WIKA TC82 Instrucciones de funcionamiento

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

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

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

14486176.01 07/2021 EN/DE

WIKA additional operating instructions for installation of models TC82, TC83 Calitum®

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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WIKA additional operating instructions for installation of models TC82, TC83 Calitum®

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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WIKA additional operating instructions for installation of models TC82, TC83 Calitum®7

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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WIKA additional operating instructions for installation of models TC82, TC83 Calitum®

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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WIKA additional operating instructions for installation of models TC82, TC83 Calitum®9

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.

14486176.01 07/2021 EN/DE

WIKA additional operating instructions for installation of models TC82, TC83 Calitum®

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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