Daily Thermetrics _ Reactor Temperature Measurement _ January 28 2013

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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 THERMETRICS


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


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


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?


VESSEL SURFACES

Vessel Skin Sensors

HEATERS & FURNACES

Thermowells & Sensors

Technical Services

Design & Field Engineering

DAILY THERMETRICS

UPGRADE & REVAMP SOLUTIONS

FRACTIONATOR & REACTOR 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

WORLD WIDE EXPERIENCE

REACTOR & FRACTIONATOR THERMOMETRY


IDENTIFYING REACTOR ASSETS

Catalytic Processing Units: Key Investments


VESSEL /

ASSOCIATED COMPONENTS

INTERNALS,

MECHANICAL

CATALYST

WHICH INVESTMENTS REQUIRE

ADVANCED MONITORING?

(Concepts we already know.)

IDENTIFYING REACTOR ASSETS

Catalyst Investment


CATALYST

REOCCURING INVESTMENT Significant Consumable Investment

PERFORMANCE Reduce / Increase Production depending on Utilization and Condition

3 Critical Components for Properly Operating Reactors


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


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




1st GENERATION RADIAL PROFILING

TECHNOLOGY LIMITATIONS: SIGNIFICANT HARDWARE

1st GENERATION FLEXIBE SENSORS


IMPROVEMENTS





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


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


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?



IMPROVEMENTS


ACCURACY IMPROVED


PresenterPresentation NotesSubstantial improvement in reactor performanceConsiderable mechanical and safety advantagesLower total operating costs

Aerospace Technology



IMPROVEMENTS


ACCURACY IMPROVED



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.



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


IMPROVEMENTS


ACCURACY 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


$20,000-$65,000 Cost Savings per Nozzle


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


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.


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


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


IMPROVEMENTS


ACCURACY 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.


IMPROVEMENTS


ACCURACY 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.





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


ACCURACY 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


ACCURACY 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


Standard Accuracy +/- 3.2 C at 427C

Special Limits +/- 1.6C at 427C

Daily Thermetrics Accuracy +/- .80C at 427C


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:


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?


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.




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

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Daily Thermetrics _ Reactor Temperature Measurement _ January 28 2013

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