TubeMaster® System

The World’s First and Fastest Pressure-Drop Testing System
Our flagship and patented TubeMaster® System pressure-drop test equipment and software has revolutionized the manner in which pressure-drop measurements are made in catalyst-packed tubes in multi-tubular reactors in terms of unsurpassed speed, accuracy and efficiency. Introduced in 2002, the TubeMaster® System is the world’s FIRST, FASTEST and MOST COMPREHENSIVE pressure-drop system for testing catalyst-packed tubes in multi-tubular reactors and processes.

The TubeMaster® System addresses all major quality concerns to ensure the best testing possible. Our patented system, (US patent #6,725,706 with foreign patents pending world-wide) that tests 10, 20, 30, 40, 50, 60, 70, 80, 90, + or more tubes, is setting the global standard for speed and highest quality. Our patented equipment and software testing technologies allows each person to test ten tubes sequentially. All data is transmitted wirelessly to a highly integrated software program that tracks and records all pressure-drop test progress and results. TubeMaster® System’s speed allows testing to be completed by fewer people in much less time—from 4–20 people testing for 8–48 hours to 1–4 people testing for 1–8 hours or less!

Unsurpassed Speed

• TubeMaster, Inc. can test in less than half the best time ever previously taken to test and record pressure-drop data and will likely be even faster! Actual tests rates are typically 2-10 times faster than before.
  
  
• Each Tube Test Device (TTD) tests 10 tubes sequentially and at up to and over 1000 tubes per hour per device. A single TTD typically replaces the entire test crew. Use 2, 3, 4 or more TTDs and get ready to set a record.
  
  
• Multiple TTDs may be used on the same or different reactors at the same time.
  
  
• Rapidly assesses which tubes loading methods are optimal.
  
  
• Achieves a higher standard of quality by permitting reactor owner to evaluate and manage tube loading in real-time.
  
  
• So fast that all clients to date have omitted sample testing altogether, saving even more time. Since we track the location of every tube tested, there is no need to first test a sample of tubes and use that data to estimate the mean in order to set high/low (pass/fail) specifications. Simply use the TubeMaster® System to test the entire reactor, then instantly use our advanced and fully-integrated data analysis software to identify all tubes that require corrective action.

Unsurpassed Accuracy

• Tests all tubes – Laser distance sensor measures and records each tube position in each row, along with its pressure-drop data (including other important test information) ensuring that every tube is tested. Never miss a tube again.
  
  
• Automatically selects and records valid data, not the operator, thus eliminating data logging errors common to operator controlled test methods.
  
  
• Our high accuracy system is expertly set up to meet client-specific flow test requirements.
  
  
• Pressure measurement accuracy of 0.02% the highest in the industry.
  
  
• Portable and reusable calibration standard for changes in ambient conditions.
  
  
• Laser automatically measures the location of each tube position. Tracks every tube in a graphic database so you never miss a tube.
  
  
• Adjustable initial sample set size - sample set tube location determined by onboard random number feature. Since the TubeMaster® System excels at keeping track of all tubes and their test data our clients typically skip this step altogether, saving even more time.
  
  
• Statistically analyzes variations in tube pressure-drop data confirming degree of uniform packing density, in terms of resistance to flow. A comprehensive graphic user interface is used.
  
  
• Redundant recording features in the TTD and laptop computer provides uninterrupted testing in the event of a component or laptop computer failure.

Simple to Use

• Single-button operation - 95% of all testing is automatic and requires only pressing a single "Start " button, while following some basic and intuitive rules of use.
  
  
  • Simply insert TTD, press one button, move TTD, repeat.
    
    
• Manage tubes which require correction with our printed List-to-Fix™ and Electronic List-to-Fix™ Tools.
  
  
• Inflating tube-seal technology is superior to other methods such as the manual stopper and compressed rubber plugs. Our inflating tube seals easily hold back 100+ psig (7 bar) on top the catalyst. Try doing even half that with other technologies! Being able to hold back a high pressure means that more dust will be purged during blowdown so more tubes will pass. Also, a good seal is critical to obtaining a good measurement.
  
  
• System is wireless and battery powered - just connect air (or gas), calibrate and then test.
  
  
• Lightweight, easily moved and simple to operate, our system is configurable to work in any tubular reactor, any tube size, any tube spacing, any vessel man-way size, and has been used in major petrochemical plants in North America, South America and Europe with use in Asia expected to begin in early 2005.

Simple to Analyze

• Sophisticated color graphic user interface is simple to use and highly intuitive.
  
  
• Permits test progress and results to be observed at all times, both graphically and numerically.
  
  
• Displays a color-coded graphic of every tube on the tubesheet to show test progress at a glance as well as patterns and trends useful in troubleshooting, evaluating loading equipment, techniques and catalyst-handling contractors.
  
  
• Color screen grabs (snapshots) can be created, stored, transmitted and printed at any time during or after testing.
  
  
• Provides real-time graphical display of pressure-drop test status, economic analysis and compliance reports.
  
  
• Keeps client informed of all aspects of testing in terms of progress, average pressure-drop, highs, lows, open tubes, plugged tubes, out of service tubes, thermocouple tubes, thermowell tubes, as well as all test results.
  
  
• Software permits reactor pressure-drop test status monitoring on or near the vessel.
  
  
• Post-test analysis feature permits comparisons with previous reactor loadings and sister vessels.
  
  
• Documentation - at any time, during or after testing a reactor, the client can get an electronic data file that documents all test results for every pressure-drop measured by tube location, zone, corrected tube test results, and more, for a complete and fully documented record.

Significant Cost Savings

• Significantly reduces test time.
  
  
• Optimization of uniform packing density reduces feedstock bypass, increases product quality, increases conversion, extends catalyst life and provider higher yield.
  
  
• Software permits vessel owners to readily access which tubes pass and which tubes require correction based on catalyst supplier or client specification requirements as well as number of tubes, depending on time and spare catalyst available or both.
  
  
• Gets reactor online faster with complete documentation.
  
  
• Available by lease or license - no expensive equipment to buy, store, maintain and then become obsolete.
  
  
• Gets the fastest technology in your plant today and keeps it that way with upgrades and additions as a licensee.

Greatly Improved Safety

• Great attention to detail and our pursuit of excellence have yielded the most impressive of desirable goals, a perfect safety record! After using the TubeMaster® System on over 40 reactors, there were no recordable injuries with only one very minor laceration has ever occurred, requiring a simple Band-Aid®.
  
  
• Improves safety by reducing personnel.

The TubeMaster® System is useful for testing any catalyst in any tube including: Acetone, Acrylic Acid, Acrylonitrile, Ammonia, Aniline, Cyclohexanone, Ethylene Dichloride, Ethylene Oxide, Formaldehyde, Hydrogen, Maleic Anhydride, Methanol, Nitrogen, Methyl Methacrylate, MEK, Phthalic Anhydride and Vinyl Acetate.

Our system has increasingly been used on reactors of various processes to locate and troubleshoot problems in reactors experiencing problems. Along with what is arguably the fastest and most comprehensive testing technology available, the TubeMaster® System is customized for each client’s specific testing requirements. Our TubeMaster, Inc. staff is increasingly recognized as a leading expert in pressure-drop (flow) testing technology for tubular reactors. Our expertise is up to the task of your most challenging test issues.

Please contact TubeMaster, Inc. or your TubeMaster, Inc. representative for a free analysis of your testing needs to ensure that all testing is valid for your test requirements. If you do not know what your test requirements are, just call us for a no-obligation consultation. All information provided during this consultation will be kept confidential and an equitable, two-way non-disclosure agreement may be initiated.

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