SO4 Inconel Converter Replacement

Purpose: The procedure below will guide you thru the removal and replacement of the SO4 Inconel tubing, Quartz tubing, and if necessary the thermocouple.

Required Equipment:  9/16” and 5/8” wrenches

Phillips head screw driver

Metal tubing cutter

Tubing bender

24” of new Inconel tubing

Replacement Quartz tubing

SO4 Oven Thermocouple

6’ of ¼” Teflon Tubing

¼” Nuts and Ferrules

Reference:  SOPMAN

SO4 Inconel tubing removal / replacement

1. On DataVeiw go to the Tools Tab and select Set Flags.

2. From the Set Flags tab select SO4 in the Channel Name drop down box, and then click Down Single Channel.

3. Power off and unplug the SO4 oven.

4. Allow the oven to cool enough so that you can safely work on it.  Propping the oven open will speed the cooling, but expect this to take 45mins – 1 hour.

5. Disconnect the Inconel tubing on both ends using the appropriate wrenches, being careful not to flex or break the Quartz tubing.

6. Remove the old Inconel tubing from the oven.

7. Measure, cut and bend the new Inconel tubing to match the length and shape of the old tubing.

8. Reuse the old Quartz tubing if possible.  If the old Quartz tubing is damaged (broken or bent) install new Quartz tubing. 

9. Install the new Inconel tubing into the SO4 Oven and connect the fittings at both ends using the appropriate wrenches, being careful not to flex or break the Quartz tubing.

10. Cover the ends of the Quartz tubing with insulation were the oven closes onto the quartz and close the SO4 oven.

11. Remove the orange insulation on the Teflon tubing that extends from the inconel to the Teflon Filter pack (see diagram below) and replace the tubing.

12. Replace the tubing from the filter to the analyzer.  During the initial replacement the filter will need to be removed from the Control Box.  Follow the diagram below for all tubing placement.

13. Leak check the system.  If the leak check is good (+/- 0.05) continue.   

14. Plug the SO4 Oven back in and turn it on.

15. If you see the current temp increasing as the Oven heats up you are finished.  Wait for the temperature to stabilize at 1000C, then up the SO4 DAS channel.  If you see “b.o” on the top line and set point on the bottom line your thermocouple is bad, go to replacing the thermo-couple below.

Replacing the SO4 Thermocouple

1. Power off and unplug the SO4 oven.

2. Using a Phillips head screw driver remove the SO4 ovens back cover.

3. Using a flat head screw driver remove the two thermocouple mounting screws.

4. Carefully remove the thermocouple from the oven.

5. Using a flat head screw driver loosen the two lead screws and remove the leads from the old thermocouple taking note of there orientation.

6. Using the flat head screw driver loosen the two lead screws on the new thermocouple and attach the leads to the new thermocouple and then tighten the screws.

7. Carefully insert the new thermocouple into the oven, and secure the two mounting screws.

8. Reattach the back cover, plug in and power on the SO4 oven

9. Wait for it to come up to the set point temp, then up the SO4 channel.