WIKA TC96-R Flex-R Flexible Multipoint Thermometer

WIKA TC96-R Flex-R flexible multipoint thermometer for reactors

The WIKA TC96-R, sold by WIKA as the Flex-R, is a flexible multipoint thermocouple assembly for measuring temperature profiles inside catalytic reactors, regenerators and columns. Instead of one reading at one depth, a bundle of thin mineral-insulated cables carries up to 100 measuring points through a single nozzle and then spreads them through the catalyst bed, so hotspots, channeling and uneven flow show up as real readings. WIKA quotes a response time of 4 to 8 seconds. Seven Star LLC supplies the TC96-R in Oman and the GCC as an independent supplier in Muscat; this page describes the model variants and what must be defined for an RFQ.

What a multipoint thermometer does for a reactor

Refining and petrochemical units are asked to run longer between turnarounds, change catalysts and process new feeds. Temperature profiling gives early warning of maldistribution of the catalyst, hot spots and runaway conditions. The TC96-R is described by WIKA as offering real radial profiling, high point density, secondary containment, adaptability to existing reactor nozzles and greater process control. Each unit is engineered for the vessel, which is why many geometric details are marked as varying with the flange and the number of thermocouples.

TC96-R technical specifications

TC96-R-C, TC96-R-R and TC96-R-N compared

The Radial Tap models use a high-pressure coupling, available in all required sizes and pressure ratings, with primary and secondary containment. Special connections to customer specification are listed, including welding sockets, flange connections and valves.

The five assemblies of a TC96-R

WIKA divides the instrument into five parts that are specified separately: the pressure monitoring arrangement, the neck tube including primary and secondary connection, the process connection, the multipoint MI cable bundle and the terminal enclosure. The terminal enclosure shown in the datasheet is only a sample, because its design depends on the application and is engineered individually for each assembly. Plan the field cabling and junction box location early, since 100 points may need a large enclosure.

Routing and length of the cable bundle

The correct length of each cable is critical, because it decides where the junction ends up inside the bed. The datasheet has a section on routing the MI cable inside the reactor: lengths must allow for catalyst settling and thermal expansion, so an assembly is built to the vessel drawing with the bed levels, nozzle position and desired point layout. Because the bundle is flexible, it can be inserted through a small nozzle and then positioned, which is what makes it suitable for retrofit to an existing reactor.

Sensor options and choosing them

Type K covers most reactor temperatures, type E gives a higher signal at moderate temperatures, and type J is used for lower ranges. Ungrounded junctions are less sensitive to electrical noise and ground loops, while grounded junctions respond slightly faster. Double elements give a redundant reading at the same point. For details on accuracy, WIKA refers to the technical information on thermocouples (IN 00.23).

Installation and operation

• Verify the nozzle dimensions, flange class and bolting before the assembly is built
• Keep the wooden crate until the reactor is ready, and lift the bundle without kinking the cables
• Check each point for continuity and insulation resistance before and after insertion
• Label each thermocouple and compare the profile with the process model after start-up
• Record baseline temperature profiles to compare during later runs

Applications in Oman and the GCC

The listed industry is refining and petrochemical, and the use cases are temperature profiles in reactors, regenerators and a range of columns. In the Gulf, hydrotreaters, hydrocrackers, reformers and polymer reactors are the normal places to find multipoint thermometers, where tight temperature control protects catalyst life and the vessel.

TC96-R ordering checklist

• Model variant: -C, -R or -N
• Reactor drawing with nozzle, flange standard and class
• Number and position of measuring points, and thermocouple type
• MI cable diameter and sheath material, and cable length
• Single or double element, grounded or ungrounded junctions
• Terminal enclosure, hazardous-area requirement and documentation

Information to send with an RFQ

Provide the reactor datasheet, the nozzle details, the number of points, material requirements and certification needs. A sketch or existing drawing of a previous multipoint assembly helps match dimensions.

Site conditions in Oman for the TC96-R

Field instruments in Oman are exposed to strong sun, high ambient temperature, wind-blown dust and, on coastal plants, salt in the air. When you specify the TC96-R, check the ambient and process temperature limits, the enclosure rating and the wetted and housing materials against the actual installation point, and consider sunshades for transmitters mounted in direct sunlight. Cable entries should be sealed with suitable glands so that dust and moisture cannot enter the housing.

Calibration and verification planning matters as much as selection. Record the range, configuration and tag data of each TC96-R at commissioning, define a check interval that suits the criticality of the loop, and keep the certificates with the plant documentation so that audits and shutdown work can proceed without delay.

Documents and quotation

The WIKA data sheet TE 70.10 for the TC96-R is attached on this page. Send us the specification and quantity for a quotation from Muscat as an independent supplier.