Thermocouple Documentation TEMP-PRO Inc. Project Name: Yura S A - Yura Cement Plant Contract No. 0820208 FLS Equip No: 851.IP851
Attachments: STW-1217 A48 B20-FLS 990309
Sheet 1 Sheet 1-11
Cement Kiln T/C ASM Instruction & Installation Manual
FLSmidth Inc. Document Number: 60072687 Ver. 1.0
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
Instruction Manual
INSTRUCTION AND INSTALLATION FLS PO NO.: 4-0820208-263317A MANUAL CONTRACT NO.: 25-08-20208-910 EQUIPMENT NO.: 851.IP851
TEMP-PRO Inc. • 200 Industrial Drive • Northampton, MA 01060 Telephone: (413) 584-3165 • Toll Free: (800) 991-9093 • Fax: (413) 586-3625 E-Mail:
[email protected] • Web Site: www.temp-pro.com
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
Instruction Manual
INSTRUCTION MANUAL Operation And Maintenance Instructions 1. General Information The Temp-Pro Thermocouple assembly you have selected is a precision temperature sensing unit which offers accurate readings under your specified industrial field conditions. Reasonable care, however, must be exercised in handling these sensors. Specified operating limits (see Table 1 on page 2) must not be exceeded. Rough handling, bending, or dropping of the sensor must be avoided.
2. Unpacking and Inspection Immediately upon receipt, the sensors should be examined for possible in-transit damage and for physical conformance to specifications, In the case of damage, file a claim with the carrier and notify Temp-Pro Inc. without delay.
3.
Thermocouple Assemblies and Technical Requirements 3.1. EMF Values: Each thermocouple has been manufactured to meet the EMF vs. Temperature characteristics specified by NIST (National Institute of Standards and Technologies). These tables are available at Temp-Pro and can be supplied to you upon request. 3.2. Calibration: Temp-Pro has a calibration Laboratory for calibration and verification of Temperature vs. EMF of the thermocouples supplied to the customers and provides calibration data when requested by the customer. 3.3. General Information: General information related to commonly used thermocouples in industries are shown in Table 1 (page 2) including the temperature range, color coding, tolerances, etc. 3.4. Insulation Resistance (IR) Test of the Thermocouples: This is the most common test done on UNGROUNDED Thermocouples (and RTDs). See test method under MEASURING IR on page 6 of this manual.
TEMP-PRO Inc. • 200 Industrial Drive • Northampton, MA 01060 Telephone: (413) 584-3165 • Toll Free: (800) 991-9093 • Fax: (413) 586-3625 E-Mail:
[email protected] • Web Site: www.temp-pro.com
1
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
Instruction Manual
TABLE 1 INITIAL CALIBRATION TOLERANCES TO THERMOCOUPLE THERMOCOUPLE TYPE
ºC
WIRE ALLOYS
COLOR CODE
ANSI TYPE SYMBOL
Copper (+) vs. Constantan (-)
Blue Red
T
*Iron (+) vs. Constantan (-)
White Red
Chromel™ (+) vs. Constantan (-)
Chromel™ (+) vs. *Alumel™ (-)
TEMPERATURE RANGE
ºF
STANDARD LIMITS
SPECIAL LIMITS
-200º to -650º -65º to +130º +130º to +350º
±1.5% ±1º ±0.75%
±0.8% ±0.5º ±0.4%
J
0º to +285º +285º to +750º
±2.2º ±0.75%
Yellow Red
E
-200º to -170º -170º to +250º +250º to +340º +340º to +900º
±1% ±1.7º ±1.7º ±0.5%
Yellow Red
K
-200º to -110º -110º to 0º 0º to +285º +285º to +1250º
Nicrosil (+) vs. Nisil (-)
N
Platinum 10% Rhodium (+) vs. Platinum (-)
TEMPERTURE RANGE
STANDARD LIMITS
SPECIAL LIMITS
-330º to -85º -85º to +270º +270º to +660º
±1.5% ±1.8º ±0.75%
±0.8% ±0.9º ±0.4%
±1.1º ±0.4%
+32º to +545º +545º to +1400º
±4º ±0.75%
±2º ±0.4%
±1º ±1º ±0.4% ±0.4%
-330º to -270º -270º to +480º +480º to +640º +640º to +1600º
±1% ±3º ±3º ±0.5%
±1.8º ±1.8º ±0.4% ±0.4%
±2% ±2.2º ±2.2º ±0.75%
±1.1º ±0.4%
-330º to -165º -165º to +32º +32º to +545º +545º to +2300º
±2% ±4º ±4º ±0.75%
±2º ±0.4%
0º to 285º +285º to +1250º
±2.2º ±0.75%
±1.1º ±0.4%
+32º to +545º +545º to +2300º
±4º ±0.75%
±2º ±0.4%
S
0º to +600º +600º to +1450º
±1.5º ±0.25%
±0.6º ±0.1%
+32º to +1110º +1110º to +2650º
±2.7º ±0.25%
±1.1º ±0.1%
Platinum 13% Rhodium (+) vs. Platinum
R
0º to +600º +600º to +1450º
±1.5º ±0.25%
±0.6º ±0.1%
+32º to +1110º +1110º to +2650º
±2.7º ±0.25%
±1.1º ±0.1%
Platinum 30% Rhodium (+) vs. Platinum 6% Rhodium (-)
B
+870º to +1700º
±0.5%
±0.25%
+1600º to +3100º
±0.5%
±0.25%
Tungsten (+) vs. Tungsten -26% Rhenium (-)
WR
+400º to 2300º
±1%
+800º to +4200º
±1%
Tungsten 3% Rhenium (+) vs. Tungsten 25% Rhenium (-)
W3
+400º to 2300º
±1%
+800º to +4200º
±1%
Tungsten 5% Rhenium (+) vs. Tungsten 26% Rhenium (-)
W5
+400º to +2300º
±1%
+800º to +4200º
±1%
* Magnetic ™ Trademark, Hoskins Manufacturing Co. T not ANSI type symbol NOTE: Percent limits apply directly to temperature in degrees Celsius, but for degrees Fahrenheit equivalents are applied to the number of degrees Fahrenheit above or below the ice point (+32 degrees Fahrenheit). [i.e., Limit (degrees F) = (Temperature (degrees F) - 32 (degrees F)) * Percentage]
2
TEMP-PRO Inc. • 200 Industrial Drive • Northampton, MA 01060 Telephone: (413) 584-3165 • Toll Free: (800) 991-9093 • Fax: (413) 586-3625 E-Mail:
[email protected] • Web Site: www.temp-pro.com
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
Instruction Manual
4. Resistance Thermometer Detector (RTD) Assembly and Technical Requirements 4.1. Outputs and Measurements: The output of RTD is resistance and can be measured with a Digital Multimeter. 4.2. General Information: General Information about different types of RTDs are shown in Table 2 below. TABLE 2 RESISTANCE TEST READING ELEMENT TYPE
TEMP. COEF. (TCR)
OHMS AT 0° C
OHMS AT 25° C
Platinum (DIN)
.00385
100.00
109.73
Platinum
.00392
100.00
109.91
Nickel
.00426
90.38
99.11
Nickel
.006720
120.00
140.20
C opper
.004274
9.04
10.00
Nickel - Iron
.005188
604.00
676.00
4.3. Temperature vs. Resistance: Temperature vs. Resistance of the most commonly used RTDs are shown in Table 3 on page 5. 4.4. Insulation Resistance of the RTDs: The Insulation Resistance Test of RTD is similar to Thermocouple except, use maximum 100 VDC as an applied voltage when using a megohmmeter (see Measuring IR on page 6) 4.5. Maintenance of RTDs, including Platinum RTDs: Normally, RTDs do not require maintenance. Should there be any apparent change in response time or drift in signal output, remove sensor from the assembly (or thermowell) and check for any deposits of foreign materials on the tip of the probe, or on the terminal screws inside the enclosure. 4.6. Checking Failure Conditions: If any failure occurred during the operation, check operating conditions against sensor specifications (verify the output against those in Table 3, on page 5, for the RTD type).
TEMP-PRO Inc. • 200 Industrial Drive • Northampton, MA 01060 Telephone: (413) 584-3165 • Toll Free: (800) 991-9093 • Fax: (413) 586-3625 E-Mail:
[email protected] • Web Site: www.temp-pro.com
3
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
Instruction Manual
4.7. Calibration of RTD: To determine the Resistance vs. Temperature characteristic of an RTD, the unit must be calibrated at a fixed temperature. The most commonly used fixed calibration environment is the ICE BATH. For instructions and the calibration method, see Figure 1 below: Figure 1: RTD Resistance Measurement Calibration Method
4.8. Bench Test of RTD. Use a Digital Multimeter for resistance measurement and a megohmmeter for Insulation Resistance Measurement. 4.8.1. Wipe dry external surfaces of sensor. 4.8.2. Refer to wiring diagram on the drawing and connect Digital Multimeter leads across opposite terminals of the platinum resistance winding extension wires. Resistance should read approximately 110 ohms at room temperature and 100 ohms in the ice bath. See the RTD calibration set-up and instruction, Figure 1 on page 4. 4.8.3. Test Insulation Resistance by connecting one megohmmeter lead to wires on terminal (all wires shorted together) and the other to the external sheath (metal protection casing) of the sensor. Resistance reading should exceed 5 megohms unless otherwise specified (applied voltage should not exceed 100 VDC). See also Insulation Resistance Test of the Thermocouples, Measuring IR, on page 7 of this instruction manual.
4
TEMP-PRO Inc. • 200 Industrial Drive • Northampton, MA 01060 Telephone: (413) 584-3165 • Toll Free: (800) 991-9093 • Fax: (413) 586-3625 E-Mail:
[email protected] • Web Site: www.temp-pro.com
Instruction Manual
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
TABLE 3 T EMPERAT URE RESISTANCE CHARACT ERIST ICS RESISTANCE IN OHMS
T EMPERAT URE DEGREES
PLAT INUM WINDINGS
°C
°F
*ALPHA .00385
*ALPHA .00392
-130 -110 -90 -70 -60 -50 -40 -30 -20 -10 +-0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140 +150 +160 +170 +180 +190 +200 +210 +220 +230 +240 +250 +260 +280 +300 +320 +340 +360 +380 +400 +420 +440 +460 +480 +500 +520 +540 +560 +580 +600 +620 +640 +660 +680 +700 +720 +740 +760 +780 +800 +820 +840
-202 -166 -130 -94 -76 -58 -40 -22 -4 +14 +32 +50 +68 +86 +104 +122 +140 +158 +176 +194 +212 +230 +248 +266 +284 +302 +320 +338 +356 +374 +392 +410 +428 +446 +464 +482 +500 +536 +572 +608 +644 +680 +716 +752 +788 +824 +860 +896 +932 +968 +1004 +1040 +1076 +1112 +1148 +1184 +1220 +1256 +1292 +1328 +1364 +1400 +1436 +1472 +1508 +1544
47.93 56.13 64.25 72.29 76.28 80.25 84.21 88.17 92.13 96.07 100.00 103.90 107.79 111.67 115.54 119.40 123.24 127.07 130.89 134.70 138.50 142.28 146.06 149.82 153.57 157.32 161.04 164.76 168.47 172.16 175.84 179.51 183.17 186.82 190.46 194.06 197.70 204.88 212.03 219.13 226.18 233.19 240.15 247.06 253.93 260.75 267.52 274.25 280.93 287.57 294.16 300.70 307.20 313.65 320.05 326.41 332.72 338.99 345.21 351.38 357.51 363.59 369.62 375.61 381.55 387.45
47.28 55.52 63.71 71.86 75.92 79.96 83.99 88.01 92.02 96.02 100.00 103.97 107.93 111.88 115.82 119.75 123.66 127.56 131.45 135.33 139.20 143.06 146.90 150.73 154.55 158.36 162.16 165.94 169.71 173.47 177.22 180.96 184.69 188.40 192.10 195.80 199.47 206.80 214.07 221.30 228.48 235.62 242.70 249.74 256.74 263.68 270.58 277.43 284.24 291.00 297.71 304.37 310.99 317.56 324.08 330.56 336.99 343.37 349.70 355.99 362.23
NICKEL WINDINGS *ALPHA .00426
*ALPHA .006720
68.27 71.19 74.24 77.39 80.56 83.77 87.04 90.38 93.80 97.31 100.91 104.60 108.39 112.28 116.27 120.36 124.55 128.85 133.26 137.78 142.40 147.11 151.91 156.79 161.89 167.13 172.46 177.95 183.55 189.40 195.35 201.55 208.00 214.60 228.45 242.70
73.10 79.62 86.17 92.76 99.41 106.15 113.00 120.00 127.17 134.52 142.06 149.79 157.74 165.90 174.27 182.85 191.64 200.64 209.86 219.30 228.96 238.85 248.97 259.37 269.92 280.79 291.96 303.46 315.31 327.53 340.14 353.14 366.53 380.31 409.07 439.43
COPPER WINDINGS *ALPHA .004274
7.10 7.49 7.88 8.26 8.65 9.04 9.42 9.81 10.19 10.58 10.97 11.35 11.74 12.12 12.51 12.90 13.28 13.67 14.06 14.44 14.83 15.22 15.61 16.00 16.39 16.78 17.17 17.56 17.95 18.34 18.73
* TCR = Temperature Coefficient of Resistance = Ohm / Ohm / Degree Celsius
TEMP-PRO Inc. • 200 Industrial Drive • Northampton, MA 01060 Telephone: (413) 584-3165 • Toll Free: (800) 991-9093 • Fax: (413) 586-3625 E-Mail:
[email protected] • Web Site: www.temp-pro.com
5
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
Instruction Manual
Measuring IR T/C TERMINAL HEAD TERMINAL (POST)
MEASURING SHEATH
JCT. (TIP)
INDICATING SCALE SHOWS INSULATION RESISTANCE
MEGGER INSULATION TESTER
Insulation Resistance may be performed to test ungrounded thermocouples or RTD's. Measuring IR need not be of the highest precision, in that low IR should be grounds for rejection. Precision instrumentation is not therefore required, although calibration must be dependable, and any recognized megohmmeter is satisfactory. To measure IR, you would use an IR tester, which is a portable instrument that's essentially a resistance meter, or ohmmeter, with a built in hand cranked or line-operated DC generator that develops high DC voltage. This voltage (usually 500V or more) causes a small current to flow through and over the insulation's surface. The tester provides a direct reading of IR in ohms or megohms. Test is made with clips connected to the sheath and to all leads tied together. Insulation resistance may be expected to be in excess of 1000 megohms at room temperature and not less than 20 megohms at 200 degrees Celsius. The above picture shows a typical megohmmeter test instrument hook-up to measure insulation resistance. You can use an IR meter and obtain measurements. A high resistance value would indicate a "good" insulation, while a relatively low resistance value would point to a "poor" insulation. In actual applications, resistance values can be higher or lower due to the effects of factors such as temperature, humidity, the moisture content of the insulation, and even the person doing the testing. Therefore, the IR reading can be very different for the same wire tested on different days.
6
TEMP-PRO Inc. • 200 Industrial Drive • Northampton, MA 01060 Telephone: (413) 584-3165 • Toll Free: (800) 991-9093 • Fax: (413) 586-3625 E-Mail:
[email protected] • Web Site: www.temp-pro.com
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
Instruction Manual
Installation of Thermocouples or RTDs 5.
Installation Instruction 5.1. Complete unit: Complete unit may be secured into process location without sensor disassembly, in the case of those with threaded or flanged thermowells or fittings. 5.2. Weld-in Thermowell Assembly: On a weld-in thermowell assembly, the sensor inset must be removed before welding in place, to prevent possible damage by overheating during welding.
6. RTD Spring-Loaded: Removal And Assembly Instructions Into Thermowell (Refer to Figure 2 on page 8) 6.1. To remove RTD inset, take off connection head cover and loosen the two terminal block retaining screws until they are disengaged from the connection head. 6.2. Withdraw inset from connection head without further disassembly, and place in a safe location to prevent bending and possible damage. 6.3. With an ohmmeter, check and verify resistance of the unit. A 100 ohm platinum RTD should have a resistance of about 110 ohms at room temperature between red and blue and/or black and white respectively. There should be no continuity between the leadwires and the sheath of the probe. 6.4. Screw the RTD connection head and extension into the existing thermowell. 6.5. Replace the RTD inset (reverse of §6.1). 6.6. Connect extension leads to the terminal block. Be careful to observe color coding polarity. 6.7. Tighten terminal block retaining screws in the terminal block. Spring should be compressed about 3/16". Spring may be repositioned as required.
TEMP-PRO Inc. • 200 Industrial Drive • Northampton, MA 01060 Telephone: (413) 584-3165 • Toll Free: (800) 991-9093 • Fax: (413) 586-3625 E-Mail:
[email protected] • Web Site: www.temp-pro.com
7
Instruction Manual
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
Figure 2: Removal and Assembly Instructions into Thermowell
Retaining Screws
Option 1 Option 2 Option 3 Terminal Block
7. Thermocouple Spring-Loaded: Removal and Assembly Instructions into Thermowell (Refer to Figure 2 above) 7.1. To remove the thermocouple inset, open the cover of the thermocouple connection head and loosen the two terminal block retaining screws, until they are disengaged from the connection head. 7.2. Carefully remove the terminal block and thermocouple inset. Avoid bending or straining the thermocouple bare wires. Close cover. 7.3. Screw the thermocouple head and extension with the extension into the existing thermowell. 7.4. Replace the thermocouple inset. 7.5. Insert the thermocouple block into the head allowing the bare thermocouple wires to pass through the 5/16" diameter hole in the terminal block. The negative leg of the thermocouple wire is color coded red and is to match with the brass post next to the stamped negative sign in the terminal block. 7.6. Connect extension wires through the head conduit connection port and into the brass post. Close cover. Figure 3: Thermocouple Inset
8
TEMP-PRO Inc. • 200 Industrial Drive • Northampton, MA 01060 Telephone: (413) 584-3165 • Toll Free: (800) 991-9093 • Fax: (413) 586-3625 E-Mail:
[email protected] • Web Site: www.temp-pro.com
Instruction Manual
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
8.
Screw-In Thermowell Installation 8.1. If necessary, remove sensor assembly from thermowell by unscrewing nipple from well or by breaking the extension at the union. (Refer to §6 and §7). Use care whenever removing or replacing the sensor element. 8.2. Insert thermowell into process connection and screw in until snug. Apply additional torque until the threads are well engaged. The following chart (see Table 4) indicates the approximate length of thread engagement of various pipe sizes: TABLE 4 PROCESS
ENGAGEMENT
1/2" NPT
1/2"
3/4" NPT
1/2"
1" NPT
5/8"
1-1/4" NPT
5/8"
1-1/2" NPT
5/8"
2" NPT
5/8"
2-1/2" NPT
3/4"
3" NPT
3/4"
"L”
"U"
SENSOR CONNECTION MAX. DIA.
MIN. DIA. PROCESS CONNECTION
TEMP-PRO Inc. • 200 Industrial Drive • Northampton, MA 01060 Telephone: (413) 584-3165 • Toll Free: (800) 991-9093 • Fax: (413) 586-3625 E-Mail:
[email protected] • Web Site: www.temp-pro.com
9
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
Instruction Manual
PRODUCTS •Thermocouple's •Sub-Zero up to 5,000 °F. •Gas Turbine T/C •Multipoint •Specials •Plastics Industry •Platinum •RTD's •Copper •Platinum •Nickel •Ni-Iron •Flat Strip (Stator) •Immersion •Custom •Thermistors •All Applications, Including Compressor
•Thermocouple & RTD Wire •Compensated Terminal Blocks •Plugs, Jacks, and Fittings •Selector Switches •Reference Junctions •Transmitters/Controllers/Scanners •Thermometers •Bimetal Thermometers •Filled System Thermometers •Hydrogen Activity Probes
•Thermowells •Industrial Glass Thermometers •Limited Space Threaded •Raised Face Flanged •Sanitary Thermowells •Socket-Weld •Steam Sampling Nozzles •Threaded •Van Stone •Weld-In •Electrical Accessories •Junction Boxes •Turning Gear Boxes •Wiring Harnesses •Cable Assemblies •Gauge Panels •Control Panels •Circuit Boards •Liquid Level Detectors •Remote Terminal Units (RTU's) •Remote Sensing •Swamping (Averaging) T/C Boards •Logistics Management •Purchasing •Warehousing •Assembling/Kitting •Shipping Services •Research & Development in Temperature Sensing Products
Reg. No. 950 98 0142
Form 990309
TEMP-PRO Inc. • 200 Industrial Drive • Northampton, MA 01060 Telephone: (413) 584-3165 • Toll Free: (800) 991-9093 • Fax: (413) 586-3625 E-Mail:
[email protected] • Web Site: www.temp-pro.com
