General Information and Technical Data for Tube Bundles ... · 2.2.2 Steam traced tube bundles The...

PSG Petro Service GmbH & Co. KG, Tel.: +49 (0) 6171 / 9750-0, FAX: +49 (0)6171 / 9750-30, Email: [email protected]

General Information and Technical Datafor

Tube Bundles and Analyser Lines

1. Application

Tube bundles and analyser lines can be used for the transportation of liquids and gases and can provideeither frost protection or the maintenance of process temperatures. They are mainly found in the chemicaland petrochemical industry as sampling, exhaust gas, analyser or instrumentation lines.

2. Versions

The different versions vary basically in the type of the protection jacket, the heat tracing and in the quantityand material for the process tube.

2.1 Types of protection jackets

The flexibility as well as the ambient conditions of the lines depends on the type of the protection jacket.There are three different types:

• Rigid lines, sheathed with plastic (PVC, TPU or PA)• Flexible lines, encased with a corrugated plastic (PA) or metal tubing• Highly flexible lines, sheathed with a plastic (PA) protection braiding

2.1.1 Rigid lines (tube bundles with extruded plastic jacket)

Jacket material: • PVCAccording to VDE 0207, part 52,flame retardant,continuous temperature T = -45°C up to +105°C

• TPUaccording to VDE 0282, part 10,maximum wear resistance and tear propagation strength,flame retardant,continuous temperature T = -25°C up to +80°C

• PEfor extremely low ambient temperatures,flame retardant, free of halogens,continuous temperature T = -60°C up to +70°C

Insulation: • Thermal fleececontinuous temperature up to 200°C

• Glass fibrecontinuous temperature up to 500°C

Application: • Lengths up to 300m(Depending on the power supply and power rate, required for heating, up to 165 m in one heating circuit. The maximum tube bundle length is extensible using multiple power suppliesfor additional heating circuits)

• Permanent installation• For inside and outside installation

PSG Petro Service GmbH & Co. KG, Tel.: +49 (0) 6171 / 9750-0, FAX: +49 (0)6171 / 9750-30, Email: [email protected]– 3 –

2.1.2 Flexible lines (analyser lines)

Jacket material: • Corrugated plastic hose, made of polyamide 6 or 12IP 68 according to EN 60529,air and liquid tight,oil resistant up to + 80°C, benzene resistant, highly resistant to acid and solvents,free of silicone, cadmium and halogens,self-extinguishing and flame retardant,UV resistant,continuous temperature = -40°C up to +115°C

• Corrugated metal hose, made of galvanised steelIP 40 according to EN 60529,stretch and lateral compression resistant,continuous temperature = +220°COptional:• PVC sheath

IP 68 according to EN 60529,watertight,highly resistant to seawater, acids and oil,free of silicone and cadmium,continuous temperature = -25°C up to +80°C

• PU sheathIP 68 according to EN 60529,watertight,highly resistant to oil, grease, benzene, acids and solvents,free of silicone, cadmium and halogens,continuous temperature = -40°C up to +80°C

Insulation: • Silicone foam hosecontinuous temperature up to 200°C

Application: • Lengths up to 150 m(depending on the power supply and power rate required for heating)

• Confined space installation possible(small bending radius)

• Permanent installation or mobile sampling points(lab/test bed)

• For inside and outside installation

2.1.3 Highly flexible lines (analyser lines)

Jacket material: • Plastic protection braiding, made of PAhighly resistant to oil, benzene, acids and solvents,free of halogens,self-extinguishing and flame retardant,continuous temperature = -55°C up to +125°C

• Metal protection braiding, made of galvanised steelcontinuous temperature = -+300°C

Insulation: • Silicone foam hosecontinuous temperature up to 200°C

Application: • Short length• Very confined space installation possible

(small bending radius)• Permanent installation or mobile sampling points

(lab/test bed)• No mechanical loading• For inside installation only


2.2 Heating-elements

The heating of the tube bundles and analyser lines can be realised either electrically or with steam.

2.2.1 Electrical heating

Depending on the application of a line, there are various types of electrical heating units available, such asself-regulating heating elements, parallel heating elements and heating elements with fixed resistance.

2.2.1.1 Self-regulating heating elements

Self-regulating heating is based on conductive-polymer technology in both monolithic (solid core) and fibrewrap heating cable designs. The heating element is made of polymers mixed with conductive carbonblack.

These special compound materials create electrical paths, which conduct current between the parallel buswire conductors along the entire cable length. In the heating cable core the number of electrical paths bet-ween the bus wires change in response to temperature fluctuations. As the ambient temperature surroun-ding the heating cable decreases, the conductive core or fibre contracts microscopically. This contractiondecreases the electrical resistance and creates numerous electrical paths between the bus wire conduc-tors. The result is that the flow of current increases and thus warms the core or fibre. As the temperature ri-ses, the core or fibre expands microscopically. This expansion increases the electrical resistance, as thenumber of electrical paths decrease. As a result, the heating cable automatically reduces its power require-ment.

Technical data:

Voltage: 230 V or 115 VFrequency: 50…60 HzPower rate: 9…65 W/mCurrent: depending on the length of the heater cable

Source: Tyco Thermal Controls


Application: • Frost protection and maintenance of process temperatures up to 150°C

Characteristics: • Approved for hazardous areas according to ATEX• Steam purging resistant up to 215°C• Length adaptation can be easily carried out on site, shortening the cable with

a termination set

2.2.1.2 Parallel heating elements

The heating elements consist of two current carrying copper wires, wrapped with chrome nickel wire as aheating spiral. The heating spiral is connected with the current carrying wires every 60 cm., so that parallelheating segments are formed, each with equal resistance values.

A highly heat resistant polyamide foil of Kapton® (up to 400°C) isolates the current carrying wires from theheating spiral and also the heating spiral from the metal protection braiding. Not only the high dielectricstrength (2500 V/mm), the resistance to organic chemicals, solvents and fuels is also worth mentioning.

Technical data:

Voltage: 230 V or 115 VFrequency: 50…60 HzPower rate: 40 W/m or 60 W/mCurrent: depending on the cable length (i.e. number of the heating elements)

Application: • Maintenance of process temperatures up to 200°C

Characteristics: • Length adaptation can be easily carried out on site, shortening the cable using a termination set (possible each 60 cm)

• For a power rate of 60 W/m a temperature controller will be required(e.g. PSG ST-49 controller, see section „Accessories“)

• Approved for hazardous areas according to the American FM (Factory Mutual Research Corporation). Not approved by ATEX!


Contact point

Heating spiralKapton® Polyamide foil

2.2.1.3 Heating element with fixed resistance

The heating element with fixed resistance is a multi-wired conductor, wrapped on a glass fibre core according to VDE 0253. The isolation between the current carrying wire and the protection braiding,as well as the outer jacket, are made of PTFE (Teflon®).

Technical data:

Voltage: 230 V or 115 V, single or three phaseFrequency: 50…60 HzPower rate: 90 W/m or 120 W/mCurrent: depending on the length required

Application: • Maintenance of process temperatures up to 250°C

Characteristics: • Approved for hazardous areas according to ATEX• Highly flexible• Single or three-phase power supply• Controller will be required

(e.g. PSG-ST49 controller, see section „Accessories“)

2.2.2 Steam traced tube bundles

The steam tracing requires an additional steam tube, made of either stainless steel or copper, which is placed parallel to the process tube.Depending on the length and the diameter of the tubes, the maintenance temperature can reach, at asteam pressure of 16 bar(g), almost 205°C.

2.2.3 Heat insulated tube bundles

Unheated tube bundles, which will be insulated with glass fibre or thermal fleece.The process tube can be made either of PTFE, stainless steel or copper.


2.3 Design

Electrical heated tube bundles and analyser lines are made up of a heating element and a single or multipleprocess tubes, as well as insulation and a protection jacket (steam traced and heat insulated tube bundleswill, of course not have heating elements).

The maximum number of process tubes per line depends on their diameter. The diameter of the line, on theother hand, will depend on the number of process tubes (see table on page 12).

2.3.1 Self regulating heating elements and parallel heating elements

The heating element is run parallel to the process tube(s). The construction of tube(s) and heating elementwill be wrapped with a heat reflecting protection foil in order to ensure that an equal maintenance tempera-ture is held within the process tube(s).Depending on the required temperature, the insulation of tube bundles will either be made of thermal fleece(<200°C) or glass fibre (<500°C). Analyser lines will be insulated with a silicone foam hose, as a standard.The protection jacket is optionally either with extruded plastic (tube bundles), corrugated tube or braiding(analyser lines).

PSG tube bundles have the special property, in that the multiple process tubes are twisted. As a result of the twisting the process tubes will always be in the correct position inside the tube bundle so this will ensured that alltubes have direct contact with the heating element, even if the tube bundle has to be bent.

Heating element

Heat reflectingprotection foil

Process tube(s)

Insulation

Protection jacket


2.3.2 Heating units with fixed resistance

Depending on the temperature requirements the heater cable is wrapped around the process tube(s) withmore or less intensity.

A Pt100 resistance thermometer or thermocouple element, required for the temperature controller, will bewrapped between the heater cable and the process tube(s) in a position as required.

The insulation consists of two layers. The first layer, a glass fibre hose, will be wrapped around the tube(s)and heating element, which will then be further covered with a silicone foam hose (second layer).

In case of very high media temperatures, the insulation can be made completely of glass fibre.

Depending on the application, the protection jacket will either be delivered with corrugated tubing or braiding.

Process tube

Heating cable

Glass fibre hose

Silicone foam hose

Protection jacket


2.4 Process tube

The selection of the process tube depends on the pressure, temperature and chemical resistance, as wellas the required flexibility of the line.Besides the standard tubes made of PTFE, there are also other plastics, such as PFA or PE and flexiblestainless steel tubes available.Stainless steel tubes are also available in various, commercially available, alloys.

2.4.1 Pressure resistance and temperature resistance

2.4.1.1 PTFE tubes

The following table shows the recommended working pressures (0,25 x short-time burst pressure) for thestandard dimensions 6, 8, 10 and 12 mm outer diameter at a wall thickness of 1 mm.

Please note that other dimensions (i.e. 1/8”, 1/4” etc.) are available upon request

2.4.1.2 Steel wire armoured PTFE tube

Where, not only, resistance to high pressure is required, but also tube flexibility, then PTFE tubes with asteel wire armour, are available according to the table below:


Material of steel wire armour: WN 1.4301 (DIN)/304 (ASTM)

Working temperature [°C] 20 50 75 100 150 200 250

Tube diameter Working pressure

6 x 1 mm 12,5 11 9,5 8,5 6,5 5 3,5

8 x 1 mm 9 8 7 6 5 3,5 2,5

10 x 1 mm 7 6 5,5 5 4 3 2

12 x 1 mm 6 5 4,5 4 3 2,5 1,5

Working pressure [bar]

Working temperature [°C] max. 250

Hose diameterDynamic Static

6 x 1 mm 275 440 50

8 x 1 mm 240 385 75

10 x 1 mm 200 320 100

12 x 1 mm 175 280 120

min.bending radius

(mm)


2.4.1.3 Stainless steel tube

The following table shows recommended working pressures for seamless stainless steel tubes in standardalloys according to DIN 14758 or respectively ASME B31.3, in standard dimensions 6, 8, 10 and 12 mm outside diameter with a wall thickness of 1 mm.For welded tubes, a reduced coefficient of 0,8 must be considered in order to ensure the integrity of theweld seam.


2.4.2 Chemical resistance and surface treatment of stainless steel tubes

Stainless steel tubes in tube bundles and analyser lines will be free of oil and grease as a general standard.

The surface of the tubes can be additionally treated upon request.Depending on the application there are different kinds of treatments available:

• Chemical cleanedaccording to ASTM A 632, supplement 3

• Electrochemical polishedcorrosion prevention, reduction of pressure drop

• Sulfinert® passivatedparticularly applicable for the measurement of sulphurous process media in very small concentrations

• Silicosteel® passivatedparticular applicable for sour/acid and aggressive process media, such as hydrochloric acid,nitric acid, sulphuric acid and sea water

The degree of chemical resistance for PTFE and stainless steel tubes alloys, as mentioned above, are sho-wn in „Table for Material Application“ on page 13. The table indicates which materials can be used for aparticular application.

Arbeitsdrücke [bar] bei 200∞C BetriebstemperaturMaterial keyacc. DIN (ASTM)

1.4571(316Ti)

1.4404(316L)

1.4401(316)

1.4306(304L)

1.4301(304)

2.4360(Monel 400)

Tube dimension Working temperature [°C]

6 x 1 mm 446 352 439 359 425 331

8 x 1 mm 320 256 319 261 309 244

10 x 1 mm 250 201 250 204 242 189

12 x 1 mm 205 165 206 168 199 158


2.4.3 Line diameter and number of the process tubes per line

The outside diameter of a line depends on the dimension and the number of process tubes.The maximum number of process tubes per line will depend on their dimension and the maximum possibleline outside diameter.

The following table shows the diameter of the process tubes, the number of process tubes and the approximate total line diameter.

For small process tube diameters (i.e. 6 x 1 and 8 x 1 mm) the maximum number of process tubes per tube bundlecan be more than four.The combination of different tube dimensions (e.g. 2 x 6 x 1 mm and 1 x 8 x 1 mm) is also possible. Please contactus in order that we can verify your requirements for a particular application.

Equivalent diameterof process tubes [mm] Protection jacket

tube bundle Protection jacket

analyser line

1 x 6 x 1 mm 6 42 38 or 43

2 x 6 x 1 mm 12,5 47 43

3 x 6 x 1 mm 13,4 48 43

4 x 6 x 1 mm 15 49 43

1 x 8 x 1 mm 8 43 38 or 43

2 x 8 x 1 mm 16,5 51 43

3 x 8 x 1 mm 17,7 52 53

4 x 8 x 1 mm 19,8 55 53

1 x 10 x 1 mm 10 45 43

2 x 10 x 1 mm 20,6 56 53

3 x 10 x 1 mm 22,2 57 53

4 x 10 x 1 mm 24,7 60 53

1 x 12 x 1 mm 12 47 43

2 x 12 x 1 mm 24,6 60 53

3 x 12 x 1 mm 26,4 61 53

4 x 12 x 1 mm 29,6 64 53

Qty. ofprocess tubes x

OD x wall thickness

Line outside diameter [mm]


3. AppendixTable for Application of Materials

Chemicals

PTF

E

PFA

PV

C

PA

Sili

kon

VA

1.4

571

(316

Ti)

VA

1.4

404

(316

L)

VA

1.4

401

(316

)

VA

1.4

306

(304

L)

VA

1.4

301

(304

)

2.43

60M

onel

400

Acetone – pure + + - + + + + + +

Acrylonitrile – pure + + - - + + +

Ammonia (gaseous) – pure + + - + + + + + + +

Aqua regia + + - - - - - - -

Benzene – pure + + - + - + + + + +

Benzine (hexane) – pure + + + + - + + + + +

Bromine (liquid) – pure + + - - - -

Butadiene (gaseous) – pure + + + + - + + + + +

Butane (gaseous and aqueous) + + + + - + + + + +

Carbon dioxide – dry + + + + + + + + + +

Carbon dioxide – moist + + + + + + + +

Carbon monoxide (carbonic oxide) + + + + + + + + + +

Carbon tetrachloride – pure + + - + - + + + + +

Caustic potash (potassium hydroxide) – aqueous + + + - + + + + +

Chlorine (aqueous) – pure + + - - - + + + + +

Chlorine (gaseous) – aqueous (chlorine water) + + - - - - - - - -

Chlorine (gaseous) – dry + + - - - + + + + +

Cyclohexane – pure + + + + - + + + + +

Dichloromethane (methylene chloride) – pure + + - - - + + + + +

Diethyl ether (ether) – pure + + - + - + + + + +

Dioxane – pure + + - + - + + + + +

Ethane – pure + + - + - + + + + +

Ethyl alcohol – pure + + + + + + + +

Ethyl acetate – pure + + - - + + + + +

Ethyl alcohol – pure + + + + + + + +

Ethylene glycol – pure + + + + + + + + +

Ethylene oxide – pure + + - - - + + + + +

Exhaust gas, containing hydrogen fluoride + + + + + + + +

Exhaust gas, containing carbon monoxide + + + + + + + + + +

Exhaust gas, containing NOx + + - + + + + +

Exhaust gas, containing hydrochloric acid + + + - -

Exhaust gas, containing sulphur dioxide (dry) + + + + + +

Exhaust gas, containing sulphuric acid (SO3 moist) + + + - + + + + +

Fluorcarbons (difluorodichloromethane) + + +

Formaldehyde – aqueous + + + + + + + + + +

Formic acid – pure + + - - - + + +

Heptane, hexane (benzine) – pure + + + + - + + + + +

Hydrobromic acid – aqueous + + + - - - - - - -

Hydrochloric acid – aqueous (36%) + + + - + + + + +

Hydrofluoric acid – aqueous - - - -

Hydrogen peroxide 0,5% + + - + + + + + + +

Hydrogen peroxide 30% + + - - +

Hydrosulphide – aqueous + + - - + + + + +


+ very low or no material damage: – resistant o low to medium heavy corrosion: – limited resistance– heavy to total corrosion: – non-resistant

All data shown in the table above are for reference only, without any responsibility for any service application made by the custo-mer. The data corresponds to the properties of the chemicals at room temperatures. It is therefore important for the customer tocheck with a material specialist, when he is not sure of the materials stability regarding temperature, pressure, and concentrationof the service medium.

Chemikalien

PTF

E

PFA

PV

C

PA

Sili

kon

VA

1.4

571

(316

Ti)

VA

1.4

404

(316

L)

VA

1.4

401

(316

)

VA

1.4

306

(304

L)

VA

1.4

301

(304

)

2.43

60M

onel

400

Inert gas + + + + + + +

Isobutanol – pure + + - + + + + + + +

Kerosene (benzene) + + + + - + + + + +

Marsh gas (methane) + + + - + + + + +

Methane (marsh gas) – pure + + + - + + + + +

Methanol (methyl alcohol) + + + + + + + +

Methyl alcohol (methanol) – pure + + + + + + + +

Methyl chloride – pure + + - - + + + + +

Methylene chloride (dichloromethane) – pure + + - - - + + + + +

Natural gas + + + + - + + + + +

Nitric acid – aqueous (40%) + + - - + + + + +

Nitro toluene (o-, m-, p-) – pure + + - - + + + + +

Nitrogen + + + + + + + + +

Oleum (fuming sulphuric acid) + + - - + + + + +

Paraffin oil (mineral oil) + + + + + + + +

Peracetic acid – aqueous (6%) + + + - + + + + +

Perchloroethylene (tetrachloroethylene) – pure + + - - + + + + +

Petroleum benzine, petroleum ether + + + + - + + + + +

Phenol aqueous (saturated) + + + - + + + + +

Phosgene (aqueous) – pure + + - + + + + +

Phosgene (gaseous) – pure + + + - + + + + +

Phosphoric acid – aqueous + + + - - + + +

Phosphoric chloride – pure + + - -

Propane (aqueous and gaseous) – pure + + + + - + + + + +

Propanol (isopropanol) – pure + + + - + + + + +

Propylene glycol – pure + + + + + + + + +

Pyridine – pure + + - + - + + + + +

Sea water + + + + +

Silicone oil + + + + + + + + +

Solvent naphtha – pure (Shellsol D) + + + - + + + + +

Sour gas + + +

Styrene + + - + - + + + + +

Sulphur dioxide (aqueous) – pure + + - - - + + + + +

Sulphur dioxide (gas, moist) + + - + + + + +

Sulphur dioxide (gas, dry) – pure + + - + + + + +

Sulphuric acid – aqueous + + + - - + + + + +

Sulphuric acid – concentrated (96%) + + - - - - - - - -

Sulphuric acid – aqueous (30%) + + + - - - - - - -

Tetrachloroethylene (perchloroethylene) + + - - + + + + +

Toluene – pure + + - + - + + + + +

Vinyl chloride – pure + + - -


Stock of our Tubing


1. Tube bundles and analyser lines

1.1 Electrically traced tube bundles andanalyser lines with self-regulatingheating elements

Technical data

Power consumptionrelative to the number of process tubes and their diameter at an ambient temperature of 10°C

Maximum heating circuit lengthat an ambient temperature of 10°C and with a 16 A (25 A) circuit breaker

The shown ratings apply to a single heating circuit. In case of multiple power supplies for additional heating circuits, the maximum tube bundle length (also in hazardous areas) will be: Number of power supplies x max. heating circuit length (for further details see data sheet for „Accessories for tube bundles and analyser lines“).

Power rate [W/m] 16 25 38 47 63

Max. heating circuit length; meter

230 V 165 (165) 105 (165) 75 (120) 60 (95) 45 (75)

115 V 82 (81) 52 (182) 37 (60) 30 (47) 22 (37)

Maintenance temperature [°C] 30 80 100 120 150

Power rating W/m

1x6x1, 1x8x1, 1x10x1, 1x12x1 mm 16 25 38 47 63

2x6x1, 2x8x1, 2x10x1, 2x12x1 mm 25 38 47 63 upon request

1x6x1, 1x8x1 replaceable core 25 38 47 63 upon request

Maintenance temperature up to 150°C

Explosion-proof

Steam purging resistant up to 215°C

PVC, TPU, or PA corrugated/metal sheath

PTFE, PFA or stainless steel process tubes

Easy installation

Prefabricated lengths acc. to requirements or drum delivery

Application

Frost protection and maintaining of process temperatures up to150°C, also in hazardous areas.

Description

Electrically traced tube bundles and analyser lines with self-regula-ting heating elements work without need for a temperature controllerand can therefore be connected directly to the power supply. Theheating elements will be rated according to the required temperatureand the local conditions on site. Upon request the tube bundles canbe prefabricated (i.e. cut to the required lengths and terminated), ordelivered on coils and provided with termination sets. The terminati-on and installation on site is relatively simple, because the tubebundles can be cut at any point. Further information regarding self-regulating heating elements, as well as the design of the tubes, typesof protection jackets, insulation, number of the process tubes andtheir dimensions can be found in the section „General informationand technical data for tube bundles and analyser lines“.


Temperature and power rating graphics

The graphics apply to process tubes with the sizes 1x6x1 mm and 1x8x1 mm (stainless steel or PTFE)

63 W/m

47 W/m

30 W/m

25 W/m

16 W/m

Process tube temperature [°C]

Po

wer

Rat

ing

[°C

]

63 W/m

47 W/m

30 W/m

25 W/m

16 W/m

Ambient Temperature [°C]

(Pro

cess

tub

e te

mp

erat

ure

[°C

]


1.2 Electrically traced tube bundles andanalyser lines with parallel heatingelements – CPD

Technical data

Voltage: 230 V or 115 VFrequency: 50…60 HzPower rate: 40 W/m or 60 W/m

At a power rate of 60 W/m a temperature controller will be required (e.g. PSG ST-49 controller)

Maximum heating circuit lengthusing a 16 A (25 A) circuit breaker and suitable controller with an adequate switching capacity

Power rate [W/m] 40 60


230 V 75 (115) 50 (75)

115V 38 (58) 25 (38)


Temperature resistant up to 260°C

Prefabricated lengths acc. to require-ments

PVC, TPU, or PA corrugated/metal sheath


Explosion-proof(not according to ATEX!)

Application

Maintaining of process temperatures up to 200°C.

Description

Tube bundles and analyser lines with parallel heating elements aregenerally used to transport gases with high dew points, as requiredin exhaust emission measurements according to BImSchV (FederalEmission Control Act). Another application is the flow improvementof viscous media. Also substances with a high melting point can betransported reliably. Upon request the tube bundles can be prefabri-cated (i.e. cut to the required lengths), or delivered on coils. The par-allel heating elements are in segments of a defined length, thereforeshortening is only possible every 60 cm. The line must be cutexactly at the correct point (the point where the heating element segment and the current-carrying wires are connected) in order toprevent a cold line end. An overview of the various types of line ter-minations is available in the section „Accessories“. Further informati-on regarding parallel heating elements, as well as the design of thetubes, types of protection jackets, insulation, number of the processtubes and their dimensions can be found in the section „General in-formation and technical data for tube bundles and analyser lines“.


Temperature graphics

The graphics apply to process tubes with the sizes 1x6x1 mm and 1x8x1 mm (stainless steel or PTFE)

60 W/m


(Pro

cess

tub

e te

mp

erat

ure

[°C

]

40 W/m


(Pro

cess

tub

e te

mp

erat

ure

[°C

]


1.3 Electrically traced analyser lines withfixed resistance heater

Technical data

Voltage: 230 V or 115 V, single or three phaseFrequency: 50…60 HzPower rate: 90 W/m or 120 W/m

Maximum heating circuit lengthusing a 16 A (25 A) circuit breaker and suitable controller with an adequate switching capacity

Power rate [W/m] 90 (1~) 90 (3~) 120 (1~)


230 V 35 (50) 105 (150) 25 (38)

115V 16 (25) 32 (50) 12 (20)

Flexibel


Explosion-proof

Prefabricated terminations

Corrugated plastic/metal tubing or plastic braiding


Application

Maintenance of process temperatures up to 250°C.

Description

Electrically traced analyser lines with fixed resistance heaters servemainly the transportation of gases with high dew points, as requiredfor exhaust emission measurements according BImSchV (FederalEmission Control Act) or for motor vehicle exhaust gas measure-ments. Another application is the flow improvement of viscous media. Also substances with a high melting point can be transportedreliably. Flexible lines with corrugated plastic or metal tubing, as wellas high flexible lines with a plastic or metal braiding are particularlysuitable for mobile applications, such as labs and test beds. The lines will be delivered prefabricated, i.e. manufactured in definedlength and terminated. An overview of the various types of line termi-nations is available in the section „Accessories“. Further informationregarding the heaters with fixed resistance, as well as the design ofthe tubes, types of protection jackets, insulation, number of the process tubes and their dimensions can be found in the section „General information and technical data for tube bundles and analyser lines“.


Temperature graphic

The graphic applies to process tubes with the sizes 1x6x1 mm and 1x8x1 mm (stainless steel or PTFE)

120 W/m

90 W/m


(Pro

cess

tub

e te

mp

erat

ure

[°C

]


1.4 Steam traced tube bundles and analyser lines

Temperature/Tube length graphicbased on an ambient temperature of -30°C

The graphic applies to process and steam tubing 2x6x1 mm (1x process and 1x steam tracing).

100

120

140

160

180

200

220

0 10 20 30 40 50 60 70

length

Pro

cess

tub

e te

mp

erat

ure

2 bar

16 bar

Particularly suitable for hazardousareas

PVC, TPU, or corrugated plastic/metal tubing

Stainless steel or copper process/steam tubing

Easy installation

Prefabricated lengths acc. to require-ments or Drum delivery

Application

Maintaining of process temperatures up to 205°C, also in hazardousareas.

Description

Steam traced tube bundles and analyser lines are generally used totransport gases with high dew points, as required in exhaust emissi-on measurements according BImSchV (Federal Emission ControlAct). Another application is the flow improvement of viscous media.Also substances with a high melting point can be transported reliab-ly. Steam traced lines operate without any electrical connections.Therefore they are particularly suitable for use in hazardous areas.On customer’s request the lines will be prefabricated, i.e. cut in defined length and terminated, or delivered on coils with providedtermination sets. An overview of the various types of line terminati-ons is available in the section „Accessories“. Further information regarding the design of the tubes, types of protection jackets, insulation, number of the process tubes and their dimensions can befound in the section „General information and technical data for tubebundles and analyser lines“.


1.5 Insulated tube bundles and 1.5 analyser lines

Application

Frost protection and maintaining of process temperatures.

Description

Insulated tube bundles and analyser lines are generally used totransport liquid and gaseous media, in non-critical temperature ap-plications. The maintaining of temperature depends on many factors,the process media temperature, the ambient temperature, the flowvelocity, the tube length, the tube diameter as well as the process tube material and therefore must be carefully calculated for each application. Upon request the tube bundles can be prefabricated (i.e.cut to the required lengths), or delivered on coils. An overview of thevarious types of line terminations is available in the section „Acces-sories“. Further information regarding the design of the tubes, typesof protection jackets, insulation, number of the process tubes andtheir dimensions can be found in the section „General informationand technical data for tube bundles and analyser lines“.

PVC, TPU, or corrugated plastic/metaltubing

PTFE, stainless steel or copper processtubes

Easy installation

Prefabricated lengths acc. to requirements or Drum delivery


Installation and start-up operation

General

All PSG-lines, which are electrically heated, must be treated as „electrical equipment“. The constructionand connection design are according to the acknowledged technology standards. Equally the regulationsfor mounting start up and operation must be observed.

Chemical resistance

In the PSG Project data sheet the customer is required to specify the process medium. With this information PSG will determine which material for the process tubes, such as PTFE, PFA or stainless steel is suitable.


Temperature measurement and automatic control

For measuring the temperature, sensors are installed on the surface of the process tube. It has to be fun-damentally decided whether temperature control or 2-point (Relays) operation is required.

The ambient temperatures at the point where the sensors are located influence the whole control philoso-phy and accordingly the internal temperature of the sample line. Therefore, for safety reasons, the sensorshould be placed where the highest ambient temperature will be experienced.

Sensors for safety temperature switches must always be placed where the ambient temperature is the hig-hest. As a rule the switch will be set at the max. permitted temperature. After this, the temperature control-ler sensor may be set according to customer's requirements.

Installation

All lines, except those with self-regulation, shall not be installed in conduit or closed cable trays, becausethere is a danger that overheating of the line might occur.

We recommend that the lines be installed on „C“ type profile channel and fixed with mounting clamps. Thedistance between lines, except those with self-regulation, should always be kept to at least 25 mm.

The laying of heat traced sample lines outdoors should always have some form of protection (otherwisethere is the possibility of heat losses due to wind).

Where the lines pass through wall and ceiling ducts the lines must be laid free, i.e. without any insulation.

Installation hints for lines with a PVC jacket:

Smallest bending radius approx. 200 mmMin. temperature for tube/line pulling approx. -9 °CHorizontal distance between fixations every 1,2 mVertical distance between fixations every 3,5 m

Installation hints for lines with a PA jacket:

Smallest bending radius approx. 100 mmMin. temperature for tube/line pulling approx. 0 °CHorizontal distance between fixations every 1,0 mVertical distance between fixations every 2,5 m


The installation must be carried out, so that there will be no movement or stress exerted directly at the connec-ting point. Flanges, fittings, valves etc. must not be used as pulling or suspension points. For the vertical lay-ing the minimum distances between fixations has to be observed, otherwise it is recommended to install asupport wire for stress relief.

Line coils have to be uncoiled carefully, so that no torsional strain is exerted, since the lines are not designedfor such forces. They have to be mounted in such a manner that the centre line of the tube and the directionof movement will lie in the same plane. The bending radii have to be larger than the permissible values.

When screwed fittings and connections are to be tightened then a counteracting spanner has to be used. On-ly clamps, tightening straps or similar holding devices, which do not considerably impair the insulation layer,are allowed (Pressure points should not be deeper then 10% of the jacket total diameter).

The lines should not be laid across sharp edges and through cutouts. For very robust applications we re-commend a corrugated metal hose for the jacket.

Please also observe the installation and laying instructions on the following pages. The mounting instructionsenclosed in the mounting kits from PSG must be observed. Check if hose, sensor, temperature control, linesections and fuse are well suited to each other. Mixing up sensors and overloading controllers may lead tothe line being damaged. Please observe that self-regulating heating elements may have a fivefold startingcurrent, depending on the ambient temperature. Always make sure to use fuses with a „C“-characteristic.

When in doubt ask your PSG serviceman.

The heating-up of the sample lines may take up to 1 hour, depending on the ambient temperature. Pleaseconsider this before you allow the process medium to flow through the lines for the first time. Only mountingkits approved by PSG should be used for the finishing and, if necessary, for the alteration of line lengths.


Lay heated lines on „C“-profiles by means of cable clamps.

Distance: 25 mm (about an inch)Fixation: horizontal lines

every 1.2 mvertical linesevery 3.5 m

Min. bending radius: 200 mmTemperature for laying: -9,5 °C

Do not lay heated sample lines bundled togetherin cable trays, especially not when these are covered.

Do not form any syphons during the installation,especially not near the sampling point.

Do not lay heated sample lines in conduit.


Do not squeeze the heat insulation with theclamps so much, that the braid is pressed on tothe heating conductor. Failure to observe thismay lead to damage of the protecting braid andthe tube.

Bundling or laying the tubes so that they come in-to contact with each other, leads to overheatingin the contact area.

Remedy: A space of 25 mm between the tubes.

Wall ducts must not be filled with foam or insula-ted. Use bulkhead plates with glands (M).

Heat accumulation also occurs when insulatingmaterial is wrapped around the heating tube,which leads to local over-heating. If the area aro-und the sensor is covered, then the remainingparts of the tube will cool down.

If for example powdery substances, glue or otherheat insulating material is poured on to heatingtubes, over-heating in these places will occur.

Remedy: Clean tubes persistantly and eliminatethe reason for the trouble.

If heating tubes are layed in a duct or trench, heatwill accumulate.

Remedy: The tubes must not touch each other.Moreover, sufficient ventilation has to be provi-ded. Distance between tubes 25 mm.

wrong right


Head-end prefabrication for parallel heating element 60 W/m

– remove cable insulation until cable is uncovered

– measure ohmic resistance between short-circuited conductors and the heating coil made of resistancewire

– 19,5 ohm correspond to 1 cm

Example: a measured value of 1500 ohmcorresponds with 1500 ohm

58 cm to the next grid(contact point).

19,5 ohm/cm

– continue removing the cable insulation until about 2 cm remain to the grid

– cut off heating cable so that at least 3 cm remain to the grid (contact point) and split the ends

– cut away the heating coil up to the cable insulation

– connect by means of PIDG-crimper the screen and the stripped conductors with the supply cable(3 x 2.5 mm2)

– seal the line end with silicone compound and push end piece on top of it

– seal the end piece and the line by means of the heatshrinking sleeve

heating cable

grid process tube


Seal line end and end piece with heat shrinkingsleeve.The heat-shrinking should, if possible, be carriedout with a hot air blower.

Push the end piece over the process tube heatshrinking sleeve.

Splice heating cable ends and insulate them fromthe process tube by means of the enclosed heatshrinking sleeve.

Cut away about 20 cm from the jacket of the line. Push back heat insulation and seal line end withpotting compound.

Gas sample conductor

potting compound

heating cable braid

heating coilresistance wire

1 cm offset insulated

copper conductor

heating cablebraid heat-shrinking sleeve

Gas sample conductor

potting compound

heat-shrinking sleeve


Mounting instruction for sample lines with parallel-heater (probe side)


Twisting Machine

Twisting machine head


Heating elements (self-controlling)

The sample lines of the series 50.01- and 50.02- are equipped with self-controlling heating cables.

Self-controlling heating cables consist of cross-linked polyolefines and of fluoropolymers with portions ofgraphite. The graphite portion determines the electrical resistance, which in turn increases steeply on anincrease of temperature. Accordingly on temperature increase the current consumption and the heat dissipation will reduce to zero. The reverse will then take place when the temperature drops.

It is interesting to note that this control is independent of the position in the heating cable, it is only dependent on the temperature at that particular point in the cable.

This effect therefore enables the heating cable to be used in explosion-proof areas without any thermostatic control.

tinned copper wire

self-controlling heating elementmade of semiconducting material

electrical insulation

protecting braid made of tinned,stranded copper wire

protecting sheath of polyolefine


order no.

PSG analysis linesfor temperatures up to 30 °C(frost-protection) ready-made, self-controlling

Line for sampling, analysis and instruments is fully insulated and ready-madewith a PSG end piece, gland and mounting kit for the line end.

Jacket, extruded and flame retardant, made of PVC YM4 according to VDE 0207.

Self-controlling heating element

Diameter: 42 mmGland: M 63 x 1,5

1 x 6 x 1 mm stainless steel process tube (inside dia. 4 mm) 50.01.01.001 x 8 x 1 mm stainless steel process tube (inside dia. 6 mm) 50.01.02.00

1 x 6 x 1 mm PTFE process tube (inside dia. 4 mm) 50.01.03.001 x 8 x 1 mm PTFE process tube (inside dia. 6 mm) 50.01.04.00

Termination for self-regulating line, prefabricated 50.05.02.00

Termination set (analyser side) 50.05.55.00Termination set (sample side) 50.05.44.00


order no.

Explosion-proof analysis lines from PSGfor temperatures up to 30 °C (frost-protection)ready-made, self-controlling



Self-controlling heating element, PTB explosion-proof zone 1, class T3




Termination (analyser side) for hazardous area, prefabricated 50.08.10.00Termination (sample side) for hazardous area, prefabricated 50.08.11.00

Termination set (analyser side) for hazardous area 50.08.12.10Termination set (sample side) for hazardous area 50.08.12.12


order no.

Analysis lines from PSGfor temperatures up to 100 °Cready-made, self-controlling



Self-controlling heating element




Termination for self-regulating line, prefabricated 50.05.02.00

Termination set (analyser side) 50.05.55.00Termination set (sample side) 50.05.44.00


order no.

Explosion-proof analysis lines from PSGfor temperatures up to 100 °Cready-made, self-controlling

Line for sampling, analysis and instruments is fully insulated and ready-made witha PSG end piece, gland and mounting kit for the line end.


Self-controlling heating element, PTB explosion-proof zone 1, class T3




Termination (analyser side) for hazardous area, prefabricated 50.08.10.00Termination (sample side) for hazardous area, prefabricated 50.08.11.00

Termination set (analyser side) for hazardous area 50.08.12.11Termination set (sample side) for hazardous area 50.08.12.13


Protection jacket extruding machine


Heating cables (parallel heaters)

The sample lines of the series 50.03- and 50.04- are, according to the required heating power, equippedwith parallel heating cables (constant power density, CPD). In these cables the heating elements consist oftwo parallel copper wires and a heating spiral made of chrome-nickel wire.

At certain distances - standard is 60 cm - there are parallel grids with equal resistance and therefore equalpower.

The insulation of the heating cables is primarily PTFE (Teflon), further Kapton surrounded by woven glass fibres and coated with PTFE.

The shield is made of wire of the size AWG 37; 50% tinned copper and 50% stainless steel.

Resistance wire

PTFE-insulation

One of the grids, alternately arranged

Nickel-plated copper

Dielectric/damp proofing madeof Kapton

Electrical insulation madeof Kapton

protecting braid made oftinned, stranded copper andstainless steel wire


order no.

PSG analysis lines for temperatures up to 200 °Cready-made



CPD heating element

Diameter: 42/43/47 mmGland: M 63 x 1,5



2 x 6 x 1 mm PTFE process tube (inside dia. 4 mm) 50.03.05.00

Termination for controlled line 50.05.01.00Termination for uncontrolled line 50.05.02.00

Termination set (analyser side) with replaceable temperature sensor (sleeve well) 50.05.05.00Termination set (analyser side) with temperature sensor (fixed) 50.05.05.01Termination set (sample side) 50.05.04.00


order no.

Analysis lines from PSG, tube replaceable for temperatures up to 200 °C, ready-made



CPD heating element

The process tube (6 x1 mm PTFE-Teflon) is layed inside a supporting tube(10 x 1 mm PTFE).This technique makes it possible to replace the process tube later. In addition, it has the advantage of diffusion protection which can be used for highly sensitive measurements.

Diameter: 45/47 mmGland: M 63 x 1,5

1 x 6 x 1 mm PTFE (inside dia. 4 mm) process tube replaceable 50.04.01.001 x 8 x 1 mm PTFE (inside dia. 4 mm) process tube replaceable 50.04.02.00

Termination for controlled line 50.05.01.00

Termination set (analyser side) with replaceable temperature 50.05.05.00sensor (sleeve well)Termination set (analyser side) with temperature sensor 50.05.05.01Termination set (sample side) 50.05.04.00


Heating elements with fixed resistance

The analysis lines of the series 51.01 are equipped with fixed resistance heating cables. The PSG productselection comprises a great number of different designs according to the specific application.

Heating cables used by PSG comply with the VDE-Guideline 0253.

A PTFE-insulation together with a nickled copper braid is wound around the resistance wire. This braid isalso useful for the fault current control.

The thermal insulation of the analysis lines is achieved by a silicone hose, which is heat-stabilised and hasclosed pores. The sheath is, depending on customer’s request, a plastic or steel braid or a corrugated hose.

stainless-steel braid

PTFE process tube

heating conductor

thermal insulation

sheath

silicone cap

power supply 220 V andtemperature sensor

process valve


order no.

PSG analysis line for temperatures up to 250 °Chighly flexible

Lines for sampling, analysis and instruments. Thermal insulation by means of a heatstabilised silicone foam hose with closed pores. External protecting braid of woven,black polyamid.

Rated voltage: 230 V 1 x 6 x 1 mm PTFE (NW4), 100 °C 51.01.01.00basic price, see 51.01.11.00

Heating: Heating cable PTFE with fixedresistance and protecting braidaccording to VDE 0253 1 x 8 x 1 mm PTFE (NW6), 100 °C 51.01.02.00

basic price, see 51.01.22.00Prefabrication: Silicone cap with StSt (1.4571)

connector without joint, 1 x 6 x 1 mm PTFE (NW4), 200 °C 51.01.03.00diameter ca. 41 mm, basic price, see 51.01.33.00min. bending radius approx. 50 mm

1 x 8 x 1 mm PTFE (NW6), 200 °C 51.01.04.00Temperature- Resistance thermometer PT-100, basic price, see 51.01.44.00probe: DIN 43760

1 x 6 x 1 mm PTFE (NW4), 250 °C 51.01.05.00Supply cable: standard length 3 m basic price, see 51.01.55.00

Process tube: 6 x 1 mm PTFE withone braiding layer 1 x 8 x 1 mm PTFE (NW6), 250 °C 51.01.06.00of StSt-wire basic price, see 51.01.66.008 x 1 mm PTFE with onebraiding layer of StSt-wire Pt-100 probe 50.06.15.00

Operating temperature switch 50.06.16.00temperatures: 100 °C - 200 °C - 250 °C tread proof type 51.01.70.00

Metal braided protection jacket 51.01.71.00


order no.

PSG analysis lines for temperatures up to 250 °Chighly flexible, with exchangeable process tube

Lines for sampling, analysis and instruments. Thermal insulation by means ofa heat stabilised silicone foam hose with closed pores. External protectingbraid of woven, black polyamid.


Heating: Heating cable PTFE with fixedresistance and protecting braidaccording to VDE 0253 1 x 8 x 1 mm PTFE (NW6), 100 °C 51.02.02.00

basic price, see 51.02.22.00Prefabrication: Silicone cap with StSt (1.4571)

Connector without joint, 1 x 6 x 1 mm PTFE (NW4), 200 °C 51.02.03.00diameter ca. 41 mm, basic price, see 51.02.33.00min. bending radius approx. 50 mm

1 x 8 x 1 mm PTFE (NW6), 200 °C 51.02.04.00Temperature- Resistance thermometer Pt-100, basic price, see 51.02.44.00probe: DIN 43760

1 x 6 x 1 mm PTFE (NW4), 250 °C 51.02.05.00Supply cable: standard length 3 m basic price, see 51.02.55.00

Supporting tube: 10 x 1 mm PTFE with onebraiding layer 1 x 8 x 1 mm PTFE (NW6), 250 °C 51.02.06.00of StSt-wire basic price, see 51.02.66.00

Process tube: 6 x 1 mm PTFE Pt-100 probe 50.06.15.00

Supporting tube: 12 x 1 mm PTFE with one braidinglayer of StSt-wire temperature switch 50.06.15.00

tread proof type 51.01.70.00

Process tube: 8 x 1 mm PTFE

Operatingtemperatures: 100 °C - 200 °C - 250 °C


order no.

PSG analysis lines for temperatures up to 250 °Chighly flexible, adaptation with hard cap

Lines for sampling, analysis and instruments. Thermal insulation by means of a heatstabilised silicone foam hose with closed pores. External protecting braid made ofpolyamid 6. Corrugated hose, flame retardant, non-halogen, black. The ready-madehard cap is service friendly. It enables you to adapt the analysis line during mounting, when self-controlling or CPD heating cables are used.


Heating: Self-controlling heating cables, with power depending on 1 x 8 x 1 mm PTFE (NW6), 60 °C 51.03.02.00temperature range, for ca.120 °C. basic price, see 51.03.22.00Heating cables with fixed resistance 1 x 6 x 1 mm PTFE (NW4), 100 °C 51.03.03.00for ca. 250 °C. basic price, see 51.03.33.00

Prefabrication: Hard-cap adaptation, 1 x 8 x 1 mm PTFE (NW6), 100 °C 51.03.04.00hose diameter ca. 42 mm, basic price, see 51.03.44.00min. bending radius ca. 50 mm

1 x 6 x 1 mm PTFE (NW4), 200 °C 51.03.05.00basic price, see 51.03.55.00

Temperature- Resistance thermometer PT-100,probe: DIN 43760 1 x 8 x 1 mm PTFE (NW6), 200 °C 51.03.06.00Supply cable: fixed on hard cap with PG 11 gland basic price, see 51.03.66.00

Process tube: 6 x 1 mm PTFE 1 x 6 x 1 mm PTFE (NW4), 250 °C 51.03.07.008 x 1 mm PTFE basic price, see 51.03.77.00

Operating 1 x 8 x 1 mm PTFE (NW6), 250 °C 51.03.08.00temperatures: 60 °C - 100 °C - 200 °C - 250 °C basic price, see 51.03.88.00

PT-100 probe 50.06.15.00temperature switch 50.06.16.00tread-proof type 51.01.70.00StSt-adapter 6 mm 51.03.12.00StSt-adapter 8 mm 51.03.23.00Metal braided protection jacket 51.01.71.00


order no.

PSG analysis lines for temperatures up to 250 °Chighly flexible, adaptation with hard cap

Lines for sampling, analysis and instruments. Thermal insulation by means of a heatstabilised silicone foam hose with closed pores. External protecting braid made ofpolyamid 6. Corrugated hose, flame retardant, non-halogen, black.

Rated voltage: 230 V, supply via hard cap 1 x 6 x 1 mm PTFE (NW4), 100 °C 51.04.01.00basic price, see 51.04.11.00

Heating: Heating cable with fixed resistance, PTFE with protecting braid 1 x 8 x 1 mm PTFE (NW6), 100 °C 51.04.02.00according to VDE 0253 basic price, see 51.04.22.00

Prefabrication: Hard cap adaptation, 1 x 6 x 1 mm PTFE (NW4), 200 °C 51.04.03.00hose diameter ca. 42 mm, basic price, see 51.04.33.00min. bending radius ca. 100 mm

1 x 8 x 1 mm PTFE (NW6), 200 °C 51.04.04.00Temperature- Resistance thermometer PT-100, basic price, see 51.04.44.00probe: DIN 43760,

1 x 6 x 1 mm PTFE (NW4), 250 °C 51.04.05.00basic price, see 51.04.55.00

Supply: By hard cap 1 x 8 x 1 mm PTFE (NW6), 250 °C 51.04.06.00basic price, see 51.04.66.00

Process tube: 6 x 1 mm PTFE PT-100 probe 50.06.15.008 x 1 mm PTFE temperature switch 50.06.16.00

tread proof type 51.01.70.00Operating StSt-adapter 6 mm 51.03.12.00temperatures: 100 °C- 200 °C- 250 °C StSt-adapter 8 mm 51.03.23.00

Metal braided protection jacket 51.01.71.00


order no.

Highly flexible sample line for temperatures up to 250 °C, ready-made

Special line for a connection without any thermal losses between the sample,preparation and analysis areas.

The sample line is operated with a resistance heating, which compensates for thetemperature losses at the top and at the bottom of the line. The heat insulation ismade of a superior (inorganic) glass fibre.

The jacket is a corrugated polyamid hose. Within the flange connections thetransition from a stainless steel adapter to a PTFE process tube is achievedwithout any thermal loss. Voltage supply via multipole connector. The sampleline is delivered with 2 integrated Pt-100 temperature probes.

Connection adapter with diameter 6 mm, material StSt 51.05.05.00

Tread proof type, additional price, see 51.01.70.00

Treat proof type, PVC coated, watertight, additional price 51.01.77.00


order no.

51.0X.XX.00


order no.

PSG analysis lines, steam heated

Lines for sampling, analysis and instruments. K-Tex heat insulation made of (inorganic)glass fibres. Jacket made of extruded, flame retardant PVC.

Temperature range:Operating temperature 205 °C at a steam pressure of 16 bar contact temperature 60 °Cdiameter ca. 40 mm.

process tubes/steam tubes

2 x 6 x 1 mm (NW4), StSt (1.4571), max. 350 bar/200 °C 52.01.01.00




pro

cess

-tub

e te

mp

erat

ure

°C

pro

cess

-tub

e te

mp

erat

ure

°C

at -40 °C ambient temperature at -26 °C ambient temperature

length (m) length (m)


order no.

PSG heat-insulated tubes

For product, sampling and instrument lines. K-Tex heat insulation made of (inorganic)glass fibres. Jacket made of extruded, flame retardant PVC. Operating temperatureor process tube at 200 °C, contact temperature for jacket at 60 °C.

Outer diameter

6 x 1 mm 28 mm dia.8 x 1 mm 30 mm dia.10 x 1 mm 32 mm dia.12 x 1 mm 33 mm dia.

Process tube

1 x 6 x 1 mm (NW4) copper max. 180 bar/20 °C 52.02.01.001 x 8 x 1 mm (NW6) copper max. 125 bar/20 °C 52.02.02.001 x 10 x 1 mm (NW8) copper max. 100 bar/20 °C 52.02.03.001 x 12 x 1 mm (NW10) copper max. 180 bar/20 °C 52.02.04.00

1 x 6 x 1 mm (NW4) StSt 1.4571 max. 350 bar/200 °C 52.02.05.001 x 8 x 1 mm (NW6) StSt 1.4571 max. 263 bar/200 °C 52.02.06.001 x 10 x 1 mm (NW8) StSt 1.4571 max. 210 bar/200 °C 52.02.07.001 x 12 x 1 mm (NW10) StSt 1.4571 max. 175 bar/200 °C 52.02.08.00

1 x 1.475 equivalent to 316 StSt


Temporary stock


2. Accessories

PSG Petro Service will pleased to provide you with all the main accessories required for the installation ofyour tube bundles and analyser lines.

Our thermometers are replaceable and therefore, in case of a failure, can be repaired. The controllers meetthe industrial standards and feature minimum and maximum alarms, so that they not only serve as control-lers but also provide alarm indication.

The EEx temperature controller combination with min. and max. switches can be installed on site in hazar-dous areas. For selection of the explosion proof heating elements, we set high priority on the simple man-ner in which they can be installed. Our accessories for the assembly of tubes/lines are designed to make apractical installation as easy as possible.

Moreover, we offer you a number of termination and connection boxes, which you can heat, e.g. using anexcess of heating cable from the connected line. All our accessories have been tested in practice and meetthe standard requirements of industrial users.


2. Accessories

2.1 Terminations for analyser and sampling points

POM/PTFE cap

POM/PTFE cap for hazardous area

POM/PTFE cap for hazardous area, with power supply via hard cap

Material: POM or PTFEhard cap made of glass fibre reinforced polyamide

Temp. stability: POM max. +95°CPTFE max. +250°CHard cap max. +100°C

Power supply: Heater cable overhang of 500 mmconnected to EEx e termination box

If the required length is longer than the maximum heating circuit length, thenthis can be realise with multiple power supplies and additional heating circuits to complete the required tube bundle length. Please contact us inorder that we can verify your requirements for a particular application.

Material: POM or PTFETemp. stability: POM max. +95°C

PTFE max. +250°CPower supply: Heater cable overhang of 500 mm

connected to EEx e termination boxOptional: Resistance thermometer PT100

in Ex or non-Ex versionusing a non-Ex PT100 in a hazardous area requires a safetybarrier, the Ex-PT100 (dip-tube) is inserted at front end ofthe line.

Material: POM or PTFETemp. stability: POM max. +95°C

PTFE max. +250°CPower supply: Silicone cable

3x1,5 mm2 or 3x2,5 mm2,length 3 m

Optional: Resistance thermometer PT100or thermocouplelocated inside the line between process tube and heatingelement, connection cable separated from power supplythrough cable gland M12


Silicone cap (connection cable exit front or rear end)

Silicone cap (connection cable exit at the side)

Silicone cap for hazardous area

Material: SiliconeTemp. stability: max. +200°CPower supply: Heater cable overhang of 500 mm

connected to EEx e termination boxOptional: Resistance thermometer PT100,

in non-Ex versioninserted inside the line between process tube and heatingelement, using a non-Ex PT100 in a hazardous area requi-res a safety barrier signal cable exit front end together withprocess tube

Material: SiliconeTemp. stability: max. +200°CPower supply: Silicone cable

3x1,5 mm2 or 3x2,5 mm2,length 3 m, exit sideways

Optional: Resistance thermometer PT100or thermocoupleinserted inside the line between process tube and heatingelement, signal cable exit sideways separated from powersupply

Material: SiliconeTemp. stability: max. +200°CPower supply: Silicone cable

3x1,5 mm2 or 3x2,5 mm2,length 3 m, exit rear orat front end together with process tube

Optional: Resistance thermometer PT100or thermocoupleinserted inside the line between process tube and heatingelement, signal cable exit rear or at front end together withprocess tube


Hard cap

Metal cap

Flange

Material: Stainless steel (St. St. 316Ti), PTFE, aluminium,polyamide

Temp. stability: max. +250°CSpecial feature: Replaceable stainless steel connection nipple

6x1 mm or 8x1 mm,with metal support and flange connection,diameter 42/50 mm, bore size Ø 6 mm.

Power supply: Silicone cable3x1,5 mm2 or 3x2,5 mm2, length 3 m, led out througha cable gland M20 with a separate hard cap,inserted at any suitable position

Optional: Resistance thermometer PT100or thermocoupleinserted inside the line between process tube and heatingelement, signal cable separated from power supply, bothterminated in the same way.

Material: Stainless steel (St. St. 316Ti), PTFE, aluminium,polyamide or silicone


6x1 mm or 8x1 mm,alternatively with metal support or silicone cap

Power supply: Silicone cable3x1,5 mm2 or 3x2,5 mm2, length 3 m, led out througha cable gland M20 by a separate hard cap,inserted at any suitable position


Material: Glass fibre reinforced polyamide, PTFETemp. stability: max. +250°CPower supply: Silicone cable

3x1,5 mm2 or 3x2,5 mm2, length 3 m,led out through a cable gland M20, at the rear end of the orby a separate hard cap, inserted at any suitable position



Kroneck sleeve/hard cap

Thimble – Heat-shrinkable sleeve

Thimble – Heat-shrinkable sleeve for hazardous areas

Material: Polyester-elastomerTemp. stability: max. +150°CPower supply: Heater cable overhang of 500 mm

connected to EEx e termination boxOptional: Resistance thermometer PT100,

in non-Ex versioninserted inside the line between process tube and heatingelement, signal cable exit at the front end of the line together with process tube, using a non-Ex PT100 in a hazardous area requires a safety barrier

Material: Polyester-elastomerTemp. stability: max. +150°CPower supply: Silicone cable

3x1,5 mm2 or 3x2,5 mm2, length 3 m,connected to the front end of the line together with processtube,

Optional: Resistance thermometer PT100or thermocoupleinserted inside the line between process tube and heatingelement, signal cable exit at the front together with processtube

Material: Chrome-plated sheet metal,glass fibre reinforced polyamide


as screw on connector 1/8” NPT, 6x1 mm or 8x1 mmPower supply: Silicone cable

3x1,5 mm2, length 3 m,exit at rear end with an aluminium block

Optional: Resistance thermometer PT100or thermocoupleinserted inside the line between process tube and heatingelement, signal cable exit at rear end with an aluminiumblock together with power supply


Termination set for tube bundles and analyser lines

End seal kit for hazardous area

Connection kit for hazardous area

Heat shrinkable connection kit for self-regulating heating elements inhazardous areas.

The tracing for tube bundles and analyser lines with self-regulating heating elements must exit the line and be connected to power supply with an explosionproof termination box.The heating elements must be connected to a termination box, which has thesame certification as the tube/line itself.The heating connections entrance to the termination box must be a M25 x 1,5mm cable gland with a special heater cable sealing.

Certification according to ATEX:

Heat shrinkable end seal kit for self-regulating heating elements in hazardous areas.

The tracing for tube bundles and analyser lines with self-regulating heating ele-ments must be terminated with an end seal kit, which has the same certificationas the tube/line itself.


The termination set for the tube/line end consists of:

• POM cap• Heat shrinkable sleeve• Silicone

In addition for the electrical supply the termination set will include:

• Silicone cable 3x1,5 mm2 or 3x2,5 mm2, length 3 m• Equipment for electrical connection


2.2 Temperature controller

EEx d thermostat „Raystat EX-02“

2.3 Temperature sensor

Resistance thermometer PT100

This PT100 is suitable for the controlling and monitoring of heat tracedtube bundles and analyser lines.Depending on the chosen type of line termination, then the PT100 canbe inserted inside the line between the process tube and heating element. The connection cable is led out either together with or separate from the power supply.

Measuring range: -70°C…+550°CDimension: L = 10 mm, Ø = 3 mmSheath material: Stainless steel St. St. 316TiElectrical supply: 2x0,14 mm PTFE isolated cable

This EEx d approved thermostat can be used for temperature control ofall tube bundles and analyser lines, installed in hazardous areas. The re-quired temperature can be set by means of a protected external adju-stable knob. It has a single pole changeover switch. The supply cableentrance to the housing is with a 3/4“-NPT thread for a cable gland. Thecontroller will be delivered with a 3 m long capillary tube sensor, speci-fied for a temperature range of -50°C to +215°C.

Range: -4°C…+163°CAmbient operating conditions: -40°C…+60°CSwitch rating: 22 AContinuous rating: 32 A

Certification according to ATEX: II 2 G/DEExd IIC T6


Resistance thermometer PT100 as insertion element

Resistance thermometer PT100 as insertion element for hazardous areas

Thermocouple

Thermocouples are suitable for the controlling and monitoring of heattraced tube bundles and analyser lines.Depending on the type of line termination chosen, the thermocouplewill be inserted inside the line between the process tube and heating element. The connection cable is led out either together with or separate from the power supply.

Thermocouples: NiCr-Ni (type K) or Fe-CuNi (type J)Measuring range: Type K: -40°C…+1200°C,

Type J: -40°C…+750°CElectrical supply: 2x0,22 mm PTFE isolated cable

This PT100 is specially designed so that the controlling and monitoringof heat traced tube bundles and analyser lines can carried out in hazar-dous areas. It is manufactured in the protection class EEx m, so that intrinsically safe circuits are not necessary. The line is terminated with aPOM/PTFE cap, specially equipped with a special sleeve support sothat PT100 element can be correctly positioned between the processtube and heating element.

Measuring range: -50°C…+600°CDimension: L = 300 mm, Ø = 3 mmSheath material: Stainless steel (St. St. 316Ti)Electrical supply: Rubber sheath cable, L = 5 m


This PT100 is suitable for the controlling and monitoring of heat tracedtube bundles and analyser lines.The line is terminated with a POM/PTFE cap, specially equipped with aspecial sleeve support so that PT100 element can be correctly positioned between the process tube and heating element.

Measuring range: -70°C…+550°CDimension: L = 250 mm, Ø = 3 mmSheath material: Stainless steel (St. St. 316Ti)Electrical supply: Lemo connector, 2x0,14 mm LIYCY, L = 5 m


2.5 Cable glands

Ex M63 cable gland (for hazardous area)

M63 cable gland

Heat shrinkable sleeve

Heat shrinkable sleeve required for tube bundles and analyser line entrances into analyser cabinets, sample conditioning cabinets, transmitter boxes or other housings.

Material: Polyamide/PolyolefinThread: 3,5” (88,9 mm)/2,36” (59,94 mm)Line diameter range: 36…70 mm/19…51 mm Working temperature: -55°C…+90°CShrink temperature: min. 121°C

Cable gland required for tube bundles and analyser line entrances intoanalyser cabinets, sample conditioning cabinets, transmitter boxes orother housings.

Material: PolyamideThread: M63x1,5 mmLine diameter range: 37…44 mmProtection class: IP 68Working temperature: -20°C…+80°C

Cable gland required for tube bundles and analyser line entrances intoanalyser cabinets, sample conditioning cabinets, transmitter boxes orother housings.

Material: PolyamideThread: M63x1,5 mmLine diameter range: 37…44 mmProtection class: IP 68Working temperature: -20°C…+80°C



2.6 Insulation material

Silicone foam hose

Thermal/glass fibre fleece

Silicone

Single component silicone to plug the terminations of tube bundles andanalyser lines.

Special features:

• corrosion prevention• very good isolation ability• excellent resistant to moisture, UV radiation and chemicals

Working temperature: -60°C…+200°C (+260°C)

Insulation tape for the insulation of tubes, hoses and instruments

Dimensions: Width = 40 mm, thickness = 2 mmWorking temperature: Thermal fleece up to +200°C

Glass fibre up to +500°C

Silicone foam hose for the insulation of tubes and small hoses

Dimensions: Outer Ø = 40 mm, thickness = 10 mmDensity: 0,3…0,8 g/cmWorking temperature: -80°C…+200°C (+300°C)Special feature: Free of cadmium

Other dimensions are available on request


2.7 Tools

Trumpet

Flexible face spanner

Hot air blower

Professional high powered electronically controlled hot air blower withcontinuously variable temperature and airflow.

Dimension: 260 x 90 x 205 mmPower supply: 230 V/50 HzPower rate: 2300 WTemperature: +50°C…+650°CAir flow: 150…500 l/min (continuously variable)Weight: 850 g

Special tool required to change the replaceable connection nipple of tube bundles and analyser lines (metal cap and flange termination). Theflexible face spanner is used to loosen or tighten the union nut, whichconnects the Stnl. Steel nipple to the process tube.

The trumpet is a special tool for the termination of tube bundles andanalyser lines with replaceable connection nipple (metal cap and flangetermination). To ensure a tight connection between the conical Stnl.St.-nipple and the process tube (in this case a PTFE hose), the hosemust be expanded at the hose ends and pressed into the sockets. Therefore the hose has to passed through the sockets at the line ends,heated by a hot air gun and moulded into the socket with the trumpet.


order no.

Temperature controller PSG ST-49

This microprocessor controller serves to control the temperature to a high degreeof accuracy. The multi-sensor can accept inputs from resistance elements andthermocouples, as well as 0…10 V and/or 4…20 mA. The controller PID functionsand/or thermostat set values can be activated by the parameter settings. Thecontroller outputs available can be selected from a voltage output to the SSR,two relay contacts, as well as an analogue signal output. Red LED lamps indicatethe status of the output relays. The set points and parameters for determining theprocess control can be adjusted on a 4 key plastic foil board.

Measuring range: Depending on sensor typeDimensions: 55 x 75 x 110 mmInstallation: Rail clip-on mounting Display: 3-digit LED display, height 10 mm, colour red

3 LED for status indicationConnector: Screw terminals for cable 2,5 mm2, max. 12 AMounting: DIN-rail 35 x 7,5 mm

DIN 45277 page 3Weight: 0,36 kg (Type 50.07.08)

Controller with 12 V output for solid-state relay 50.07.08.00Controller with 12 V output, with SSR (25A) and cooler 50.07.88.00

Solid-state relay 25A 50.07.20.00Cooler 50.07.21.00


order no.

Temperature controller and switch in combination for protection type EEx d IIC T 6 50.07.10.00

The temperature controller and the switch have a capillary probe made of stainless steel,each 1 m long. The controller and the switch can be adjusted continously. The switchhas a mechanical reset button. Polyester housing with protection classIP 65, 260 x 160 x 190 mm

Protection type: EEx d IIC T6Certificate of conformity: PTB-No. Ex-83/1055Protection class: IP 65/DIN 40050Adjustment range: 0 °C to 300 °CSwitch-off accuracy: + 4.5 KSwitching difference: 9 KProbe dimensions: 4 mm dia., 175 mm longSwitching by means ofprecision microswitches: 15 A/380 Vglands: 2 x M 25 x 1,5


order no.

Termination box 50.08.05.00

Manufacturer: RoseHousing material: PolyesterSurface resistance: < 109 OhmProtection class: IP 65Dimensions (mounting plate): 210 x 180 mmProtection class: EEx e II T 6

For tube bundles and analyser lines with self-regulating heating elements, complete prefabrication on mounting plate.


order no.

Coupling box

for joining two heated sample lines

Polyester standard box with 30% hot pressed glass fibre

Protection class: IP 65Colour: RAL 7000, greyDimensions: 300 x 150 x 130 mm

with terminal block for the connection of electrical leads as well as with hoseconnector made of PTFE.

Coupling box 50.08.07.00for joining heated sample lines (with tube 1 x 6 x 1 mm)type 50.03.03 and 50.04.01

Coupling box 50.08.08.00for joining heated sample lines (with tube 1 x 8 x 1 mm) type 50.03.03.00 and 50.04.01.00

Coupling box 50.08.09.00with middle power input


Order matrix for tube bundles and analyser lines

Order matrix for tube bundles and analyser lines

Protection jacket Material of theprocess tube

Power supply

Code example*

Remarks:

SR self-regulatingPH parallel heating elementFWS fixed resistance

* The code example “111013Ex10A1P1” describes a tube bundle with PVC protection jacket, 1x6x1 mm PTFE tubing, thermal fleece insulation, self-regulating heating elements with a power rate of 30 W/m, suitable for hazardous areas, power supply 230 VAC single phase, without temperature sensor and line terminations with POM caps (Ex-proof type)

0 without1 PVC extruded2 TPU extruded3 PE extruded4 Corrugated PA tubing5 PA braiding6 Corrugated metal tubing7 Corrugated metal tubing, PVC coated8 Corrugated metal tubing, PU coated9 Metal braiding

0 PTFE1 PTFE, steel wire armoured2 PFA3 Stainless steel, welded4 Stainless steel, seamless5 Stainless steel, chemical cleaned6 Stainless steel, electrochemical polished7 Stainless steel, Sulfinert® passivated8 Stainless steel, Silicosteel® passivated

1 1 1 0 1 3 Ex 1 0 A1 P1

Insulation

0 without1 Thermal fleece2 Glass fibre3 Silicone foam hose

Number ofprocess tubes

0123456789

0 without heating elements1 230 VAC, 1~2 230 VAC, 3~3 115 VAC, 1~4 115 VAC, 3~

Explosionprotection

0 withoutEx with

Temperaturesensor

0 without1 PT1002 PT100, Ex3 Fe-CuNi4 NiCr-Ni

Dimensionsprocess tube

0 3x0,5 mm1 6x1 mm2 6x1 mm replaceable3 8x1 mm4 8x1 mm replaceable5 10x1 mm6 12x1 mm7 1/8”x0,035”8 1/4”x0,035”9 1/2”x0,035”

Heater-element

0 without1 15 W/m SR2 25 W/m SR3 30 W/m SR4 47 W/m SR5 63 W/m SR6 40 W/m PH7 60 W/m PH8 90 W/m FWS9 120 W/m FWS

P0 withoutP1 POM capP2 PTFE capP3 Silicone capP4 Hard capP5 Metal capP6 FlangeP7 Kroneck sleeveP8 Heat shrinkable sleeve

Termination atsample point

A0 withoutA1 POM capA2 PTFE capA3 Silicone capA4 Hard capA5 Metal capA6 FlangeA7 Kroneck sleeveA8 Heat shrinkable sleeve

Terminationanalyser side

PSG Petro Service GmbH & Co. KG, Tel.: +49 (0) 6171 / 9750-0, FAX: +49 (0)6171 / 9750-30, Email: [email protected]

PSG Petro Service GmbH & Co. KGTel.: +49 (0) 6171 / 9750-0FAX: +49 (0) 6171 / 9750-30Email: [email protected]: www.psg-petroservice.de 1st issue, dated on 01/2008

General Information and Technical Data for Tube Bundles ... · 2.2.2 Steam traced tube bundles The...

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Transcript of General Information and Technical Data for Tube Bundles ... · 2.2.2 Steam traced tube bundles The...