Method and apparatus for installing a retractable thermocouple

1. A method of installing a retractable thermocouple for sensing a flame of a flare pilot at an upper end of a flare stack, said method comprising the steps of:

(a) pushing said retractable thermocouple through a first set of offset straightening rollers to straighten said retractable thermocouple in a first plane; then

(b) pushing said retractable thermocouple through a second set of offset straightening rollers to straighten said retractable thermocouple in a second plane different from said first plane; and then

(c) pushing said retractable thermocouple through a conduit which extends upwardly toward said flare pilot at said upper end of said flare stack,

wherein each of said straightening rollers in said first set and said second set of said offset straightening rollers has a non-metallic contacting surface which contacts said retractable thermocouple.

2. The method of claim 1 wherein said retractable thermocouple is pushed through said first set of said offset straightening rollers in accordance with step (a), said second set of said offset straightening rollers in accordance with step (b), and said conduit in accordance with step (c) using a set of drive wheels having non-metallic contacting surfaces which contact said retractable thermocouple.

3. The method of claim 2 wherein said first set and said second set of said offset straightening rollers each individually comprise:

a first idler roller which is positioned on a first lateral side of and is in contact with said retractable thermocouple;

a second idler roller which is also positioned on said first lateral side of and is in contact with said retractable thermocouple, said second idler roller being located downstream of said first idler roller in a direction of travel of said retractable thermocouple; and

an adjustable deflecting roller which is positioned between said first and said second idler rollers in said direction of travel and is located on a second lateral side of said retractable thermocouple opposite said first lateral side, said adjustable deflecting roller being adjustably moveable toward and away from said retractable thermocouple,

wherein said adjustable deflecting roller is set in contact with said retractable thermocouple such that said adjustable deflecting roller deflects said retractable thermocouple toward said first lateral side as said retractable thermocouple travels from said first idler roller to said second idler roller.

4. The method of claim 3 wherein a centerline of said retractable thermocouple is deflected by said adjustable deflecting roller toward said first lateral side by an amount in a range of from about ⅛ to about ¾ of an inch.

5. The method of claim 4 wherein said centerline of said retractable thermocouple is deflected by said adjustable deflecting roller toward said first lateral side by an amount in a range of from about ¼ to about ½ of an inch.

6. The method of claim 3 wherein said first set and said second set of said offset straightening rollers each individually further comprises an adjustable exit angle roller which is positioned downstream of said second idler roller in said direction of travel and is located on said second lateral side of said retractable thermocouple, said adjustable exit angle roller being adjustably moveable toward and away from said retractable thermocouple and said adjustable exit angle roller being set in contact with said retractable thermocouple such that said adjustable exit angle roller deflects said retractable thermocouple toward said first lateral side.

7. The method of claim 6 wherein said first idler roller, said second idler roller, said adjustable deflecting roller, and said adjustable exit angle roller are each formed of urethane.

8. The method of claim 7 wherein said urethane is 95A urethane.

9. The method of claim 2 wherein said set of drive wheels comprises a first pair of opposing drive wheels and a second pair of opposing drive wheels, said retractable thermocouple being positioned between said first pair of opposing drive wheels and between said second pair of opposing drive wheels such that each of said first pair and second pair of opposing drive wheels applies a shear force to said retractable thermocouple which pushes said retractable thermocouple through said first set of said offset straightening rollers, said second set of said offset straightening rollers, and said conduit.

10. The method of claim 9 further comprising the step of turning said first pair and said second pair of opposing drive wheels using a power tool.

11. The method of claim 10 wherein said power tool rotates a drive gear which turns said first pair and said second pair of opposing drive wheels and wherein said power tool is operably linked to said drive gear by a gear box and a chuck adaptor.

12. The method of claim 11 wherein said power tool is an electric or pneumatic drill.

13. The method of claim 9 wherein each of said drive wheels is formed of urethane.

14. The method of claim 13 wherein said urethane is 93A urethane.

15. The method of claim 2 further comprising the step of guiding said retractable thermocouple into said set of drive wheels by receiving said retractable thermocouple through a non-metallic guide.

16. The method of claim 15 wherein said non-metallic guide is formed of urethane.

17. The method of claim 2 wherein:

said set of drive wheels and said first set and said second set of offset straightening rollers are secured on a portable mounting structure and

said method further comprises the step of removably securing said portable mounting structure at a lower end portion of said flare stack.

18. The method of claim 2 wherein:

said set of drive wheels and said first set and said second set of said straightening rollers are secured on a portable mounting structure and

said method further comprises the step of removably securing said portable mounting structure outside of an enclosure or fence for said flare stack.