Engineered Temperature

Solutions for heavy process industries

Temperature at Endress+Hauser

The Endress+Hauser Group of companies

Endress+Hauser is a global supplier of products and solutions for
the process industries.
Innovative technologies that lead to an excellent price/
performance ratio of our products and services support the
competition ability of our customers in quality, reliability and
efficiency. With a finely tuned network of production, sales
companies and representatives Endress+Hauser has a strong
presence on all world markets.
Endress+Hauser stands for continuity, branch specific know-how
and for long-term customer relationships.

Areas of activities:

The production locations in Nesselwang (Germany) and Pessano

near at Milan (Italy) are the competence centers for temperature
measurement technology within the Endress+Hauser group.
Here transmitters, measurement inserts, thermowells and Temperature
assemblies as well as bespoke solutions are produced Accredited
calibration laboratories (DKD, SIT) are available in both sites.

Endress+Hauser Wetzer Endress+Hauser Sicestherm


Temperature measurement in the petrochemical industry
It is impossible to imagine our daily lives without mineral oils.
It is a long process from crude oil to the end product:
From exploration to production until final processing in refineries,
petrochemical and chemical plants.

Temperature measurement technology is particularly demanding

for the different methods of petrochemical and chemical processes.
Temperature assemblies for process furnaces, desulfurization
reactors or Claus-furnaces require a high degree of experience and
know-how in order to be able to design the sensors for a safe and
reliable measurement in accordance with the requirements.

In addition to the high-quality standard temperature assemblies

Endress+Hauser also offers custom-made solutions for surface
temperature measurement as well as individually designed multi-
point measurement systems in reactors.

Innovative developments to increase safety, optimize flexibility

and thereby increasing process availability offer real additional
benefits.

A complete portfolio of transmitters with the most modern

fieldbus technology rounds off the product basket.

Contents Page

Temperature at Endress+Hauser ...............................................2-3

Project management..................................................................4-5

Temperature measurement in process furnaces..........................6-7

Temperature measurement in reactors..................................... 8-10

Process connection with safety chamber.....................................11

System integration...................................................................... 12

Certification and tests........................................................... 13-14

Other documentation................................................................. 15


 Project management

Coordinated project management in the different process areas and

industries is becoming increasingly important.
To do justice to these requirements, Endress+Hauser has analyzed and
optimized the internal processes for project management in detail over
the last few years.
Projects with custom-designed solutions for temperature measurement
require a higher degree of coordination between customer and
supplier in comparison to projects with standard products.
For this reason numerous project teams are at the customer’s disposal
worldwide.

Engineering and services in plant life cycle

In order to achieve maximum efficiency, an interdisciplinary

Project team is formed at the beginning of a project.
The project manager guarantees a smooth course during the
Management complete engineering process.

The feasibility of the project is checked within the framework

of the Basic Engineering and the schedule is coordinated with
Engineering the customer.
(Basic Engineering)
Detailed Engineering, however, includes material selection,
drawing preparation and the selection of suitable system
components for connection to primary systems.

Nowadays computer supported planning tools make

mechanical simulation possible and support the optimization of
Engineering the plant in the engineering phase.
(Detail Engineering) Endress+Hauser supports this planning with CAD data for
every device and thereby contributes considerably to the
reduction of planning time. The electronic data are provided in
2 D or 3D models on request.

Modern machine workshops, accredited welding methods and

trained specialist staff guarantee the high quality in production.
The production facility is ISO9000 certified.
Production


 Besides fixed and standardized quality controls
Endress+Hauser offers additional examinations and
Quality checks certificates especially for use in the area of the refineries and
petrochemical plants.

Inspection can take place both directly at the production site or

Factory acceptance in one of our logistics centers.
The project manager carries out the inspection of the produced
test order together with the customer and documents the results in
the acceptance report.

Custom-designed solutions require special procedures with

respect to packing and transportation. By using especially
Delivery
designed packaging, careful loading and transportation by
Despatch approved logistics partners makes sure that the measurement
systems arrive both punctually and securely.

Optionally Endress+Hauser offers the possibility of a site

acceptance test.
Site acceptance test

Fault free installation is decisive for the quality and longevity of

the measurement system.
Installation Endress+Hauser supports the project during its complete
supervision installation worldwide with an experienced supervisor.

With W@M (Web based Asset Management) Endress+Hauser

Plant life cycle offers an open and flexible information platform. This supports
you along your business processes and the complete life cycle
management of your equipment. With this all the necessary information
regarding safe installation, commissioning and maintenance of
the devices is at your displosal.


 Temperature measurement in process furnaces
If the surface temperature of a reactor wall or a pipe needs to be
measured, then in most cases the sensors, depending on the
application, are attached by soldering, welding, screwing-on or
clamping.
Since, in this case, the temperature assembly is not in contact with
the medium, the demand made of the themometer is low.
This is different when measuring the temperature pipe surfaces
in process furnaces. Here the demand made of the temperature
assembly is extremely high.
Process furnaces are indispensable modules in the various
production processes refineries, petrochemical and chemical
plants since the medium to be processed must be heated before
it is transferred to a distillation column or a reactor (see example
atmospheric distillation). Here the liquid medium is pumped
though a pipe bundle which is installed in a furnace fitted with
burners.
The measurement serves mainly to guarantee the process
efficiency and to monitor for deposits within the pipes.

Application: Atmospheric distillation

The distillation serves to separate crude oil into its natural components. It is pumped out from storage tanks through a separator into
a pipe furnace where it is heated up to approximately 650 to 750°F. As a steam liquid mixture it reaches the first distillation tower at
atmospheric pressure.

Furnace chamber Heat exchanger Skin point temperature measurement Tube-Skin-

Temperature
assembly
High temperatures, existence of aggressive burning gasses and expansion of the heat exchanger pipe bundles
make heaviest demands on the tube-skin temperature assembly used in relation to:
• Material selection.
• Temperature assembly design.
• Connection of the Temperature assembly to the pipe.


Material
The choice of material has a decisive effect on the Temperature assembly life span and therefore the reliability of the temperature
measurement. Among other things the suitable material is determined by the furnace temperature and the fuel used. By this, the
effects due to radiation and open flames should be minimized. The use of Hastelloy ® X (2.4665) has particularly proven itself in process
furnaces. Versions in AISI 316 L (1.4404 or 1.4435), AISI 321 (1.4541), AISI 347 (1.4550), Inconel® and others materials are also possible.

Design
In the Temperature assembly design the movements of the heat exchanger pipes and
the optimal positioning are taken into account in the furnace. The pipe expansion is
compensated for by expansion coils.

Outer wall
Pipe

Neck
(Nipples)
Expansion
coils

Fixing-
clamp Welded pad

Version with expansion coils:

Available as flexible sheathed material or
in a more robust execution with prepared
expansion coils fitted to the furnace geometry.

Connection to the pipe

The connection of the Temperature assembly tip to the pipe surface has a decisive influence on the measurement precision. The
measurement result can be significantly influenced by corrosion, in combination with open flames and/or radiation.
The handling during installation and removal must both be taken into consideration.

Pad

Thermocouple
Sheath

The thermocouple is fixed by formed Thermocouple with pad for welding to Thermocouple with a knife edge (wedge
brackets welded onto the pipe surface; the pipe surface. formation) for welding to the pipe surface.
if necessary the tip is pushed into a contact
block welded onto the pipe.

In addition, Endress+Hauser can deliver customer specific solutions for special problems.


 Temperature measurement in reactors
Measurement of a temperature profile
in a catalytic reactor process
Catalytic reaction processes are required if the reaction can only
take place with a sufficiently high speed in the presence of a
catalyst. These include ammonia synthesis, methanol synthesis,
but also gasoline or fuel oil desulfurization. In these methods the
reaction of the catalyst rests while it is being it is being mixed with
gas or liquid. The particles on which heterogeneous catalysts are
fixated are packed so tightly that a solid bed is generated. This is
why they are generally known as flat bed reactors.
At an uneven distribution of the reactors via the catalyst it can
sometimes come to a so-called “channeling” of the catalyst
bed. This then leads to an inefficient use of the catalyst and the
generation of local high temperature points known as “Hot spots”.
The danger here is that the catalyst is deactivated or damaged as of
a certain hot spot temperature.
The recording of temperature values in the different catalyst layers
is therefore indispensable for the operator.
On the one hand the uneven speed, concentration and
temperature profiles have a negative effect on the process cycle
and therefore on the product quality.
On the other hand this also has an effect on the life- and the
maintenance cycle of the reactor and is therefore a significant
factor in lowering the operating costs.

In the following multi-point thermometer systems from Endress+Hauser are introduced, which fulfill the mentioned requirements and
are suitable for the different forms of flat bed reactors:
• Multipoints for pipe bundle reactors - the catalyst is in thin parallel fixed pipes (diameter .5 to 2.5”).
• Multipoints for flat bed reactors with continuous catalyst reaction.
• Multipoints for flat bed reactors with catalyst beds.

The Endress+Hauser measurement solutions are individually designed under the requirement of maximum safety.


Pipe bundle reactors
Pipe bundle reactors serve the synthesis or
further processing of chemical raw materials.
The heart of the reactor coat is a pipe bundle
which is rinsed by a heat exchanger (boiling
liquids, pressure water, salt melts).
Every single pipe in the bundle is filled with
catalyst material and therefore represents a
reactor in which hot spots can appear.
One thermometer with the smallest possible
diameter and as many test points as possible
on its total length must be placed within these
pipes. For these requirements multi-point
thermocouples are used.
There are basically two versions:

Version 1: Multi-point temperature assembly with common sheathing.

Embedded centrally in highly purified magnesium oxide powder within a metallic sheath lies
the common cable (positive thermo-leg). The negative thermo-legs are placed around this. This
construction makes it possible to produce test points by connecting the thermo-legs at different
positions throughout the complete length of the thermometer.
Construction: OMP Sensor (optimized multipoint)

Middle
positive thermocouple leg
Negative thermocouple leg Stainless steel
sheath

“Hot Junction”
Thermocouple leg connection
Wall

Version 2: Multi-point element with individual sheaths

Several mineral insulated thermocouples and protected by a metallic sheath are exactly placed
into a metal tube. The generated multiple sensor is then drawn in several steps up to the
required diameter.

Due to the larger thermo-wire diameter the OMP construction considerably more robustly, the second version
makes a larger number of measurement points possible with the same outside diameter.

Both versions stand out due to the following advantages:

• Large number of measurement points with simultaneously
small sheath diameter (Ø from .12”, dependent on
construction and number of measurement points).
• Can be delivered in lengths up to more than 65 ft.
• High measurement accuracy and long term stability of the
measurement points due to insulation with highly purified
MgO powder.
• Large selection of available materials (e.g. SS316, SS304,
Inconel 600).
• Thanks to the malleable sheath material very long
thermocouples can be economically transported and
stored in coiled up form.
• Variable process connections by attaching using standard
compression fittings eg. flange.


 Temperature measurement in reactors

Rigid multi-point temperature assemblies

Frequently rigid, straight multi-point
temperature assemblies and thermowells are
used for measuring temperature profiles in flat
bed reactors.
Such a thermometer consists of a thermowell
with process connection, a number of sensors
(mostly thermocouples) and a terminal
connection box.
In addition, a construction is possible with
individual interchangeable measurement
elements. To reach high reaction speeds, the
individual measurement points are in contact
with the thermowell, thus conducting the
process temperature.
The terminals or transmitters can be fitted
in the connection box which is either fitted
directly onto the assembly or mounted
remotely.
Terminal box (EEx d version) with
transmitters for multiple measurements.

Gas tight couplings for interchangeable

thermocouples.

Fast reaction time dus to sensor contact

Multipoint thermometer with three measurement points. with the thermowell.

Octoplus systems offer the possibility to distribute measurement

point three dimensionally in the reactor. Flexible pipes are
brought into the reactor via a common process connection. The
thermocouples are distributed within the reactor according to
the specification in order to achieve the desired positions of the
measurement points.
An additional advantage of a spcially engineered Octoplus system
safeguards the exchange of single thermocouples during the down
time or during regular process times.
The flexibility allows operation and maintenance costs to be
lowered considerably.

Both systems are individually designed for the measurement task.

Process conditions such as pressure, temperature and the type
of medium are decisive for the choice of material and design.
Since most reactors have a construction especially tailored to the
process, every multi-point system is individually optimized for the
application. Reactor specifications such as accessibility, filling and
emptying as well as the product flow are taken into account when
designing the system.

10
Process connection with safety chamber
To do justice to the high safety requirements in reactors of
petrochemical plants, Endress+Hauser offers a special process
connection with safety chamber. This safety chamber represents
a second process barrier and is available both with straight
multi-point thermometers and Octoplus systems. Leaks in the
thermowell or in the sheaths are contained by the safety chamber,
the process medium cannot reach the outside environment.
Safety chamber with welded thermocouples (not interchangeable).
Positioning outside the reactor.
Pressure gauges monitor the pressure in the safety chamber and
transmit an alarm if a leakage is detected.
Optionally the safety chambers can be fitted with welded together
or interchangeable thermocouples. The interchangeable version
offers full flexibility for service and maintenance into combination
with a maximum safety.
Safety chamber; thermocouples are fed through compression fittings and
can be interchanged during down time.
11
 System integration

Process availability, reliability and plant safety are the center of the
requirements in the petrochemical processes. Additional information
regarding the measurement point and supplementary diagnoses of modern
temperature transmitters substantially contribute to this.
The diagnostics contain standardized functions which monitor and report
e.g. an open circuit or a wiring fault. Corrosion at the terminals as well as the
sensor cables is also supervised and recognized early.
Maximum safety is offered by the backup function which automatically
switches over the sensor on the 2 channel operation with a redundant
temperature measurement on failure or malfunction.

The large number of Ex-approvals regarding pressure tight

capsulation and/or intrinsic safety document the extensive
application possibilities in Ex hazardous areas.
HART® devices which have been designed to the IEC61508
regulations, today set the standards for safety and reliability in self
monitoring electronics and innovative circuit concepts.

System integration by means of transmitters can be done via 4…20mA signals or with the help of fieldbus
systems. Endress+Hauser offer a complete portfolio of temperature transmitters using the most up-to-date
technology which can be used in all types of applications.

Field housing

TMT142 TMT162 TMT162 TMT162

DIN Rail

TMT122

Head
transmitter
TMT182 TMT84 TMT85
1-channel 2-channel 2-channel 2-channel
universal universal universal universal

12
Certification and tests
Demanding processes in refineries and petrochemical plants
require a maximum amount of quality. Since temperature
measurement plays such a decisive role for the safety of the plants
the individual components of the temperature measurement point
are subject to careful examination at Endress+Hauser in their own
test centers.
The quality of the materials, processing and the important qualities
of the thermometer systems are proved by testimonials and
certificates and can be traced backwards for years.

Deviations from the specified qualities of the component can be

faults in the form of material problems or separations. These are for
example cracks, pores, cavities or composition faults. The methods
of nondestructive test are suitable for the proof of such problems.
Here the use qualities of the component are not affected.

Inspection certificate 10204 - 3.1

The inspection certificate EN10204 3.1 for medium contact parts
is produced by a department independent of the production and
confirmed by an expert independent of the production of the
manufacturer (“works expert”).
The material tests carried out and the additional quality controls
agreed on are certified with detail of the test results and under
supervision of an independent authority.
NACE
The NACE MR0175 standard is essentially a listing of materials
that are considered suitable for use in surroundings containing
sulfur hydrogen (sour gas).
New suitable materials are included in this standard after passing
through an extensive approval process (annual update).
PMI (Positive Material Identification)
This nondestructive material identification as well as check of
welding connections are frequently used at acceptance tests.
Assessment according to the pressure equipment
directives
If the multi-point thermometer is equipped with a safety
chamber (as described on page 11), this chamber represents
a pressure containment equipment. This is because in the
case of a fault condition (e.g. thermowell rupture) this piece
of equipment is filled with process pressure. Depending on
the type of fluid, the volume of the chamber and the process
pressure the corresponding conformity assessment module is
consulted and used.
X-ray testing (non destructive test)
Faults like inclusions, pores, tears etc. in the base material
and/or in the welded seam are seen.
Furthermore the exact positioning of the welded components
can be checked.

13
 Testing
Dye penetration test
Red-white-method
Suitable for checking material surfaces and welded seam
surfaces. So for example cracks can be detected.
It is applicable for the welding seams of stainless steels,
austenitic materials and metal based alloys.
Helium leakage test
Pressure tightness test for thermowells, welded seams,
screwed fittings. Depending on the thermometer design
and thermometer size it can be pressurized internally or
externally with helium gas.
14
Hydrostatic pressure test (internal/external)
Using the internal and external pressure test the strength
and pressure tightness of thermowells and process
connections can be checked.
Calibration
Our own accredited laboratories for the calibration of
resistance sensors and thermocouples to ISO/IEC 17025,
DKD and SIT guidelines are available for internationally
recognized calibration certificates.
Further documentation
• Temperature measurement
Thermometers and transmitters
for the process industry.
Brochure: FA006T09

• Competence in temperatur
for your success.
Brochure: CP002R09

• Competence in Oil & Gas

Full range of solutions to increase
safety and production efficiency.
Brochure: SO502B27

• “E+H=°C” - the law of temperature

Temperature measurement in dia-
log.Grafical Configurator.
DVD: CD016R09

• Calibration of thermometers
Basics, requirements and standards
for industrial thermometers.
Brochure: CP004R09

15
Endress+Hauser’s product portfolio

Level Pressure Flow

• Capacitance (RF) • Gauge/absolute • Electromagnetic

• Conductive • Differential pressure • Vortex shedding
• Mechanical • Hydrostatic • Coriolis mass flow
• Vibration • Ultrasonic
• Ultrasonic • Open channel
• Radar • D/P flow
• Guided radar (TDR) • Thermal mass flow
• Hydrostatic
• Gamma

Temperature Liquid Analysis Recorders & Components

• Temperature transmitters • Conductivity • Paperless recorders

• RTDs/thermocouples • pH/ORP • Visual data managers
• Sensors • Chlorine • Safety data managers
• Dissolved oxygen • Displays
• Turbidity • Barriers
• Chemical analyzers • Power Supplies
• Nitrate/organic sensors
• Sludge level

Solutions Service

• Wireless networks • Start-up www.us.endress.com/e-direct

• Inventory control • Training • Shop on-line for low-cost
• Energy monitoring • Calibration instruments, devices and
• Tank farm monitoring • Maintenance contracts components
• Life cycle management • Installed Base Audit
• Plant asset management
• Flow management solutions

ISO 9001 Certified

04.10/SCUSA
USA Canada Mexico International

Endress+Hauser, Inc.
2350 Endress Place
Greenwood, IN 46143
Tel: 317-535-7138
Sales: 888-ENDRESS (888-363-7377)
Service: 800-642-8737
Fax: 317-535-8498
inquiry@us.endress.com
www.us.endress.com
Endress+Hauser Canada
1075 Sutton Drive
Burlington, ON L7L 5Z8
Tel: 905-681-9292
800-668-3199
Fax: 905-681-9444
info@ca.endress.com
www.ca.endress.com
Endress+Hauser México S.A. de C.V. For international locations
Fernando Montes de Oca 21 Edificio A Piso 3 visit: www.endress.com/worldwide
Fracc. Industrial San Nicolás
54030 Tlalnepantla de Baz
Estado de México
México
Tel: +52 55 5321 2080
Fax: +52 55 5321 2099
eh.mexico@mx.endress.com
www.mx.endress.com

CP003R/24/en/04.10
US/INDD CS2