Today’s discerning CEO has long since acknowledged that controlling operational bottom lines goes far beyond controlling just material and labour cost. Several areas are cause for concern:

Operational concerns:
Accurate control of process parameters. 
Energy Conservation. 
Protection against corrosion and erosion 
Cost control 
Productivity 

Process control concerns:
Temperature 
Product Quality 
Increased wear and tear of equipment 
Frequent breakdowns 

Temperature Concerns:
Probably the most important — also the most neglected! 
An area which could make the difference between the Organization's balance sheet being red and black

Concerns relating to control systems:
Cost 
Installation problems — time, shut down, etc. 
Training manpower to operate the system — lack of educated shop floor workers, resistance from workers, etc 
Maintenance

Fykays Solutions:

For Boiler Plants - To ensure optimum combustion efficiency and therefore fuel savings AND To avoid surface pitting of water tubes, water walls, water drum etc and more importantly minimize the need for soot blowing

ON-LINE Oxygen analyzers using IN-SITU Zirconia Oxygen probes
Microcontroller based Analyzers and accessories as also, with minimum or nil free oxygen.
Special thermocouples especially wear resistant and corrosion resistant type
Miniature thermocouples for feed water line, economizers & de-aerators for water in and water out lines, gas in and gas out lines

For Turbo generators : Extremely fine diameter MI thermocouples as fine as 1.0 mm dia for turbine and alternator bearings, stator winding coils, steam exhaust, condenser in and out line

For Transformers: Extremely fine diameter MI thermocouples as fine as 1.0 mm dia for transformer windings, precision thermocouples and RTD’s for transformer oil, cooling water in and out temperatures etc.

Reaction Bonded: (RB) unsheathed probes
Fusion bonded: (FB) sheathed probes

Reaction bonded probes, which can be used without external sheathing and the associated assembly and maintenance problems make use of a patented process in which a ZrO2 thimble or pellet is bounded onto an Al2O3 tube by reaction through a platinum washer.Fusion bonded sensors on the other hand use sintered ZrO2 pellet cemented and fused to the Alumina tube

Wider applications :

Length of Probes

Standard lengths available are 150, 300, 600, 900, 100, 1200 and 1500 mm. Longer lengths up to 2500 mm available on special request. 

Thermocouple Specifications:

For RB sensors the thermocouples are normally type 'R' or 'S' (Pt.Pt.Rh 13 % or Pt.Pt.Rh 10 %)For FB sensors the choice is extended to 'K' type (chromel-alumel), for lower temperature applications. 

For extra temperatures probes are supplied with 'B' type (PtRh 6% - Pt 30 %) thermocouples (RB sensors only) thermocouples (RB sensors only)

Specifications :

Temperature Limits
FB sensors upto 1400C
RB sensors upto 1800C

Applications :

Energy Conservation
Boilers of any / all types
Rotary Kilns
Reheating / heating furnaces
Forging furnaces
Forging furnaces
Tunnel Kilns
Heat Treatment furnaces

End use: Power plants, Cement, Sugar, Paper, Textile, Steel, Chemicals, Petro-chemical, Fertilizers, Ceramic and other industries

Totally automates monitoring and control of Furnace temperature, excess oxygen in the flue gas and furnace pressure to achieve dramatic reduction of fuel consumption and losses due to scaling and also prevents surface decarburization.

FYKAYS offers a very wide choice of thermocouples and accessories for industrial application. Carefully chosen components including premium grade thermocouple wires and other quality raw materials and special "made to specs" designs, ensure close accuracies, fast response, long deterioration-free service and other such high 'benefits to cost' advantages to users.

Types:

1) Sheathed
2) Bare
3) Button type
4) Bow type
5) Needle type
6) Roller type
7) Flexible bow type

Choice of Thermocouple:

1) Copper-Constantan
2) Iron-Constantan
3) Chromel-Alumel
4) Platinum-Platinum Rhodium 10%
5) Platinum-Platinum Rhodium 13%
6) Platinum Rhodium 6%
7) Platinum Rhodium 30%
8) Tungsten- Tungsten Rhenium 26%
9) Tungsten 5% - Tungsten 26%

Choice of sheath material

NON-Metallic
1) Mullite
2) Silliminite
3) Recryst. Alumina Fused Silica
4) Berylia
5) Graphite, etc.
6) Fused Silica
 

METALLIC
Carbon Metal : SS 304, SS 316, SS410
Hastelloy, A,B, C or X, Monel, Tantalum, Iniconel, Incalloy Mollybdenum, etc.

Choice of construction
Simplex / Duplex, Straight, Right angle, 45 degree angle, Adjustable flange
Hot Junction: Exposed Junction, Covered Grounded or Ungrounded Junction

Calibration
Unless specified all our thermocouples are as per IPTS-68. Other calibrations can be made on request.

Accuracy
Normal : +/- 3/8 % of the read value
Special : +/- 1 C in specified range of operation
Certification : Special certification at specific reference points can be provided at extra cost.

Temperature monitoring and control by sensing soaking zone temperature and regulating the air and fuel control valves by means of a PID controller, which can be either pneumatically or electrically actuated. The air : fuel ratio is built into the controller software.  One of the noteworthy features of the temperature loop is the special facility provided for manual intervention – on occurrence of a mill breakdown, the furnace temperature can be turned down to pre-determined levels simply at the click of a button.

It is the Micouple Bow to the Industry's demand/Desire for Quality, Economy and Safety. Mi Couple is supple, Durable and Accurate to the Core. It is designed to be a part of the heating structure. In that process it stands BEATINGS in the beds and TWISTINDS in the walls so that it can keep in touch with the super hot materials and transmit the process temperatures Days in and Years out. Mi Couple represents a wide range of permanent thermocouples to be useful to many industries. Mi Couple is produced by : Fykays Engineering Pvt. Ltd. Leaders in Advanced Pyrometry.

On the lop, at the bottom and the walla throughout the arduous path to the control apparatus. Nil Couple and Micab combination of Thermocouple technology is assiduously developed for super fast and accurate temperature measurement from vital spots considered inaccessible so far, as the high temperatures and hitherto undiscovered materials of construction precluded precise probe. It now facilitates rigid quality control denied thus far to the quality conscious decision makers. While helping to improve quality Mi Couple enables closer control on fuel costs. Its contribution to Industrial Safety is a very important consideration in its favour. 

Mi Couple is imbedded at the critical process paint to catch the process temperature and transmit the signal to the control apparatus through Mi Cab. ft thus simplifies and hastens decision making for Quality, Economy and Safety. Whereas Mi Couple describes the Mineral insulated thermocouples, Mi Cab describes the Mineral insulated cables that truthfully complement the relay function of Mi Couple through a little less hostile environment. 

Mi Cab is the most reliable complement to Mi Couple because it shares its super fast signal transmission efficiency and resistance to the varying temperature zones of the traversing regions and also to static interferences through its exposed path. Mi Couple is made available in many versions, to serve varied industries. Whereas, the Nuclear, Aircraft, special steels, Ferro-Alloys and their like attract the Costlier versions; less exacting conditions in Dairies, Power stations, Pharmaceuticals may opt for the economic variety suited to their respective plants & processes. 

Depending on the specifications of each Industrial Process or Product Fykays offer a wide choice for Mi Couple - Mi Cab ingredients.