# Patent

## Title
Method for measuring back pressure in open ended chemical reactor tubes

## Abstract

A method for measuring back pressure in open ended chemical reactor tubes is provided. The method can include using automatic test heads or manual test head connected to a continuous real-time monitor and display device, a controller, a multiport manifold, and a plurality of umbilicals. Each umbilical can be used to carry compressed air, sensor signals, and power to the test heads.

## Background
FIELD
The present embodiments generally relate to a method for measuring back pressure in open ended chemical reactor tubes, such as catalyst tubes for a chemical plant.
BACKGROUND
A need exists for a method for measuring back pressure in open ended chemical reactor tubes that uses individually replaceable heads for the testing process.
A need exists for a method for measuring back pressure in open ended chemical reactor tubes that can accurately flow air to chemical reactor tubes individually, thereby ensuring that each chemical reactor tube is properly tested.
A need exists for method for measuring back pressure in open ended chemical reactor tubes that can continue to be used even if one of the test heads is defective or needs replacement.
The present embodiments meet these needs.



BRIEF DESCRIPTION OF THE FIGURES
The detailed description will be better understood in conjunction with the accompanying drawings as follows:
FIG. 1A depicts an overview of the system.
FIG. 1B depicts a cross section of an individually removable and replaceable test head umbilical.
FIG. 2 depicts a detailed view of a continuous real-time monitor and display device.
FIGS. 3A-3B depicts a detail of a controller and a controller data storage.
FIGS. 4A-4B depict detailed views of an automated test head, a chemical reactor tube, and a colored tube cap.
FIGS. 5A-5B depict detailed views of a manual test head in a pretesting position and testing position.
FIGS. 6A-6B depict a flow diagram of an embodiment of the method using an automated test head.
FIG. 7 depicts a flow diagram of an embodiment of the method using a manual test head.



The present embodiments are detailed below with reference to the listed Figures.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Before explaining the present method in detail, it is to be understood that the method is not limited to the particular embodiments and that it can be practiced or carried out in various ways.
The present embodiments relate to a method for measuring back pressure in open ended chemical reactor tubes.
The method can use a continuous real-time monitor and display connected to a programmable controller, a manifold connected to the continuous real-time monitor and display, a plurality of individual umbilicals connected to the manifold, and a plurality of test heads connected to each individual umbilical. Each test head can be automatic or manual.
The automated test heads can be remotely controlled, allowing for fewer number of employees to be present near high pressure catalysts; thereby improving safety for the employees. For example, the high pressure catalysts, which can be an explosive powder, can be located in a confined space where it can be dangerous for employees to be present.
The method can be implemented faster than manual processes currently used because the pressure heads can enable quicker seals without requiring a person to hold the seals in place; thereby preventing leakage.
The method can be versatile, because the method can include using test heads of different sizes configured to accommodate different sized chemically loaded tubes, chemically unloaded tubes, partially filled chemical tubes, partially filled with catalyst tubes, or the like.
Test heads can be individually replaceable, providing a system with a longer life span. Also, the continuous real-time monitor and display device can be individually replaced without replacing other components usable with the method.
The method can have a lower maintenance cost than current devices, in-part because if one umbilical usable with the method becomes defective, that umbilical can be replaced without replacing other components usable with the method.
Turning now to the Figures, FIG. 1A depicts an overview of the system 8. The system 8 can include a continuous real-time monitor and display device 10.
The continuous real-time monitor and display device 10 can be bi-directionally connected to a controller 50, such as through a bi-directional multiline air, power, and signal line 64.
The controller 50 can bi-directionally communicate compressed air, power, and sensor signals to and from the continuous real-time monitor and display device 10. The bi-directional multiline air, power, and signal line 64 can communicate into the continuous real-time monitor and display device 10 through a bi-directional multiline air, power, and signal port 28.
The controller 50 can be in communication with a power source 49 for receiving power therefrom. The controller 50 can also be in communication with a compressed air source 44 through a compressed air inlet 47 for receiving compressed air 46 therefrom.
The continuous real-time monitor and display device 10 can have a display housing 11.
The continuous real-time monitor and display device 10 can have a display emergency stop button 14 located on the display housing 11. In one or more embodiments, the display emergency stop button 14 can be in communication with an air regulator and a processor with computer instructions that allow a local operator to stop the operation of the system 8.
The continuous real-time monitor and display device 10 can have a display 16. Embodiments of the continuous real-time monitor and display device 10 can have a switch that can be used to turn the system 8 on and off. The switch can be mounted to the controller 50 or the display housing 11, and can be in communication with a controller processor.
The system 8 can have a multiport manifold 40 in communication with the continuous real-time monitor and display device 10. For example, the continuous real-time monitor and display device 10 can have a plurality of first compressed air outlets, such as first compressed air outlets 30a and 30f, in communication with a plurality of manifold inlets, such as manifold inlets 96a and 96f, to communicate into the multiport manifold 40.
The plurality of first compressed air outlets 30a and 30f and the plurality of manifold inlets 96a and 96f can be quick disconnects, which can allow for fast assembly of the system 8, such as a set-up time of less than 10 minutes.
The plurality of first compressed air outlets 30a and 30f can be configured to flow the compressed air 46 from the display housing 11 to each test head seal portion of a plurality of test heads, such as test heads 80a and 80f. The compressed air 46 can expand each test head seal portion against an inner wall of one of a plurality of chemical reactor tubes, such as chemical reactor tubes 36a and 36f. 
The continuous real-time monitor and display device 10 can have a plurality of second compressed air outlets, such as second compressed air outlets 31a and 31f, in communication with the multiport manifold 40 for flowing compressed air 46 from the display housing 11 through each of the plurality of the test heads 80a and 80f and into each of the chemical reactor tubes 36a and 36f. 
The plurality of second compressed air outlets 31a and 31f can be in communication with the multiport manifold 40 through a plurality of manifold inlets, such as manifold inlets 96g and 96l, which can also be quick disconnects.
The multiport manifold 40 can be in communication with the plurality of test heads 80a and 80f, through a plurality of individually removable and replaceable test head umbilicals, such as individually removable and replaceable test head umbilicals 73a and 73f. 
In operation, the multiport manifold 40 can transmit compressed air 46 to the continuous real-time monitor and display device 10. The compressed air 46 transmitted from the multiport manifold 40 to the continuous real-time monitor and display device 10 can be individually regulated and controlled within each of the plurality of individually removable and replaceable test head umbilicals 73a and 73f. In one or more embodiments, each of the plurality of individually removable and replaceable test head umbilicals 73a and 73f can have a different pressure.
The plurality of test heads 80a and 80f can be in communication with the plurality of chemical reactor tubes 36a and 36f. The plurality of individually removable and replaceable test head umbilicals 73a and 73f can include groups of similar pressurized air lines, such that a first portion of the plurality of test heads 80a and 80f can measure loaded chemical reactor tubes 36a and 36f at a first pressure, a second portion of the plurality of test heads 80a and 80f can measure partially loaded chemical reactor tubes 36a and 36f at a second pressure, and a third portion of the plurality of test heads 80a and 80f can measure empty chemical reactor tubes 36a and 36f at a third pressure. As such, the system 8 can provide for faster group analysis of various chemical reactor tubes 36a and 36f at various pressures.
In operation, compressed air 46 can be transmitted through the plurality of test heads 80a and 80f to simultaneously measure pressure in the chemical reactor tubes 36a and 36f and transmit the measured pressure as sensor signals to the controller 50.
The system 8 can be modular, which makes the system 8 easy to repair. The system 8 can also be easy to maintain, in-part because each component of the system can be individually cleaned without having to shut down and disassemble the entire system 8. For example, one test head of the plurality of test heads 80a and 80f can be removed and cleaned while the remainder of the system 8 continuous to operate; providing a major safety improvement over current test systems.
FIG. 1B depicts a cross section of an individually removable and replaceable test head umbilical 73.
The individually removable and replaceable test head umbilical 73 can include a signal line 76, an air line 78, and a power line 79, which can all be disposed within a polymer tape 98.
The signal line 76, air line 78, and power line 79 can extend parallel to each other within the polymer tape 98.
FIG. 2 depicts a detailed view of an embodiment of the continuous real-time monitor and display device 10. The continuous real-time monitor and display device 10 can provide for real-time display of sensor signals 21 and compared sensor results 23. For example, the continuous real-time monitor and display device 10 can continually update the display 16 from about every 1 second to about every 5 seconds to present the sensor signals 21 and compared sensor results 23 from each test head.
The continuous real-time monitor and display 10 can include the display housing 11 with a face plate 13. The display housing 11 and face plate 13 can be an aluminum box housing with a door, which can be sealed to enable an airtight and watertight connection between the aluminum box and the door.
The continuous real-time monitor and display 10 can be supported on a tripod 110. The tripod 110 can be a collapsible foldable support structure.
The display housing 11 can include a power and signal transmitter 12, such as a mini-transmitter model A-10 available from WIKA Instrument Corporation. The power and signal transmitter 12 can be from about 1 inch long to about 3 inches long.
The power and signal transmitter 12 can be in communication with a display processor 18 in the display housing 11. The display processor 18 can be in communication with a display data storage 20 in the display housing 11.
The display data storage 20 can have computer instructions to instruct the display processor to receive the sensor signals from the test head transmitter/sensor 22.
The display data storage 20 can have computer instructions to instruct the display processor to display the sensor signals on the display 24.
The display data storage 20 can have computer instructions to instruct the display processor to display the compared sensor results on the display 25.
In operation, the sensor signals 21 can be compared to customer preset pressure limits to form the compared sensor results 23. The continuous real-time monitor and display device 10 can be configured to present the sensor signals 21 from the test head transmitter/sensors and the compared sensor results 23 from the controller in real-time.
The face plate 13 can have a touch start button 17. The touch start button 17 can be a mechanical button mounted to the face plate 13. The touch start button 17 can be in communication with the display processor 18.
The face plate 13 can include the display emergency stop button 14, which can be in communication with the controller and the display processor 18, and can be pressed to actuate a stop of the flow of compressed air and sensor signals to and from the test heads. The display emergency stop button 14 can be used to quickly shut down chemical reactor tubes that might be over pressuring, providing an important safety benefit.
The display 16 can be disposed on the face plate 13 and can be electronic. The display 16 can be a graphical user interface configured to graphically present the sensor signals 21 and compared sensor results 23 to users. The display 16 can be in communication with the display processor 18.
The face plate 13 can include a test push button 26 in communication with the bi-directional multiline air, power, and signal port 28 on the display housing 11. The bi-directional multiline air, power, and signal port 28 can receive the sensor signals 21 from the controller. The test push button 26 can be used to start a particular compressed air test.
The face plate 13 can have an on/off switch 19a for turning the system on and off.
In operation, compressed air 46 can be transmitted through the plurality of test heads to simultaneously measure pressure in the chemical reactor tubes and transmit the measured pressure as the sensor signals 21 to the controller. The controller can use the sensor signals 21 along with data stored in a controller data storage to compute a comparison between the sensed pressure and customer preset pressure values, forming the compared sensor results 23.
FIG. 3A depicts a detail of the controller 50 with a controller housing 51.
The controller 50 can be in communication with the power source 49 through a power plug 74. The controller 50 can have a transformer 94 in communication with the power plug 74 for transforming A/C current to D/C current for operating gauges, transmitters, processors, transmitter/sensors and other components of the system.
The power plug 74 can be a 110 volt plug configured to receive power to operate a controller processor 52 and to power the controller 50. The power plug 74 can also be used to power the continuous real-time monitor and display device, and to flow power through each individually removable and replaceable test head umbilical to power each of the plurality of test head.
The controller 50 can be in communication with the compressed air source 44 through the compressed air inlet 47 for supplying the compressed air to the controller 50 and other portions of the system including the continuous real-time monitor and display device, the multiport manifold, and the plurality of test heads.
The controller processor 52 can be in communication with the transformer 94, a controller data storage 54, a network connection 72, the continuous real-time monitor and display device, and the compressed air source 44, such as through a controller emergency stop button 62.
The network connection 72 can be an Ethernet port for connecting the controller 50 and the controller processor 52 to a network 75, such as the internet, allowing for remote operation of the system by a user. For example, the controller 50 can present an executive dashboard 83 on a client device 77 using the network 75.
The controller emergency stop button 62 can be used to ensure that a local operator or user can quickly stop the flow of compressed air to the chemical reactor tubes, such as if pressure in the chemical reactor tubes is at a dangerous level.
The controller 50 can include a plurality of control transmitters, such as control transmitter 66a and 66e, which can be small or mini transmitters. Each of the plurality of control transmitters 66a and 66e can be in communication with the controller processor 52 through a controller signal line 65.
The controller 50 can include a plurality of pressure indicators, such as pressure indicators 68a and 68e. Each of the plurality of pressure indicators 68a and 68e can be in communication with one of a plurality of individual air regulators, such as individual air regulators 69a and 69e. 
The plurality of pressure indicators 68a and 68e, which can be pressure gauges, can communication with the controller processor 52 through the plurality of control transmitters 66a and 66e and the controller signal line 65. Each of the plurality of pressure indicators 68a and 68e can be in communication with a test head transmitter/sensor and one of a plurality of individual air regulators 69a and 69e. 
The controller 50 can include a master air regulator 70 connected to the plurality of individual air regulators 69a and 69e. The master air regulator 70 can be in communication with the controller emergency stop button 62 through the controller processor 52 through a controller air line 67. The controller can have an on/off switch 19b for turning the controller on and off.
FIG. 3B depicts a detail of the controller data storage 54.
The controller data storage 54 can have various computer instructions programmed therein. For example, the controller data storage 54 can have a library 58 including customer preset pressure limits 57a, 57b, and 57c. 
The controller data storage 54 can have computer instructions to instruct the controller processor to receive the sensor signals from each test head sensor/transmitter 55.
The controller data storage 54 can have computer instructions to compare the sensor signals to the customer preset pressure limits 56.
The controller data storage 54 can have computer instructions to instruct the controller processor to allow a local operator to actuate the controller emergency stop button 60.
The controller data storage 54 can have computer instructions to instruct the controller processor to allow a remote user to initiate the controller emergency stop button 61.
The sensor signals 21 and the compared sensor results 23 can be stored in the controller data storage 54.
In operation, the controller can use the sensor signals 21, data stored in the controller data storage 54, the library 58 of customer preset pressure limits 57a, 57b and 57c, and the various computer instructions in the controller data storage 54, including comparison algorithms, in order to compute a comparison between the sensed pressures of the sensor signals and the customer preset pressure limits 57a, 57b and 57c; thereby forming the compared sensor results 23.
The controller can use the controller processor and other equipment to transmit the compared sensor results 23 and/or the sensor signals 21 to the display of the continuous real-time monitor and display device.
FIGS. 4A-4B depict an automated test head 80, which can be air actuated. The automatic test head 80 can have a test head body 90, which can be a bi-directional multiline compress test head body.
The automated test head 80 can have a first test head compressed air inlet port 85 and a second test head compressed air inlet port 86.
In operation, the first test head compressed air inlet port 85 can flow compressed air into the test head body 90 to expand and seal a test head seal portion 87 against the inner wall 38 of a chemical reactor tube 36.
FIG. 4A shows the test head seal portion 87 sealed against the inner wall 38 of the chemical reactor tube 36, and FIG. 4B shows the automated test head 80 removed from the chemical reactor tube 36.
Simultaneously, while using the compressed air to seal the automated test head 80 to the chemical reactor tube 36, compressed air can be transmitted into the automated test head 80 through the second test head compressed air inlet port 86.
The second test head compressed air inlet port 86 can flow compressed air through the test head body 90 and out of a test head seal outlet 88 into the chemical reactor tube 36; thereby enabling the test head transmitter/sensor 82 to measure the pressure in the chemical reactor tube 36. In operation, the system can be used to measure the pressure in loaded, partially loaded, and unloaded chemical reactor tubes 36 for comparison purposes.
The automated test head 80 can be used to simultaneously measure pressure in the chemical reactor tube 36 and transmit the measured pressure as sensor signals to the controller through a signal line 76, which can also be called a transmitter connection.
The first test head compressed air inlet port 85, the second test head compressed air inlet port 86, and the signal line 76 can each be a portion of one of the plurality of individually removable and replaceable test head umbilicals.
The test head transmitter/sensor 82 can be connected to the automated test head 80 and the signal line 76, which can transmit the sensor signals from the automated test head 80 to the controller processor of the controller.
The automated test head 80 can be engaged within the chemical reactor tube 36, as shown in FIG. 4A. The chemical reactor tube 36 can be loaded with a catalyst 37.
To use the automated test head 80, an operator can first connect the individually removable and replaceable test head umbilical to the miniport manifold.
The operator can then connect the multiport manifold to the continuous real-time monitor and display device.
The operator can then connect the continuous real-time monitor and display device to the controller.
The operator can power the controller, such as by providing electricity to the controller, which can in-turn power the entire system.
The operator can then allow compressed air from the compressed air source to enter the controller, which can pressurize the entire system. The pressure of the compressed air can vary depending on the chemical reactor tube 36 being analyzed. For example, the pressure of the compressed air can range from about 0 pounds per square inch to about 1000 pounds per square inch, such as 90 pounds per square inch, depending upon the application.
The customer preset pressure limits can be inputted into the controller data storage.
The automated test head 80 can be tested to ensure that the compressed air is flowing, and to ensure that the test head transmitter/sensor 82 is operational using a test stand of the chemical reactor tube 36 with a known pressure. The entire system can be properly calibrated to within +/−1 percent.
Next, the automated test head 80 can be inserted into the chemical reactor tube 36, such as at a customer site.
The operator can initiate pressurization of the automated test head 80 in the chemical reactor tube 36 by activating the touch start button of the display in the continuous real-time monitor and display device.
The controller can receive the sensor signals from each of the test head transmitter/sensor 82. The controller can then compare the sensor signals to the customer preset limits.
The controller can transmit the compared sensor results to the display every two seconds to present the compared sensor results. The compared sensor results can also be transmitted to a network, such as a satellite network or the internet to client devices; enabling remote users to monitor the process, such as with an executive dashboard on the client device.
The compared sensor results and the sensor signals can be stored in the controller data storage. The operator can print out any data in the controller data storage by connecting the network connection of the controller to a printer.
A colored tube cap 112 can be placed over the chemical reactor tube 36 after testing is complete.
FIGS. 5A-5B depict a detailed view of an embodiment of a manual test head 100. FIG. 5A shows the manual test head 100 with a handle 105 extending parallel to a manual test head body 106, and FIG. 5B shows the manual test head 100 with the handle 105 extending perpendicular to the manual test head body 106. The manual test head body 106 can be pivotably connected to the handle 105.
The manual test head 100 can be operated in a similar manner as the automated test head of FIGS. 4A-4B, however, the manual test head 100 can have the handle 105 for connecting to an individually removable and replaceable test head umbilicals 73.
A manual test head seal portion 108 can be connected to the manual test head body 106.
A manual test head seal outlet 109 can be centrally formed in the manual test head seal portion 108.
A manual test head compressed air inlet port 102, which can be a portion of the individually removable and replaceable test head umbilicals 73, can flow compressed air through the manual test head body 106 and out of the manual test head seal outlet 109 to a chemical reactor tube 36.
A manual test head transmitter/sensor 103 can be connected to the manual test head body 106 for sensing pressure in the chemical reactor tube 36, and transmitting the sensed pressure as a sensor signal through a signal line 76, which can be in communication with the controller processor of the controller.
The manual test head 100 can be placed into the chemical reactor tube 36 using the handle 105, which can be axially aligned with the manual test head body 106.
To operate the manual test head 100, the handle 105 can be pivoted to be oriented at a 90 degree angle to the manual test body 106 as shown in FIG. 5B; thereby causing the manual test head seal portion 108 to extend and form a seal with the inner wall 38 of the chemical reactor tube 36 and allowing the compressed air to pass into the chemical reactor tube 36 through the manual test head seal outlet 109. In this Figure, the chemical reactor tube 36 is shown loaded with catalyst 37.
The manual test head transmitter/sensor 103 can then sense pressure in the chemical reactor tube 36 and transmit the sensed pressure as sensor signals to the controller processor of the controller.
FIGS. 6A-6B depict an embodiment of a method for measuring back pressure in open ended chemical reactor tubes.
The method can include connecting each of a plurality of test heads to individually removable and replaceable test head umbilicals, as illustrated by box 600.
The method can include connecting each individually removable and replaceable test head umbilical to a multiport manifold, as illustrated by box 602.
The method can include connecting the multiport manifold to a continuous real-time monitor and display device, as illustrated by box 604.
The method can include supporting the continuous real-time monitor and display device using a tripod, as illustrated by box 606.
The method can include connecting the continuous real-time monitor and display device to a controller, as illustrated by box 608.
The method can include providing power to the controller and transmitting power through the controller to: the continuous real-time monitor and display device, each individually removable and replaceable test head umbilical, and each test head, as illustrated by box 610.
For example, an operator can turn on the system by engaging an on/off switch to provide electricity to each component usable to implement the method via the controller.
The method can include powering the controller, the continuous real-time monitor and display device, the multiport manifold, and the plurality of test heads using a 24 volt DC continuous supply power source, as illustrated by box 612.
The method can include using a transformer disposed in the controller between a power source and the controller processor to transform A/C current to D/C current, as illustrated by box 614.
The method can include allowing compressed air to flow from a compressed air source through the controller to the continuous real-time monitor and display device, then to the multiport manifold, then to each individually removable and replaceable test head umbilical, and to each test head, as illustrated by box 616.
In operation, the compressed air can pressurize the entire system usable to implement the method.
The method can include flowing the compressed air through air supply conduits between: the controller and the continuous real-time monitor and display device, the continuous real-time monitor and display device and the multiport manifold, and the multiport manifold and the plurality of test heads, as illustrated by box 618.
The method can include using a plurality of quick disconnects to engage each air supply conduit with: the controller, the continuous real-time monitor and display device, the multiport manifold, and the plurality of test heads, as illustrated by box 620.
The method can include using a power line within the individually removable and replaceable test head umbilical to transfer power between the multiport manifold and the plurality of test heads, as illustrated by box 622.
The method can include using a signal line within the individually removable and replaceable test head umbilical to transfer the sensor signals between the multiport manifold and the plurality of test heads, as illustrated by box 624.
The method can include using an air line within the individually removable and replaceable test head umbilical to transfer the compressed air between the multiport manifold and the plurality of test heads, as illustrated by box 626.
The method can include inserting customer preset pressure limits into a controller data storage connected to a controller processor of the controller, as illustrated by box 628.
The method can include pre-testing each test head against a known loaded chemical reactor tube with a known pressure to ensure proper calibration within +/−1 percent, as illustrated by box 630.
The method can include inserting each pre-tested test head into a loaded chemical reactor tube, as illustrated by box 632.
The method can include individually initiating pressurization of each test head in the chemical reactor tubes by activating the continuous real-time monitor and display device, as illustrated by box 634.
For example, the operator can initiate pressurization of the test heads in the chemical reactor tubes by activating the touch start button on the display of the continuous real-time monitor and display device.
The method can include transmitting sensor signals to the controller from a test head transmitter/sensor on each test head to provide the controller with sensed pressures on a real-time basis, as illustrated by box 636.
The method can include storing the sensor signals and the compared sensor results in the controller data storage, as illustrated by box 638.
The method can include using the controller to compare the sensor signals to the customer preset pressure limits, forming compared sensor results, as illustrated by box 640.
The method can include transmitting the compared sensor results to the continuous real-time monitor and display device, as illustrated by box 642.
For example, the controller can transmit the compared signal results every two seconds to the display for presentation thereon. The controller can transmit the compared sensor results with or without the raw sensor signals. The controller can also transmit the compared sensor results and the sensor signals over a network.
Users can communicate with the controller, such as by using an executive dashboard on a client device, to monitor and provide emergency stop instructions to the controller.
The method can include presenting the compared sensor results to a local user on a display of the continuous real-time monitor and display device, transmitting the compared sensor results over a network to a remote user, or combinations thereof, as illustrated by box 644.
The method can include printing the sensor signals, the compared sensor results, or combinations thereof by connecting the controller to a network with a printer, as illustrated by box 646.
The method can include engaging a colored tube cap over each chemical reactor tube after pressure testing is complete to identify chemical reactor tubes that need replacement, as illustrated by box 648.
FIG. 7 depicts an embodiment of the method using a manual test head.
The method can include placing each manual test head into one of the chemical reactor tubes using the handles such that a test head body of each manual test head is oriented in parallel to the handles, as illustrated by box 700.
The method can include re-orienting the handles to be disposed perpendicular to the test head bodies and causing a test head seal portion of the manual test heads to extend and form seals with an inner wall of the chemical reactor tubes, as illustrated by box 702.
The method can include allowing compressed air to be passed into the chemical reactor tubes through a test head seal outlet of each manual test head, as illustrated by box 704.
The method can include sensing pressure in each chemical reactor tube using a manual test head transmitter/sensor of each manual test head, as illustrated by box 706.
The method can include transmitting the sensed pressures as the sensor signals to the controller, as illustrated by box 708.
While these embodiments have been described with emphasis on the embodiments, it should be understood that within the scope of the appended claims, the embodiments might be practiced other than as specifically described herein.

## Claims

1. A method for measuring back pressure in open ended chemical reactor tubes, the method comprising:
a. connecting a plurality of test heads to individually removable and replaceable test head umbilicals;
b. connecting the individually removable and replaceable test head umbilicals to a multiport manifold;
c. connecting the multiport manifold to a continuous real-time monitor and display device;
d. connecting the continuous real-time monitor and display device to a controller;
e. providing power to the controller and transmitting power through the controller to the continuous real-time monitor and display device, the individually removable and replaceable test head umbilicals, and the test heads;
f. allowing compressed air to flow from a compressed air source through the controller to the continuous real-time monitor and display device, then to the multiport manifold, then to the individually removable and replaceable test head umbilicals, and to the test heads;
g. inserting customer preset pressure limits into a controller data storage connected to a controller processor of the controller;
h. pre-testing the test heads against a known loaded chemical reactor tube with a known pressure to ensure proper calibration within +/−1 percent;
i. inserting the pre-tested test heads into a loaded chemical reactor tube;
j. individually initiating pressurization of each test head in the chemical reactor tubes by activating the continuous real-time monitor and display device;
k. transmitting sensor signals to the controller from a test head transmitter/sensor on the test heads to provide the controller with sensed pressures on a real-time basis;
l. using the controller to compare the sensor signals to the customer preset pressure limits, forming compared sensor results;
m. transmitting the compared sensor results to the continuous real-time monitor and display device;
n. presenting the compared sensor results to a local user on a display of the continuous real-time monitor and display device; and
o. transmitting the compared sensor results over a network to a remote user, or combinations thereof.

2. The method of claim 1, further comprising storing the sensor signals and the compared sensor results in the controller data storage.

3. The method of claim 1, further comprising printing the sensor signals, the compared sensor results, or combinations thereof by connecting the controller to a network with a printer.

4. The method of claim 1, wherein each of the plurality of test heads is a manual test head comprising a handle, the method further comprising:
a. placing each manual test head into one of the chemical reactor tubes using the handles such that a test head body of each manual test head is oriented in parallel to the handles;
b. re-orienting the handles to be disposed perpendicular to the test head bodies and causing a test head seal portion of the manual test heads to extend and form seals with an inner wall of the chemical reactor tubes;
c. allowing compressed air to be passed into the chemical reactor tubes through a test head seal outlet of each manual test head;
d. sensing pressure in each chemical reactor tube using a manual test head transmitter/sensor of each manual test head; and
e. transmitting the sensed pressures as the sensor signals to the controller.

5. The method of claim 1, further comprising engaging a colored tube cap over each chemical reactor tube after pressure testing is complete to identify chemical reactor tubes that need replacement.

6. The method of claim 1, further comprising using a transformer disposed in the controller between a power source and the controller processor to transform A/C current to D/C current.

7. The method of claim 1, further comprising:
a. flowing the compressed air through air supply conduits between the controller and the continuous real-time monitor and display device, the continuous real-time monitor and display device and the multiport manifold, and the multiport manifold and the plurality of test heads; and
b. using a plurality of quick disconnects to engage each air supply conduit with: the controller, the continuous real-time monitor and display device, the multiport manifold, and the plurality of test heads.

8. The method of claim 1, further comprising:
a. using a power line within the individually removable and replaceable test head umbilical to transfer power between the multiport manifold and the plurality of test heads;
b. using a signal line within the individually removable and replaceable test head umbilical to transfer the sensor signals between the multiport manifold and the plurality of test heads; and
c. using an air line within the individually removable and replaceable test head umbilical to transfer the compressed air between the multiport manifold and the plurality of test heads, wherein a polymer tape is disposed around: the power line, the signal line, and the air line.

9. The method of claim 1, further comprising powering the controller, the continuous real-time monitor and display device, the multiport manifold, and the plurality of test heads using a 24 volt DC continuous supply power source.

10. The method of claim 1, further comprising supporting the continuous real-time monitor and display device using a tripod.