WIKA TC59-V Mode d'emploi

Taper
Mode d'emploi
Operating instructions
Betriebsanleitung
Mode d'emploi
Manual de instrucciones
EN
DE
FR
ES
V-PAD
®
tubeskin thermocouple, model TC59-V
V-PAD
®
tubeskin thermocouple assembly, model TC59-V
V-PAD
®
-Rohroberächen-Thermoelement, Typ TC59-V
Installation de thermocouple de peau V-PAD
®
, type TC59-V
Termopar para supercie de tubería V-PAD
®
, modelo TC59-V
EN
DE
FR
ES
2
14131894.02 09/2016 EN/DE/FR/ES
WIKA operating instructions model TC59-V (V-PAD
®
)
Operating instructions model TC59-V Page 3 - 22
Betriebsanleitung Typ TC59-V Seite 23 - 42
Mode d'emploi type TC59-V Page
43 - 62
Manual de instrucciones modelo TC59-V Página
63 - 81
© 02/2016 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!
Lire le mode d‘emploi avant de commencer toute opération !
A conserver pour une utilisation ultérieure !
EN
Contents
1. General information 4
2. Safety 5
3. Specifications 8
4. Design and function 10
5. Transport, packaging and storage 10
6. Commissioning, operation 11
7. Maintenance 20
8. Faults 20
9. Dismounting, return and disposal 21
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WIKA operating instructions model TC59-V (V-PAD
®
) 3
Contents
EN
1. General information
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WIKA operating instructions model TC59-V (V-PAD
®
)4
1. General information
The thermocouple described in the operating instructions has been manufactured
using state-of-the-art technology. All components are subject to stringent quality and
environmental criteria during production. Our management systems are certied to
ISO 9001 and ISO 14001.
These operating instructions contain important information on handling the instrument.
Working safely requires that all safety instructions and work instructions are observed.
Observe the relevant local accident prevention regulations and general safety
regulations for the instrument’s range of use.
The operating instructions are part of the product and must be kept in the immediate
vicinity of the instrument and readily accessible to skilled personnel at any time.
Skilled personnel must have carefully read and understood the operating instructions
prior to beginning any work.
The manufacturer’s liability is void in the case of any damage caused by using the
product contrary to its intended use, non-compliance with these operating instructions,
assignment of insuciently qualied skilled personnel or unauthorised modications to
the instrument.
The general terms and conditions contained in the sales documentation shall apply.
Subject to technical modications.
Further information:
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: TE 65.59
- Application consultant:
Tel.: +49 9372 132-0
Fax: +49 9372 132-406
info@wika.com
Explanation of symbols
WARNING!
... indicates a potentially dangerous situation that can result in serious injury or
death, if not avoided.
CAUTION!
... indicates a potentially dangerous situation that can result in light injuries or
damage to equipment or the environment, if not avoided.
Information
... points out useful tips, recommendations and information for ecient and
trouble-free operation.
EN
1. General information / 2. Safety
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WIKA operating instructions model TC59-V (V-PAD
®
) 5
DANGER!
... identies hazards caused by electric power. Should the safety instructions not
be observed, there is a risk of serious or fatal injury.
WARNING!
... indicates a potentially dangerous situation in the hazardous area that can
result in serious injury or death, if not avoided.
WARNING!
... indicates a potentially dangerous situation that can result in burns caused by
hot surfaces or liquids, if not avoided.
2. Safety
WARNING!
Before installation, commissioning and operation, ensure that the appropriate
thermocouple has been selected in terms of measuring range, design and
specic measuring conditions.
Non-observance can result in serious injury and/or damage to the equipment.
Further important safety instructions can be found in the individual chapters of
these operating instructions.
2.1 Intended use
These sensors are used for temperature measurement in industrial applications.
The instrument has been designed and built solely for the intended use and may only be
used accordingly.
The technical specications contained in these operating instructions must be observed.
Improper handling or operation of the instrument outside of its technical specications
requires the instrument to be taken out of service immediately and inspected by an
authorised WIKA service engineer.
The manufacturer shall not be liable for claims of any type based on operation contrary to
the intended use.
EN
2. Safety
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WIKA operating instructions model TC59-V (V-PAD
®
)6
2.2 Personnel qualification
WARNING!
Risk of injury should qualication be insucient!
Improper handling can result in considerable injury and damage to equipment.
The activities described in these operating instructions may only be carried
out by skilled personnel who have the qualications described below.
Keep unqualied personnel away from hazardous areas.
Skilled personnel
Skilled personnel are understood to be personnel who, based on their technical training,
knowledge of measurement and control technology and on their experience and knowledge
of country-specic regulations, current standards and directives, are capable of carrying out
the work described and independently recognising potential hazards.
Special installation conditions require further appropriate knowledge, e.g. routing a sensor
within a furnace.
2.3 Special hazards
WARNING!
Non-observance of these instructions and their contents may result in the loss of
explosion protection.
WARNING!
Observe the information given in the applicable type examination certicate and
the relevant country-specic regulations for installation and use in hazardous
areas (e.g. IEC 60079-14, NEC, CEC). Non-observance can result in serious
injury and/or damage to equipment.
WARNING!
For hazardous media such as oxygen, acetylene, ammable or toxic gases or
liquids etc., in addition to all standard regulations, the appropriate existing codes
or regulations must also be followed.
EN
2. Safety
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WIKA operating instructions model TC59-V (V-PAD
®
) 7
WARNING!
Protection from electrostatic discharge (ESD) required.
The proper use of grounded work surfaces and personal wrist straps is required
when working with exposed circuitry (printed circuit boards), in order to prevent
static discharge from damaging sensitive electronic components.
To ensure safe working on the instrument, the operating company must ensure
that suitable rst-aid equipment is available and aid is provided whenever
required.
that the operating personnel are regularly instructed in all topics regarding
work safety, rst aid and environmental protection and knows the operating
instructions and, in particular, the safety instructions contained therein.
WARNING!
Residual media in contact with dismounted instrument can result in a risk to
persons, the environment and the equipment. Take sucient precautionary
measures.
Do not use this instrument in safety or emergency stop devices. Incorrect use of
the instrument can result in injury.
Should a failure occur, aggressive media with extremely high temperature may
be present at the instrument.
EN
2. Safety / 3. Specications
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WIKA operating instructions model TC59-V (V-PAD
®
)8
2.4 Labelling, safety marks
Product label
Explanation of symbols
Before mounting and commissioning the instrument, ensure you read
the operating instructions!
3. Specifications
Thermcouple types
Type Recommended max. operating temperature
IEC 60584-1 ASTM E230
K 1,200 °C (2,192 °F) 1,260 °C (2,300 °F)
J 750 °C (1,382 °F) 760 °C (1,400 °F)
E 900 °C (1,652 °F) 870 °C (1,598 °F)
N 1,200 °C (2,192 °F) 1,260 °C (2,300 °F)
Tolerance value
A cold junction temperature of 0 °C (32 °F) is taken as basis with the denition of the
tolerance value of thermocouples.
When using a compensating cable or thermocouple cable, an additional measuring error
must be considered.
TC59-V
1x Type K / Standard 0 ... +1,260 °C
ASTM E230
Made in Germany 2015
11012345
Thermocouple in accordance with standard
Model
Year of manufacture
EN
3. Specications
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WIKA operating instructions model TC59-V (V-PAD
®
) 9
Tolerance values of the thermocouples per IEC 60584 / ASTM E230
Type Tolerance value per Class Temperature range Tolerance value
K
N
IEC 60584-1 1 -40 ... +1,000 °C ±1.5 °C or 0.0040 ∙ | t |
1) 2)
2 -40 ... +1,200 °C ±2.5 °C or 0.0075 ∙ | t |
ASTM E230 Special 0 ... +1,260 °C ±1.1 °C or ±0.4 %
Standard 0 ... +1,260 °C ±2.2 °C or ±0.75 %
J IEC 60584-1 1 -40 ... +750 °C ±1.5 °C or 0.0040 ∙ | t |
2 -40 ... +750 °C ±2.5 °C or 0.0075 ∙ | t |
ASTM E230 Special 0 ... +760 °C ±1.1 °C or ±0.4 %
Standard 0 ... +760 °C ±2.2 °C or ±0.75 %
E IEC 60584-1 1 -40 ... +800 °C ±1.5 °C or 0.0040 ∙ | t |
2 -40 ... +900 °C ±2.5 °C or 0.0075 ∙ | t |
ASTM E230 Special 0 ... +870 °C ±1.0 °C or ±0.4 %
Standard 0 ... +870 °C ±1.7 °C or ±0.5 %
1) ItI is the value of the temperature in °C without consideration of the sign
2) The greater value applies
Limited error with selected temperatures in °C for thermocouples types K and N
Temperature Tolerance value IEC 60584-1
(ITS 90) Class 1 Class 2
°C °C °C
0 ±1.5 ±2.50
100 ±1.5 ±2.50
200 ±1.5 ±2.50
300 ±1.5 ±2.50
400 ±1.6 ±3.00
500 ±2.0 ±3.75
600 ±2.4 ±4.50
700 ±2.8 ±5.25
800 ±3.2 ±6.00
900 ±3.6 ±6.75
1,000 ±4.0 ±7.50
1,100 - ±8.25
1,200 - ±9.00
Other thermocouple types on request
For further specications see WIKA data sheet TE 65.59 or Technical information IN 00.23
and the order documentation.
EN
4. Design and function / 5. Transport, packaging and storage
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WIKA operating instructions model TC59-V (V-PAD
®
)10
4. Design and function
4.1 Description
Model TC59-V V-PAD
®
tubeskin thermocouple assemblies are designed to measure the
temperature of tubes typically located within boilers, cokers, furnaces, heat exchangers and
reactors. This model of thermocouple is typically used within industrial high-temperature
and/or corrosive environments where temperature measurement is critical.
The most important considerations for eective tubeskin design are repeatability, durability
and accuracy. To achieve these functions the thermocouple must incorporate within its
design excellent insulation properties, material compatibility and good physical contact with
the tube. It must also have the ability to withstand high radiant temperatures and stresses,
and in some cases harsh combustion chemistry.
With all tubeskin designs the correct installation is of prime importance. Incorrect
attachment can ultimately lead to inaccurate temperature readings.
Sheathed cable
The sheathed cable (mineral-insulated cable, MI cable) is exible. The minimum bending
radius is 5 times the sheath diameter.
TC59-V can be assembled as cable probes or as sensors with a connection head.
Optionally, a temperature transmitter can be built into the connection head. For this
temperature transmitter, separate operating instructions will be enclosed.
4.2 Scope of delivery
Cross-check scope of delivery with delivery note.
5. Transport, packaging and storage
5.1 Transport
Check the instrument for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
5.2 Packaging
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change in
installation site, sending for repair).
EN
5. Transport, packaging and storage / 6. Commissioning, operation
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WIKA operating instructions model TC59-V (V-PAD
®
) 11
5.3 Storage
Permissible conditions at the place of storage:
Storage temperature: 0 ... 70 °C (32 ... 158 °F)
Humidity: 35 ... 85 % relative humidity (no condensation)
Avoid exposure to the following factors (terminal side, connection head):
Direct sunlight or proximity to hot objects
Mechanical vibration, mechanical shock (putting it down hard)
Soot, vapour, dust and corrosive gases
Potentially explosive environments, ammable atmospheres
Store the instrument in its original packaging in a location that fulls the conditions listed
above. If the original packaging is not available, pack and store the instrument as described
below:
1. Place the instrument, along with shock-absorbent material, in the packaging.
2. If stored for a prolonged period of time (more than 30 days), place a bag, containing a
desiccant, inside the packaging.
6. Commissioning, operation
WARNING!
When the thermocouple is installed, the temperature must not drop below the
allowed operating temperature (environment, medium) or exceed it, even when
taking convection and heat radiation into account!
WARNING!
Thermocouples must be earthed (grounded) if dangerous voltages could be
expected at the connection wires (caused, for example, by mechanical damage,
electrostatic discharge or induction)!
6.1 Installation scope
The following is a guide for installation of V-PAD
®
tubeskin thermocouples. It gives
guidelines and suggestions for preparation, installation and welding V-PAD
®
thermocouples.
Due to the variety of applications some of the suggestions made here may not be
appropriate. The end user must determine if these instructions are suitable for their unique
application. Contact WIKA should you have any questions regarding the installation.
EN
6. Commissioning, operation
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WIKA operating instructions model TC59-V (V-PAD
®
)12
6.2 Before you start
Ensure there is enough MI cable to reach the termination box for each V-PAD
®
,
especially if on-site bending and expansion loops are required.
Avoid passing MI cable through hot zones.
Route the MI cable thermocouple in contact with the coolest side of the tube. This will
substantially increase the life expectancy.
Ensure all surfaces to be welded are cleaned by appropriate methods.
When grinding always use clean abrasive materials that have not been used on other
materials.
A wire brush is not adequate to properly clean the tube.
Test t the V-PAD
®
thermocouple at the desired location to ensure adequate length of MI
cable was provided.
Ensure all bending is correct and sucient allowance is provided for tube movement.
Based on the customer’s weld procedure, determine the appropriate preheat, interpass
and weld ller metal composition for the parent materials.
Determine if controlled cooling or post weld heat treatment is required.
Bend radius
Always use an appropriate tube bender for the corresponding diameter of MI cable. If
bending by another means then use bends with radius equal to or greater than those on a
tube bender. The minimum bend radius is 5 times the diameter of the MI cable.
6.3 Sensor positioning
The V-PAD
®
must be located at the peak heat ux of the tube it is mounted on in relation to
the burners. This must be done to ensure the reading accuracy of the V-PAD
®
. Remove
scale and rust from the tube in the locations required for welding to the tube.
EN
6. Commissioning, operation
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WIKA operating instructions model TC59-V (V-PAD
®
) 13
6.4 Tests/Checks
Test loop resistance of the thermocouple circuit at ambient temperature prior to welding/
routing the V-PAD
®
, record results.
After completing the welding/routing of the V-PAD
®
to the tube, test loop resistance at
ambient temperature and compare.
If a deviation of greater than 5 % between readings occurs, please contact WIKA.
Perform any non-destructive examination or heat treatment as required.
Ensure adequate tube wall thickness at the weld locations. This can be checked by
thickness testing to customer specications.
6.5 Welding process
Gas Tungsten Arc Welding (GTAW) is the suggested welding process due to its relatively
clean weld. Small diameter ller rod (2.4 mm / 3/32" OD) and Tungsten (1.5 mm / 1/16",
2.4 mm / 3/32" OD) give the best penetration, especially for the root passes. During
welding operation, the requirements of the relevant material data sheets and the applicable
directives and standards must be considered regarding the heat treatment, ller rods
or welding procedures. Proper installation is a major step in the success of a V-PAD
®
installation. Although the V-PAD
®
is one of the most rugged sensors available, it can be
destroyed by improper welding. WIKA can supply V-PAD
®
test thermocouples on request for
practice welding if required.
6.6 V-PAD
®
welding
Clamp the V-PAD
®
(using a chain clamp!) to the appropriate location on the pipe. Avoid
damaging the outer surface of the V-PAD
®
when clamping.
Ensure there is good line contact with the tube (see gure 1). Avoid tilting the
V-PAD
®
and ensure the edge makes good contact with the tube (see gure 2).
Ensure good axial alignment with the tube axis (see gure 4). This will ensure
any dierential expansion of the MI cable is smooth and does not bind with the
tube clips.
Preheat the area to be welded (including the V-PAD
®
) as appropriate for the materials.
Tack weld one end of the V-PAD
®
. Visually check alignment before proceeding with the
root pass. Watch for tilt, gap, line contact, etc.
Attach a thermocouple meter to the cold end of the thermocouple for measurement.
EN
6. Commissioning, operation
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WIKA operating instructions model TC59-V (V-PAD
®
)14
WARNING!
The temperature readings while welding the V-PAD
®
should not exceed 800 °C
(1,500 °F). If temperature readings exceed 800 °C (1,500 °F), interrupt welding
for 5 minutes before continuing welding.
Apply the root pass on both sides. Melt into the rst root pass for complete penetration
(see gure 3). Avoid melting through the V-PAD
®
wall.
Check interpass temperatures and add additional passes as required to ll the joint.
A minimum of three passes per side are required.
Control cooling rate of the weld area, if required.
Figure 4: Axial alignment
Good alignmentPoor alignment
Poor alignment Good alignment
Figure 2: Tilt
Poor (gap too large) Good
Figure 3: Weld penetration
Gap
Weld
Poor line contact Poor line contact Good line contact
Figure 1: Line contact
EN
6. Commissioning, operation
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WIKA operating instructions model TC59-V (V-PAD
®
) 15
6.7 Tube clip welding
Attach clips at predetermined locations. Preheat area before welding if required.
Weld tube clip ends only and ensure there is a loose t (no friction) between the
mineral-insulated cable and the clip (see gure 5).
The tube clip should allow axial expansion of the mineral-insulated cable.
Weld clips on the same plane as the sensor approximately 150 mm (6") to 300 mm (12")
from the V-PAD
®
then at a maximum of every 300 mm (12") to 450 mm (18") of run
(see gure 6).
6.8 Expansion loops
Expansion loops should be designed to account for maximum tube movement from start up
position to operating temperature. Loops should be designed in accordance with allowable
space available. Examples of expansion loops are S-loop, multiple coil, single coil and spiral
loop.
Figure 6: Tube clip installation
Tube clip
150 mm (6") to
300 mm (12") max.
Figure 5: Tube clip welding
MI cable
Fillet
weld
MI cable
Fillet
weld
S-loop
Single coil
Multiple coil
Spiral loop
EN
6. Commissioning, operation
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WIKA operating instructions model TC59-V (V-PAD
®
)16
6.9 Exiting the furnace
The sensor should exit the furnace as per installation requirements. MI cable must follow
best practices for routing.
WARNING!
Ensure the cable does not pass through direct ame.
6.9.1 Fixed exit
Assemble the process neck extension as per the installation.
Install and tighten compression tting to manufacturer’s specications, if included.
WARNING!
Do not place compression tting on the thermocouple transition.
Assemble instrument neck extension as per the installation requirement.
If applicable, attach connection head.
Route sensor to termination location and complete electrical connection.
EN
6. Commissioning, operation
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WIKA operating instructions model TC59-V (V-PAD
®
) 17
6.9.2 Piston/Spring exit
Pack the exit orice of the furnace wall with high-temperature ceramic ber (kaowool)
insulation to keep outside connections cool. Install plate and spring, tighten collar at desired
location. Install split washers and pipe cap.
WARNING!
Ensure thermocouple transition does not exceed 175 °C (350 °F) and is a
minimum of 150 mm (6") from the furnace entry connection.
V-Pad_Spring_Piston_OI.ai
Piston style
Spring-loaded style
Existing
Existing
EN
6. Commissioning, operation
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WIKA operating instructions model TC59-V (V-PAD
®
)18
6.10 Electrical connection
CAUTION!
Damage to cables, wires and connection points must be avoided.
Flying leads with bare ends must be nished with ferrule ends (cable
preparation).
The electrical connection is to be made according to the sensor connections/pin
assignments shown below:
Ceramic terminal block
Crastin terminal block
Cable connection
3166822.03
Single thermocouple
Dual thermocouple
+
-
+
-
-
+
+
-
+
-
-
+
Single thermocouple
Dual thermocouple
3171966.01
Single
thermocouple
Colour coding of the wire ends see table
Cable
Dual
thermocouple
EN
6. Commissioning, operation
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WIKA operating instructions model TC59-V (V-PAD
®
) 19
Colour code of cable
IEC 60584-3
Type of thermocouple Positive leg Negative leg
K Green White
J Black White
E Violet White
N Pink White
ASTM E230
Type of thermocouple Positive leg Negative leg
K Yellow Red
J White Red
E Violet Red
N Orange Red
6.11 Cable connections
The cable gland must be sealed to ensure that the required protection class is reached.
Requirements for meeting ingress protection
Only use cable glands within their indicated clamping range (cable diameter suitable for
the cable gland).
Do not use the lower clamping area with very soft cable types.
Only use circular cross-section cables (if necessary, slightly oval in cross-section).
Do not twist the cable.
Repeated opening/closing is possible; however only if necessary, as it might have a
detrimental eect on the protection class.
For cables with a pronounced cold-ow behaviour the screw connection must be fully
tightened.
CAUTION!
Seal should be checked for signs of brittleness and, if necessary, replaced.
6.12 Tapered threads (NPT)
Connections with tapered threads (NPT) are self-sealing. It should be checked whether it
may be necessary to seal them additionally with PTFE tape or thread sealant. The threads
must be lubricated with a suitable lubricant before tting.
Tighten the threads by hand when carrying out the nal assembly in the plant. Correspond
to the delivery status of the premounted components. The nal tightening and sealing must
be made with a wrench (1.5 to 3 rotations).
EN
7. Maintenance / 8. Faults
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WIKA operating instructions model TC59-V (V-PAD
®
)20
7. Maintenance
These thermocouples are maintenance-free.
Repairs must only be carried out by the manufacturer.
8. Faults
Faults Causes Measures
No signal/line breakage Mechanical load too high or
overtemperature
Replace probe or measuring insert
with a suitable design
Erroneous
measured values (of
thermocouples)
Parasitic voltages (thermal
voltages, galvanic voltage) or
incorrect thermocouple cable type
Use the correct thermocouple
cable type
Signal interference Stray currents caused by electric
elds or earth loops
Use of shielded connecting cables,
increase in the distance to motors
and power lines
Earth circuits Elimination of potentials, use of
galvanically isolated transmitter
supply isolators or transmitters
CAUTION!
If faults cannot be eliminated by means of the measures listed above, shut down the
instrument immediately, and ensure that pressure and/or signal are no longer present,
and secure the instrument from being put back into operation inadvertently.
In this case, contact the manufacturer.
If a return is needed, please follow the instructions see chapter 9.2 “Return”.
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WIKA TC59-V Mode d'emploi

Taper
Mode d'emploi