Delta Controls HTP User manual

HTP Model
Installation, Operation and Maintenance Manual
Doc No.: 00-HTP03
Revision: Rev P

Page 2
Table of Contents
Resolving Dimensional Problems........................................................................................................7
Shipping Preparation, Storage & Handling 4
Transport .............................................................................................................................................4
Storage................................................................................................................................................4
Handling...............................................................................................................................................4
Pre-Installation Preparation 4
Survey the Installation..........................................................................................................................4
Inspect the Thermocouple and Accessories.........................................................................................5
Inspect the Nozzle ...............................................................................................................................6
Installing the Thermocouple 9
Vertical Installation...............................................................................................................................9
Non-Vertical Installation.....................................................................................................................13
Non-Vertical Installation - Using the HMB Mounting Bars...................................................................14
Wiring ................................................................................................................................................15
Purge Gas Connection.......................................................................................................................16
Purge/Element Well Integrity Test......................................................................................................17
Technical Operation and Maintenance 18
Pre-Commissioning/Commissioning Procedure (Startup)...................................................................18
Shutdown...........................................................................................................................................18
Operation...........................................................................................................................................18
Maintenance......................................................................................................................................18
Troubleshooting.................................................................................................................................18
Specifications 18
Dimensions........................................................................................................................................20

Page 3
A brief video presentation of the steps of the
complete HTP/HTX installation may be found at
www.claustemp.com/
INSTALLATION GUIDE
Components of the HTP/HTX Claus Thermal Reactor
Thermocouple System Referenced in this Manual
The following listed components are required for proper installation of the HTP/HTX. Failure to utilize
these components will reduce the life of the HTP/HTX and cause possible failure.
Model Description Notes
HTP
HTX
Claus Thermal
Reaction Furnace
Thermocouple
Thermocouple assembly with mounting flange,
Body, purge connections, terminal enclosure housing
and element well.
Models HTP and HTX are identical in operation,
installation, and performan
ce. Slight differences in
dimensions are shown at the end of this manual.
HRW
Refractory Well The large refractory well collar rests in the refractory and
protects the element well
HNP Nozzle Insulation Kit
Woven and Pressed Disks for proper insulation of the
nozzle, also protection against nozzle overheating,
buildup of sulfur in the nozzle, and for physical protection
of the inner element well
HFS
Flush Gas Control
Panel
(usually shipped
separately)
Includes flow indicator, flow control valve, pressure
regulator, filter, dripwell, and
gage on stainless
steel panel with mounting hardware.
HMB
Horizontal Mounting
Bars
(usually shipped
separately)
Assists installation in non-vertical nozzles.
HTP
HTX

Page 4
Shipping Preparation, Storage & Handling
Transport
Care should be used in carrying, moving, and shipping the HTP/HTX thermocouple. A significant portion of the HTP/HTX is
constructed of ceramic. Ceramics are very brittle at ambient temperature and can be damaged by mechanical shock.
The unit is equipped with a sand-filled protective shipping tube when it leaves the factory. This tube and its sand packing
should be left in place until the persons installing the unit have arrived at the installation site and are ready to insert the
HTP/HTX and make up the flange.
The shipping tube and shipping crate should be retained for re-shipment and storage of the HTP/HTX assembly.
Storage
Store equipment in a clean, dry place. It is recommended that the equipment remain packaged until ready for installation to
prevent breakage or misplacing of components.
When storing a unit or preparing it for shipment, the shipping tube should be reinstalled and filled with clean, fine #1 blasting
sand.
Handling
Units are constructed with ceramic material that is susceptible to damage from rough handling. Units should only be handled
with their protective shipping pipes in place, and, whenever possible transported to/from the installation site in their original
shipping containers.
Pre-Installation Preparation
A video of the installation process is available at http://www.youtube.com/watch?v=r2WmrERLEaQ
You can view the video on a smartphone by scanning the QR code shown here.
Survey the Installation
a. Confirm the vessel nozzle location relative to the instrument tag number,
the planned installation location of the Delta Controls Flush Gas Control
Station and the temperature transmitter. (Note: The thermocouple
transmitter is not supplied by Delta Controls.)
b. Confirm the transmitter thermocouple compatibility with the thermocouple element type(s).
c. Confirm the availability of the proper type thermocouple extension leadwire for connection of the
transmitter. A separate cable is required for each thermocouple element. The type cable is determined
by the type(s) of elements in the thermocouple assembly as noted on the cover of this document. Note:
Thermocouple extension leadwire may be obtained from Delta Controls stock at nominal cost.
d. Secure the flange bolts, studs and required flange gasket.

Page 5
Inspect the Thermocouple and Accessories
a. Open the carton and carefully remove the top layer of the packing materials.
b. Visually inspect the HTP/HTX Assembly for damage.
c. Visually inspect the large ceramic HRW Refractory Well for damage. Be very careful not to drop the
well as it can be easily broken.
d. The protective steel pipe attached to the flange surrounds the ceramic element well. This pipe is filled
with sand to support and protect the element well during shipping. Carefully remove the thermocouple
from the carton, move it to an area where the sand can be safely emptied. Remove the end cap flange
from the end of the steel protective shipping pipe. Turn the thermocouple upright to pour out the sand
into a container.
e. Insert the tip of a large screwdriver or similar robust tool into the lug welded to the protective pipe and
using it as a lever, twist the pipe to loosen it to permit easy removal by hand at the installation site.
Occasionally, this may require the use of a pipe wrench. Loosen the pipe, but leave the pipe in place
until the thermocouple is to be inserted into the vessel nozzle.
f. Inspect inside the end of the pipe and gently touch the tip of the element well to be certain that it is not
“loose”. If loose, the thermocouple is broken and must be repaired prior to installation.
The shipping pipe and the custom built protective shipping carton are reusable and may be saved for
reshipment or storage of the HTP/HTX assembly.
g. If any parts appear to be damaged, contact Delta Controls immediately.
Sand-Filled Steel Protective
Shipping Pipe
HTX Thermocouple
shown
2. After removing the sand, loosen, but
do not remove
, the protective shipping
pipe. This permits
easy removal at the
time of installation.
1. Remove this end cap from the shipping pipe. Pour out the sand.

Page 6
Inspect the Nozzle
Because the “as-built” dimensions of the refractory and nozzle can (and often do) differ from the design
specifications, it is important to verify these dimensions before installing the thermocouple. Installing a
thermocouple that is not properly sized for the nozzle and refractory can result in breakage or inaccurate
measurements.
Inspect the inside of the vessel nozzle. The inside
of the nozzle should be clean and free from debris and
welding slag. The hole cut through the vessel shell at
the base of the nozzle should be a minimum 3-1/2” (90
mm) diameter. The top
refractory surface should be
even and free from extensive damage. The bored hole
through the refractory should be clean,2.2”to 2.4” (56-
61mm) diameter
, centered in the nozzle and in
perpendicular alignment relative to the nozzle flange
face. If the hole does not meet the above criteria, the
thermocouple can become broken shortly after start up
as refractory begins to shift.
Check the nozzle and refractory dimensions.
(Refer to the drawing on the cover of this document)
To ascertain Insertion Length “F”, lay a straight edge
across the flange face and with a measuring tape,
hook the inside surface (hot face)
of the refractory
inside the vessel and measure up to the straight edge.
Confirm this dimension is the same as the length of
the thermocouple element well as measured from the
thermocouple flange to the tip of the well.
(If the thermocouple element well
is too long, it will
contact the refractory well when it is inserted, causing
it to become broken. If the thermocouple is too short,
it may read erroneously low.
Insertion
Length ”F”
HTX
Thermocouple
shown
Insertion
Length ”F”

Page 7
Measure the refractory thickness with a measuring
tape. Confirm that this distance matches the length
of the straight portion of the HRW Refractory Well as
shown.
(If the HRW well is too short, the thermocouple will
contact it during thermocouple insertion, causing it to
break. If the HRW well is too long, there is an
increased possibility of breakage due to thermal
shock)
If there is a discrepancy of more than
0.5in (12 mm) on the above
measurements, DO NOT install the
thermocouple until the discrepancy
is resolved. (see below)
Resolving Dimensional Problems.
Carefully measure the nozzle and refractory dimensions and compare them to the dimensions on the front cover of
this manual. Dimensional discrepancies are commonly caused by the following conditions:
1. Nozzle inner diameter is not as specified – If the nozzle I.D. is too small, the hard insulating rings will
not fit. These rings can be cut down to size. This is best done in a lathe with a tapered arbor to fit the center
hole. Use a dust collector when cutting these rings to avoid breathing the dust.
2. Nozzle height is not as specified – If the nozzle is too tall, the thermocouple will not extend all the way
into the vessel and may report erroneously low temperatures. If the nozzle is too short, the thermocouple
may contact the bottom of the refractory well causing it to break. (See Note “4”, below). Contact Delta
Controls to arrange for a thermocouple correctly sized for the installation.
3. Incorrectly specified thermocouple dimensions – The design intent is for the thermocouple element tip
to be positioned even with the refractory hot face, and for the HRW Refractory Well to extend approximately
1 inch (2.5 cm) past the refractory hot face. If these conditions are not met, the result may be inaccurate
measurement and/or breakage due to mechanical interference or thermal shock. Contact Delta Controls
to arrange for a thermocouple that is correctly sized for the installation.
4. Refractory has entered the base of the nozzle –The top surface of the refractory should be even with
the inside surface of the vessel shell. If it is not, the HRW Refractory Well will not rest at the proper position
and may cause it to be broken when the thermocouple is inserted into the nozzle. If there is refractory
material inside the base of the nozzle, it must be removed to restore a flat surface that is even with the
inner surface of the vessel shell.
5. Refractory is not installed at the specified thickness – If the overall refractory is thicker than specified,
the thermocouple will not extend all the way into the vessel and may report erroneously low temperatures.
HRW Refractory Well
Refractory
Thickness
Refractory
Thickness
Note: The HRW Refractory Well is intended to
protrude approximately 1in (25 mm) beyond the
refractory hot face

Page 8
If the refractory is thinner than specified, the thermocouple will extend past the refractory hot face. This
could increase the possibility of breakage due to thermal shock. Contact Delta Controls to arrange for a
thermocouple that is correctly sized for the installation.
6. Refractory firebrick has separated from the insulating castable –It is not uncommon for the firebrick
to sag and form a gap between the firebrick and the castable or insulating brick. Often, thermal expansion
will cause this gap to close by itself when the furnace reaches operating temperature. If this is the only
cause of dimensional discrepancy, thermocouple installation may proceed.
7. Refractory has separated from the vessel shell – This condition is not common, but it is possible for a
gap to appear between the insulating refractory and the vessel shell. The result is that the thermocouple
may not extend far enough into the vessel to reach the refractory hot face and may report erroneously low
temperatures. In general, this gap will not close up at operating temperatures. The thermocouple must be
re-sized to account for the gap. Contact Delta Controls to arrange for a thermocouple that is correctly sized
for the installation.

Page 9
Installing the Thermocouple
Vertical Installation
(For non-vertical installations do steps 1-5, proceed to page 14.)
1.
Carefully set HRW Refractory Well down onto the hole in
the refractory. The collar of the HRW should rest flat
against the refractory surface and the tip should extend
about 1 inch (25 mm) beyond the refractory into the
reactor vessel. The fit should be somewhat loose.
Model HRW
Refractory Well
F+1in.
Insertion
Length,F
Element
Well
Refractory
Well
2.
Double-check for proper clearance prior to thermocouple
insertion by measuring from the bottom of the refractory well up
to the flange face. The distance should be approximately 1 inch
(25mm) longer than the insertion length of the element well
(Dimension F on the front cover of this manual).

Page 10
3.
Place the two soft compressible collar rings from the HNP
Nozzle Insulation Kit, having an I.D. of 2.75” (70 mm),
around the refractory well collar. They should fill the gap
between the outside of the refractory well collar and the
inside of the vessel nozzle.
Collar Rings
4
. Place approximately 8 – 10 each of the soft compressible
nozzle rings, with the ¾” (19 mm) center hole, in the bottom of
the nozzle. Insure that the center holes are in alignment.
Compressible
Nozzle Rings
Collar Rings
5.
Place enough of the rigid pressed 1-1/2” (38 mm) thick rings
into the nozzle so that the top half of the top ring extends
above the flange. If needed, remove or insert additional
lower soft rings to obtain this fit.
Rigid, Pressed
Rings
Gasket
6
. Place and center the flange gasket on the vessel nozzle flange.

Page 11
Note that the thermocouple is heavy
and the ceramic element well may be
easily broken. During the following
steps, do not allow any sideways
forces to be exerted on the ceramic
parts.
7.
Carefully remove the protective pipe from the thermocouple
and place it in a safe location.
Steel Protective (Shipping)
Pipe
8.
Have an assistant lift the thermocouple and turn it to a vertical
position. The installer then grasps the unit by the top housing,
permitting the unit to hang vertically plumb. With no assistance,
center the element well over the center hole in the top insulating
ring and gently lower the unit into place on the flange.
Gasket
9.
The soft compressible nozzle rings will compress as the
thermocouple is positioned into place.
Compressible
Nozzle Rings
10
. Keeping the unit centered on the flange, gently rotate it to the
desired position for electrical and purge connections. Install and
tighten the flange studs.

Page 12
After installation and before reactor startup, perform
the Purge / Element Well Integrity Test on page 17.
This will verify that the element well was not broken
during installation, and that there are no problems with
the purge connections.
Performing this test as soon as possible prior to
reactor startup will allow time to obtain replacements
in the event of element well breakage. In general,
replacement is not possible while the reactor is
running. A thermocouple that has a broken element
well or that is improperly purged will only operate for a
short time before failing.
11. Install instrument conduit, wiring and purge gas tubing as
described below.

Page 13
Non-Vertical Installation
In non-vertical installations, insertion of the thermocouple unit can be difficult. The installer must attempt to support the
full weight of the thermocouple unit while fully inserting it into the centerline of the nozzle insulating materials at the
appropriate angle without allowing the weight of the unit to impart side-loads on the element protective well.
The Model HMB Thermocouple Mounting Guide Bars provide an easy and safe means of inserting the heavy
thermocouple in non-vertical nozzles. The use of the guide bars minimizes the risk of breakage of the element protective
well due to misalignment of the unit with the nozzle centerline as it is being inserted into position.
A video showing the use of the HMB mounting bars is available at
http://www.youtube.com/watch?v=r2WmrERLEaQ
You can view the video on a smartphone by scanning the QR code shown here.
This space intentionally left blank

Page 14
Non-Vertical Installation - Using the HMB Mounting Bars
1. Install the HRW refractory well and nozzle insulation rings as described in steps 1-5 beginning on page 9.
This hole for
150#
flanges
2. Insert an R-Clip into the appropriate hole near the
threaded end of one of the mounting bars.
R-Clip
This hole for
300# flanges
Nozzle Flange
Nut
Mounting Bars
4. Similarly, install the other mounting bar on the
opposite bolt hole.
Stud with nut
Flange Gasket
5. Place studs in 3 places as shown. Place the flange
gasket
in position. The studs will temporarily hold
the flange gasket in position.
Purge connections
6. Making sure the thermocouple unit is correctly
rotated so that the purge and wiring connections are
oriented in the desired direction; allow the mounting
bars to support the weight of the thermocouple as it
is carefully guided into position.
Wiring connections
7. Loosely install studs and nuts in all empty holes to
hold the thermocouple in place as the guide bars
are removed.
9. Install the remaining studs and nuts. Verify the
flange and gasket is centered; tighten all to
specification.
10. Install instrument conduit, wiring and purge gas
connections as below.
8. Remove the mounting bar nuts. Using a large
screwdriver or pliers, pull the R-clips and remove
the mounting bars.
3. Place the threaded end of the mounting bar into a
vessel nozzle flange bolt hole as shown. Secure the
bar to the flange with the provided nut.

Page 15
Wiring
•The conduit connecting to the terminal enclosure should be equipped with a union and a flexible conduit for ease of
maintenance and to reduce strain on the terminal enclosure.
•Ensure that the insulation on thermocouple extension lead wire is rated for 400°F (200°C) continuous service.
•Installation shall comply with EN60079-14 and/or other governing codes.
The thermocouple elements are terminated on the connecting blocks, which are mounted inside the thermocouple head.
The block positions are marked “O”, “R”, and “D” to designate which thermocouple is connected at each set of two terminal
points. The negative lead position is marked with a red dot on each set. The standard arrangement is:
O: The Operating thermocouple; usually a type “R”, “S” or “B” platinum/rhodium.
R: The Reference thermocouple; same type as the operating thermocouple.
D: The Dryout thermocouple; usually a type “T” or “K” (supplied as an option on some models)
Thermocouple Terminal Connections – Operating and Reference
Thermocouples only, no Dryout
“O” Operating Pair
“R” Reference Pair
Terminal Enclosure
(Cover removed)
+ -
“D” Dryout Pair
“O” Operating Pair
“R” Reference Pair
+
_
Thermocouple Terminal Connections –Operating,
Reference, and Dryout Thermocouples
Terminal Enclosure
(Cover removed)

Page 16
Purge Gas Connection
The use of nitrogen as a purge gas is strongly recommended. The Delta Controls Model HFS Purge Control Station provides
a convenient and effective means to properly control the purge gas pressure and flow rate. Consult Document
http://claustemp.com/00-hfs01.pdf for details.
Connect the purge gas tubing to the HTP/HTX thermocouple as shown. Regulated, filtered gas enters the top purge gas
connection and exits the lower purge gas connection. Set the purge pressure to 5 psi (0.35 bar) above the maximum thermal
reactor operating pressure. Adjust the needle flow control valve for a flow rate of 11 lph as indicated on the flow meter. This
provides sufficient flow to protect the thermocouple without significantly cooling the thermocouple elements.

Page 17
Purge/Element Well Integrity Test
The following procedure should be performed after thermocouple installation to identify installation problems, and to verify that the
thermal well was not broken during installation. It should also be performed periodically (suggested weekly or bi-weekly) as routine
preventative maintenance.
1. Purge Pressure Setting – Verify that the purge pressure is at least 5 psi above the maximum operating pressure of the reactor
(normally 15 to 20 PSIG is suitable.) Adjust if necessary.
2. Purge Flow Setting – Verify the purge flow rate is correct: 11 LPH as indicated on the flow indicator. Adjust if necessary.
TO VENT
PURGE
GAS
SUPPLY
MODEL HFS
PURGE GAS
PANEL (rear view)
FRESH PURGE
SPENT PURGE GAS
THERMOCOUPLE
Claus Thermal Reaction Furnace
Pressure
Regulator
Adjustment
Purge
Pressure
Indicator
Flow Indicator
Needle Flow
Control
Valve
MODEL HFS
PURGE GAS PANEL (front view)

Page 18
3. Check for Purge Integrity - Elevate the pressure on the HFSPurge Panel Pressure regulator by approximately 10 - 15 PSIG. Verify
that the flow rate on the flow indicator increases. Reduce the pressure to its previous setting and verify that the flow rate returns to
its previous value. Note: depending on the amount of flow rate increase, cooling of the thermocouple by the purge gas could show
up as an apparent drop of a few degrees in reported temperature.
Failure of the flow indicator to respond to changes in purge pressure can indicate:
•Leaks – which will allow the purge gas to escape to atmosphere and not return to the flow indicator.
•Breakage of the element well – Which allows purge gas to escape into the reaction vessel and allows reaction gases to contact
the thermocouple element, leading to increasing inaccuracy and ultimately complete failure from contamination and corrosion.
•Plugging of the purge lines – usually, this is caused by an element well breakage. Sulfur condenses in the purge lines and
plugs them. Such a condition is often accompanied by a visible yellow sulfur deposit on the inside surface of the glass flow
indicator.
Technical Operation and Maintenance
Pre-Commissioning/Commissioning Procedure (Startup)
Make sure that the purge is properly supplied to the thermocouple prior to reactor startup.
Use the pressure regulator adjustment on the HFS purge panel to set the purge pressure to approximately 5 psi
above the maximum operating pressure of the reactor.
Using the needle flow control valve on the HFS purge panel, adjust the purge flow rate to 11 LPH as shown on the
flow indicator.
Shutdown
Continue purging the thermocouple during shutdown until the reactor has cooled and reaction gases are no longer present
in the reactor.
Operation
The thermocouple has no adjustments or controls. Operation consists of maintaining purge gas flow to the thermocouple.
Maintenance
No periodic maintenance is required on the thermocouple. It is recommended that the Purge/Element Well Integrity Test on
page 17 be performed on a weekly or bi-weekly basis in order to assure that purge is maintained to the thermocouple and
to detect any breakage of the thermal well (which would lead to subsequent failure of the thermocouple due to exposure to
corrosive gases.) Such breakage is sometimes cause by shifting of the refractory due to thermal expansion. When properly
installed, the thermal well can withstand some shifting of the refractory, but large shifts can cause failures.
Troubleshooting
For diagnostic procedures, see Delta Controls document AN-HTP39, available at www.claustemp.com/
Specifications
Absolute Maximum Ratings:
Maximum Operating Pressure: 150psi (10 bar)
Maximum Gas Purge Pressure 150psi (10 bar)
Maximum Operating Temperature: 3092ºF (1700ºC)*
Minimum Operating Temperature: -4ºF (-20ºC)
Maximum Flange Temperature: 500ºF (260ºC)

Page 19
Maximum Terminal Enclosure Temperature 383ºF (195ºC)
T/C types: B,S,R
Materials:
Flange material: SA-516-70 Carbon Steel
Trim/Bolting/Seats: Stainless Steel
Protective well: Blended alumina, ceramic
Purge Requirements: dry nitrogen, 0.4scfh
* type ‘B’ thermocouple. Max operating temperature is limited by the thermocouple melting point.
Model Numbering System

Page 20
Dimensions
Model HTX Thermocouple
Model HTP Thermocouple