissioned, as it is
generally not possible to replace the measuring instrument during operation.
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10
Setting of the purge gas pressure
The purge gas pressure must be at least 0.25 … 0.35 bar [3.6 ... 5.1 psi] over the maximum
operating pressure of the reactor.
Setting the purge gas flow rate
The suitable flow rate of the purge gas normally ranges around 10 … 12 litres per hour.
Depending on the process an adjustment of given values can be required.The
responsibility rests with the operator.
Functional check of the flushing
Increase the pressure on the pressure controller of the purge gas control panel by about
0.7 ... 1 bar [10 ... 15 psi]. Check that the flow rate on the flow indicator increases.Then
reduce the pressure to the previous setting and check whether the flow rate returns to the
previous value.
The integrity check causes a temporary drop in the measured temperature.
If the flow indicator does not respond to changes in purge pressure, this may be due to the
following:
■
Leakage, causing the purge gas to escape into the atmosphere and not to return to the
flow indicator
■
Breakage of the thermocouple protection tube, causing purge gas to escape into the
reactor and reaction gases to come into contact with the thermocouple, leading to
increasing inaccuracy of the measurement and eventually to complete failure, corrosion
and poisoning of the thermocouple.
■
Blockage of the purge lines by condensed sulphur
This is usually caused by a break in the thermocouple protection tube. An indicator
of this problem may be a visible sulphur deposit on the inner surface of the glass flow
indicator.
4. Horizontal installation
Horizontal installation of the thermometer presents particular difficulties for the installer.
They must support the full weight of the thermometer while inserting it into the nozzle,
without the weight of the thermometer exerting a lateral load on the protection tube, which
is at risk of breakage.
The WIKA model IR80 installation rods offer a simple and safe way to support the heavy
thermocouple during installation and thus minimise the risk of damage or breakage of the
protection tube.
3. Integrity check / 4. Horizontal installation
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