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If you are experiencing audio problems please call the teleconference number below 1-408-600-3600 Access code 660 637 935 Bill Bergquist, Sr. Applications Engineer Jeff Wigen, National Account Manager
Thermowell Selection and Application
Bill
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Jeff
Performance
Wake frequency & strength Immersion length Time response Definitions/codes Typical drawing Details Testing & certifications Options
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Thermowelltypesaredesignatedbythestyleof stemorwettedportionofthewell.Protection tubesaretypicallyusedforthermocouplesand arenotsuitedforusewithRTDsbecausetheydo notprovideenoughsupportforthesensor. Mostthermowellsaremachinedfrombarstock toinsureintegrityforhighpressureapplications. Flangesarejoinedtoathermowellstemmost commonlybyaweldingprocess.Smallerwells maybeconstructedfromtubingandhavethe endweldedclosedandaprocessconnection weldedon.Thesearetypicallyusedinlow pressureapplications.
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Stepped
Tapered
Straight
Burns Engineering Thermowell Selection and Application
Connection styles
Flange
ANSI B16.5 Van Stone
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Connectionstotheprocessareaccomplished withtaperedpipethreadsoradaptationsofpipe orsanitarytubingflangeconnections.Ablankor blindflangeismodifiedtoacceptthethermowell stemandtheneasilyattachestostandard flanges. Weldinstylesareusedforconvenienceorwhere exposedthreadsmaycollectcontaminantssuch asinfoodprocessingorpharmaceutical production. AspecialtytypeofconnectionincorporatesanO ringtosealinsideasleeveweldedtoatank. SometimesreferredtoasanIngoldfittingafter thecompanythatinventeditforphandoxygen sensors.
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Sanitary Weld-In
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Sanitary Flange
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Anotherstyleofsanitarywellusesasanitary flangeforattachmentofthetemperaturesensor.
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Notoolsarerequiredtoinstallorremovethe sensorwhichmakesforeasiermaintenance.
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O-Ring
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Lag length
Added thermowell length outside process to reach through insulation
Whenselectingaprocessconnectionthereare severalthingstoconsider.Threadedconnections aretheeasiest,flangeconnectionrequirea flangesize,pressurerating,andgasketsurface style. Laglengthisanextensionofthenonwetted portionofthewelltoreachthroughinsulationor otherobstaclestoprovidewrenchaccess. Typicallyspecifiedforthreadedwells. Testwellsthatsitemptyforlongperiodsoftime shouldhaveaplugintheinstrumentconnection topreventdebrisfromentering.
Materials
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Factors to consider
Define the conditions
Corrosion/erosion Temperature Pressure Fluid Properties
Materialselectioncanbeassimpleaschoosing thesamematerialasthetankorpipewhereitis tobeinstalled.Thisworksmostofthetimebut thereareexceptions.Inthecaseofcorrosionor erosionanobjectplacedintoaflowismore susceptibletothoseeffectsandadifferent materialwillbenecessarytoprovidelongerlife. Therearecorrosionchartsavailablefrom thermowellmanufacturersthatlistthepreferred materialforchemicalsatdifferentconditions.
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Materials Corrosion
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Chemical
Condition
Material
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Corrosion
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Corrosion
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Materials - Erosion
Materials Cobalt-Chromium (Stellite) Cobalt-Nickel (Wallex) Tungsten Carbide Silicon Carbide (Hexoloy) Alumina
Photo courtesy of Lisa Danielson
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Surface finish
Improved corrosion resistance Sanitary applications
Electropolish Passivation
Burns Engineering Thermowell Selection and Application
Avarietyofmaterialscanbeusedtoconstruct thermowells.Surfacecoatingscanbeusedto improvecorrosionanderosionresistance. PlasticssuchasTeflonarehighlycorrosion resistantandceramicsofferhightemperature capabilitiesandcanbeagoodchoiceforerosive applications. Tantalumisusedforacidresistanceandcanbe appliedasasleeveoritcanbebondedtothe surfaceofnearlyanythermowellstyle. Improvingthesurfacefinishwillincrease corrosionresistanceandmakeiteasiertoclean. Fewerridgesandcrevicesmeansasmaller surfaceareaforthecorrodenttoattack. Electropolishingorpassivatingthesurface furtherincreasescorrosionresistance.
Materials
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Sometimeslessexpensivematerialsturnoutto bethebestchoice.OriginallyaTeflonplated metalwellwasusedformonitoringthe temperatureofanacidicwasteproduct.Teflon platingiseasilydamaged(thinkofyourfrying pan)andtheacidquicklyateawaythemetalwell causingittoleak.Thesolutionwastouse standard3PVCpipetoconstructthewellwhich wasabout10ftlongandattachedwithaflange connection.Aninternalwellwasmadewith PVCtohousethetemperaturesensorallowingit tostickoutacoupleinchesforbettertime response.
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PositiveMaterialIdentification(PMI)referstothe identificationandanalysisofvariousmetalalloys basedontheirchemicalcompositionin nondestructivetesting(NDT).Measurement resultsareshownintheformofelemental concentrationinpercentageorbyspecificalloy namesuchasSS316LorInconel625.PMIisa fieldtestingmethodmadepossiblebythe portabilityofmostPMIanalyzers.These instrumentsalsocanbeusedinthelaboratory TheXRayFluorescenceTechniqueXRF XRFinstrumentsworkbyexposingasampletoa beamofXrays.Theatomsofthesampleabsorb energyfromtheXrays,becometemporarily excitedandthenemitsecondaryXrays.Each chemicalelementemitsXraysataunique energy.Bymeasuringintensityandcharacteristic energyoftheemittedXrays,anXRFanalyzercan providequalitativeandquantitativeanalysis regardingthecompositionofthematerialbeing tested.
Performance
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Measurement accuracy
Wake frequency and strength calculations
ASME PTC 19.3 TW-2010
Immersion length
Elbow well
Time response
Heat transfer paste Bore and probe diameter
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Measurementaccuracycanbeadverselyaffected byathermowellunlessafewprecautionsare taken.Wakefrequencyandstrengthcalculations areprobablythemostimportant.These calculationswilltellyouhowlongthewellcanbe immersedintoyourprocessbasedontheflow conditions(moreonthislater).Thishastobe balancedwiththeaccuracyneedsofthesensor tobeimmersedsufficientlytopreventstem conductionorimmersionerror. Finally,timeresponseisslowerwiththeaddition ofathermowellandforprocessesthatchange temperaturerapidlythiscanbeasignificanterror source.
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The long awaited PTC 19.3 TW-2010 is a completely new standard that establishes the practical design considerations for thermowell installations in power and process piping. This code is an expanded version of the thermowell section contained in the PTC 19.3-1974, and incorporates the latest theory in the areas of natural frequency, Strouhal frequency, in-line resonance and stress evaluation. ASME responded to changing industry demands for a more comprehensive set of thermowell evaluations. Key enhancements over the 1974 edition include: Expanded coverage for thermowell geometry Natural frequency correction factors for mounting compliance, added fluid mass, and sensor mass Consideration for partial shielding from flow Intrinsic thermowell damping; Steady state and dynamic stress evaluations Improved allowable fatigue limit definition. Excerpted from ASME website:
Burns Engineering Thermowell Selection and Application
Thenewreleaseofthethermowellsectionofthe PowerTestCodeincorporatethelatesttheoryfor wakefrequencyandstrengthcalculations.If youreapipingdesignerallthisprobablymeansa lottoyou.Forsomeoneselectingathermowell itmaybealittlelikelearninghowtobuilda chainsawtocutdownatree.Interestingbutnot reallynecessary.Yourthermowellsupplierwill providethecalculationsbasedyourprocess conditionsanddesiredthermowellconfiguration. Youneedtoknowthatyouwantthecalculations donetothenew2010versionofthestandard.
http://staging.files.asme.org/Catalog/Codes/PrintBook/25750.pdf
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Whenacylindricalobjectisplacedinaflowthere isadisturbancecreatedonthedownstreamside thatoscillatesbackandforth.Thefrequencyof theoscillationincreasesastheflowrate increases.Iftheresonantfrequencyofthe thermowellmatchesthefrequencyofthe vorticesthewellwillstarttovibrateandwillfirst damagetheRTDandthenthewellwillfail. Therearealotofgoodillustrationsofthis phenomenaontheinternet.Asearchforvon karmanorwakefrequencywillreturnseveral.
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Thermowell Selection
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Information Required
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Thisistypicaloftheinformationthatisneeded toperformthecalculations.
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Stress Crack
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Alittlebetterviewofthecrackthatformed.
Stress Crack
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Immersion Length
Direct immersion RTDs require 10 x probe diameter plus sensitive length to avoid stem conduction errors. Thermowells require about 4.5.
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25C
200C
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Immersion Error
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35.00
30.00
25.00
20.00
15.00
10.00
5.00
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Installation in a Tee
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Good
SENSOR INSTALLED PARALLEL TO FLOW
Better
Best
Fluid
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Anti-Immersion?
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Specifying - Definitions/Codes
Process connection P Immersion length U Lag length T Bore depth A usually overall length minus Tip diameter D Root diameter Q Stem style Instrument connection Material
Coatings
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Standardvariablelettersareusedtodescribe thermowelldimensions.
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An ounce of prevention
Preventive maintenance
Thermowell
; ; ; ; ; Bore cleaning Heat transfer compound Product buildup on wetted portion Cracks in flange weld or leaky gasket RTD bottoms in well and spring loads
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Summary
Thermowell basics Purpose Types Process connection styles Materials, coatings and surface finish Performance Wake frequency & strength Immersion length Time response Custom designs Specifying Definitions/codes Typical drawing Details Testing & certifications Options Preventive Maintenance Selection Checklist
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