Thermowell Selection and Application Notes

Thermowell Selection and Application
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Bill Bergquist, Sr. Applications Engineer
Jeff Wigen, National Account Manager
Bill
Burns Engineering
Jeff
What Well Cover
The thermowell used with your temperature sensor provides critical

protection, access, and measurement integrity. Well shed some light
on how, why, and when to apply this important device.
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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Thermowell Basics - Purpose

Why use a thermowell?
Protect the temperature sensor from:
Excessive pressures
Excessive material velocities & viscosities
Corrosion
Erosion
Simplify maintenance
Sensor replacement without draining the system
Eliminate potential for contamination system stays closed
Protection increases potential life of the sensor
Improve temperature measurements
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Athermowellsmainpurposeistoprotectthe
temperaturesensortoinsurelonglifeand
accuratemeasurement.Maintenanceisaidedby
allowingthesensortoberemovedwithout
havingtodrainthepipeortank.Sensorchanges
canbedoneonthefly.
Thermowell Basics - Types
Thermowell types
Stepped
Tapered
Straight
Sanitary
Protection tube
Typically made from pipe
Usually not suited for RTDs
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Thermowelltypesaredesignatedbythestyleof
stemorwettedportionofthewell.Protection
tubesaretypicallyusedforthermocouplesand
arenotsuitedforusewithRTDsbecausetheydo
notprovideenoughsupportforthesensor.
Mostthermowellsaremachinedfrombarstock
toinsureintegrityforhighpressureapplications.
Flangesarejoinedtoathermowellstemmost
commonlybyaweldingprocess.Smallerwells
maybeconstructedfromtubingandhavethe
endweldedclosedandaprocessconnection
weldedon.Thesearetypicallyusedinlow
pressureapplications.
Thermowell Basics - Stem Types
Stepped
Stepped,sometimesreferredtoasreducedtip,
wellsareusuallydiameterandstepdownto
diametertoimprovetimeresponse.Tapered
wellsareabalancebetweenstrengthandtime
response.Straightwellsarespecifiedwhere
increasedlifeisdesiredduetocorrosionor
erosion.
Tapered
Straight
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Thermowell Basics - Process Connections
Connection styles
Flange
ANSI B16.5
Van Stone
Socket weld
Weld-in
Threaded
Sanitary flange
O-Ring
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Connectionstotheprocessareaccomplished
withtaperedpipethreadsoradaptationsofpipe
orsanitarytubingflangeconnections.Ablankor
blindflangeismodifiedtoacceptthethermowell
stemandtheneasilyattachestostandard
flanges.
Weldinstylesareusedforconvenienceorwhere
exposedthreadsmaycollectcontaminantssuch
asinfoodprocessingorpharmaceutical
production.
AspecialtytypeofconnectionincorporatesanO
ringtosealinsideasleeveweldedtoatank.
SometimesreferredtoasanIngoldfittingafter
thecompanythatinventeditforphandoxygen
sensors.
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Asanitaryweldinstylesuchasthisoneisusedin
sanitaryprocesstankswherecracksandcrevices
arenotdesired.
Sanitary Flange
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Thesearejustafewoftheseveralstyles
available.Anyimaginablepipeortubing
connectionstyleeitherhasbeenorcouldbe
adaptedtoathermowellprocessconnection.
Sanitary Weld-In
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Thisisathermowellwithasanitaryflange
connectionwhichissometimesreferredtoasa
TriClampconnector.Itisthemostcommon
styleofsanitaryconnection.Thehighpolishand
largeradiusbetweenstemandflangeimprove
corrosionresistanceandmakecleaningeasier.
Sanitary with Process & Instrument Flange
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Sanitary Easy Access Tri-Clamp
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Anotherstyleofsanitarywellusesasanitary
flangeforattachmentofthetemperaturesensor.
Sanitary Process and Instrument Flange
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10
12
Notoolsarerequiredtoinstallorremovethe
sensorwhichmakesforeasiermaintenance.
O-Ring
13
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14
Process connection selection

Thread size
Typically tapered pipe thread
Flange size and rating

Gasket surface type
Raised
Flat
RTJ
Lag length
Added thermowell length outside process to reach through
insulation
Brass or SS plug for test wells

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Factors to consider
Define the conditions
Corrosion/erosion
Temperature
Pressure
Fluid Properties
Match the pipe or tank materials

Refer to corrosion charts
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Whenselectingaprocessconnectionthereare
severalthingstoconsider.Threadedconnections
aretheeasiest,flangeconnectionrequirea
flangesize,pressurerating,andgasketsurface
style.
Laglengthisanextensionofthenonwetted
portionofthewelltoreachthroughinsulationor
otherobstaclestoprovidewrenchaccess.
Typicallyspecifiedforthreadedwells.
Testwellsthatsitemptyforlongperiodsoftime
shouldhaveaplugintheinstrumentconnection
topreventdebrisfromentering.
Materials
Themostcommonstyleofinstrument
connectionisaNPTfemalethreadasshown
hereonthisOringstylewell.Thisstylewell
installsintoasleeveweldedtoatankwhich
acceptsthewellandthethreadednutholdsitin
place.AtightfitinsuresthattheOringseals
securely.
Materialselectioncanbeassimpleaschoosing
thesamematerialasthetankorpipewhereitis
tobeinstalled.Thisworksmostofthetimebut
thereareexceptions.Inthecaseofcorrosionor
erosionanobjectplacedintoaflowismore
susceptibletothoseeffectsandadifferent
materialwillbenecessarytoprovidelongerlife.
Therearecorrosionchartsavailablefrom
thermowellmanufacturersthatlistthepreferred
materialforchemicalsatdifferentconditions.
Materials Corrosion
Chemical
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16
Condition
Material
Materialselectiontablesareavailablefor
numerouschemicalsandconditions.Notethat
concentrationandtemperaturehavean
influenceontherecommendedmaterial.The
higherthetemperatureand/orconcentrationthe
morecorrosivethechemicalcanbe.
Corrosion
17
Choosingthewrongmaterialcanresultinfailure
ofthewell.Herethetiphascorrodedawayand
allowedtheprocessfluidtoleakinsidethewell.
18
Thisisaviewinsidethetipsectionshowing
corrosionontheinsidefromtheleakingprocess
fluid.
Photo courtesy of Alloy Engineering

http://www.thermowells.com/library.html
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Corrosion

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Materials - Erosion
19
Materials
Cobalt-Chromium (Stellite)
Cobalt-Nickel (Wallex)
Tungsten Carbide
Silicon Carbide (Hexoloy)

Alumina
Photo courtesy of Lisa Danielson
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Materials - Selection
20
Materials
Metals
Plastic
Ceramic
Surface coatings
Teflon
Tantalum
Ceramic
Hard facing
Surface finish
Improved corrosion resistance
Sanitary applications
Electropolish
Passivation
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Materials
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Particlessuspendedinafluidorpowdered
materialscancauseerosionofthewellover
time.Thereareseveralmaterialsavailableto
slowdowntheerosion.Mostarehardmaterials
thatareappliedthroughaweldingorspraying
process.Sometimesjustpickingthecorrect
thermowellmaterialissufficienttominimizethe
erosionaffects.
21
Avarietyofmaterialscanbeusedtoconstruct
thermowells.Surfacecoatingscanbeusedto
improvecorrosionanderosionresistance.
PlasticssuchasTeflonarehighlycorrosion
resistantandceramicsofferhightemperature
capabilitiesandcanbeagoodchoiceforerosive
applications.
Tantalumisusedforacidresistanceandcanbe
appliedasasleeveoritcanbebondedtothe
surfaceofnearlyanythermowellstyle.
Improvingthesurfacefinishwillincrease
corrosionresistanceandmakeiteasiertoclean.
Fewerridgesandcrevicesmeansasmaller
surfaceareaforthecorrodenttoattack.
Electropolishingorpassivatingthesurface
furtherincreasescorrosionresistance.
Sometimeslessexpensivematerialsturnoutto
bethebestchoice.OriginallyaTeflonplated
metalwellwasusedformonitoringthe
temperatureofanacidicwasteproduct.Teflon
platingiseasilydamaged(thinkofyourfrying
pan)andtheacidquicklyateawaythemetalwell
causingittoleak.Thesolutionwastouse
standard3PVCpipetoconstructthewellwhich
wasabout10ftlongandattachedwithaflange
connection.Aninternalwellwasmadewith
PVCtohousethetemperaturesensorallowingit
tostickoutacoupleinchesforbettertime
response.
Positive Material Identification (PMI)
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Performance
23
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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22
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.
Measurementaccuracycanbeadverselyaffected
byathermowellunlessafewprecautionsare
taken.Wakefrequencyandstrengthcalculations
areprobablythemostimportant.These
calculationswilltellyouhowlongthewellcanbe
immersedintoyourprocessbasedontheflow
conditions(moreonthislater).Thishastobe
balancedwiththeaccuracyneedsofthesensor
tobeimmersedsufficientlytopreventstem
conductionorimmersionerror.
Finally,timeresponseisslowerwiththeaddition
ofathermowellandforprocessesthatchange
temperaturerapidlythiscanbeasignificanterror
source.
ASME PTC 19.3 TW-2010
24
ASME PTC 19.3 TW - 2010

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:
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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Von Krmn Vortex
25
Von Krmn vortex street, by [http://www.mcef.ep.usp.br/staff/jmeneg/cesareo/Cesareo_HomePage.html

Cesareo de La Rosa Siqueira
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Thermowell Selection
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Whenacylindricalobjectisplacedinaflowthere
isadisturbancecreatedonthedownstreamside
thatoscillatesbackandforth.Thefrequencyof
theoscillationincreasesastheflowrate
increases.Iftheresonantfrequencyofthe
thermowellmatchesthefrequencyofthe
vorticesthewellwillstarttovibrateandwillfirst
damagetheRTDandthenthewellwillfail.
Therearealotofgoodillustrationsofthis
phenomenaontheinternet.Asearchforvon
karmanorwakefrequencywillreturnseveral.
26
Thisgraphshowstheacceptableflowratesfor
variousthermowelldesignsandadiameter
directimmersionRTD.Notethatashortincrease
inimmersionlengthhasalargeaffectonthe
allowableflowrate.
Information Required
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27
Thisistypicaloftheinformationthatisneeded
toperformthecalculations.
Stress Crack
28
Anexampleofwhatcanhappenifthewake
frequencyandstrengthcalculationsarenot
done.Thiswellincorporatesasupportpartway
downthestemtoprovidesupportbutitwasnt
enough.Acrackformedasoutlinedaroundthe
stem.
ASMEPTC19.3doesnotrecommendtheuseof
supportssuchasthis.Shorterimmersionor
largerdiameterarethepreferredsolutions.

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Alittlebetterviewofthecrackthatformed.
Stress Crack
29

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Immersion Length
30
Direct immersion RTDs require 10 x probe diameter plus sensitive length to

avoid stem conduction errors. Thermowells require about 4.5.
25C
Aruleofthumbforminimumimmersionlength
toavoidstemconductionerroris10timesthe
probediameterplusthesensitivelengthofthe
probe.MostRTDshaveasensitivelengthof
approximately1.0.SoforadiameterRTDthe
minimumrecommendedimmersionis3.5.
Thermowellsrequireabout4.5asaminimum
forbestaccuracy.
200C
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Immersion Error
31
Immersion Error for 200L05ANN135TT302

40.00
35.00
Indicated Error (% Delta T)
30.00
25.00
20.00
Ice Bath
Athermowell/RTDassemblywasimmersedina
bathtodeterminethestemconductionat
variousdepths.At4.5inchesmostoftheerror
hasdisappeared.Asyoucanseetheerroris
mostlyindependentofthebathtemperature
used.Theerrorisexpressedasapercentageof
thedeltaTbetweenambientandprocess
conditions.
100C Oil Bath

200C Oil Bath
15.00
10.00
5.00
0.00
0
10
12
-5.00
Im m e rs ion De pth (Inche s )
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Specialty Elbow Wells
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32
Whenlinesizedoesntallowforalongenough
immersionlengthaspecialtythermowellsuchas
thiscanbeused.Notetheflarearoundthe
internalthermowellwhichavoidsflow
restriction.
Elbow Well Drawing
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33
Forthoseapplicationsthatrequireathermowell,
theelbowstyleworkswellifsizedcorrectly.An
immersionlengthofatleast4formost
applicationsisnecessarytoprovideanaccurate
measurement.Shorterimmersionlengthsmay
workforsomeprocessfluidsandflowrates.
Installation in a Tee
34
SENSOR INSTALLED
PERPENDICULAR TO FLOW
Good
SENSOR INSTALLED
PARALLEL TO FLOW
SENSOR INSTALLED
PARALLEL TO FLOW
Better
Best
Insmalldiameterlinesthereistypicallynot
enoughroomtogettheproperimmersionlength
toavoidstemconduction.Thisillustratesthree
methodsofmodifyingthepipingtoprovideextra
room.Theoneontherightisthebestmethod
becauseitprovidesfortheflowcomingdirectly
atthetipofthesensorforlessstressonthe
probeanditalsowashesoutthedeadlagportion
ofthetee.
Fluid
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Anti-Immersion?
35

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Anotherinstallationmethodwhichwedont
recommend.Theresprobablyajokebehindthis
suchasitsforroomairtemperatureorit
makesanicehandhold.Likelyjustthe2ndshift
crewhavingfunwiththe1stshiftcrew.Inany
case,aremindertoalwaysdoublecheckyour
installation.
Performance - Time Constant
36
Adding heat transfer

paste cuts these
times nearly in half.
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TimeConstantisdefinedasthetimeittakesfor
thesensortoindicate63.2%ofastepchangein
temperatureinwatermovingat3fps.
Specialty Fast Response Tip
37
Afewspecialtywellssuchasthisonecan
improvethetimeconstantsignificantlywitha
smalldiametertip,heattransferpaste,anda
specialdesignRTD.
Time constant is about 4 seconds

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Specialty Flow-Through Design
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Thiswellprovidesprotectiontothesensorbut
allowsflowintothesensorforimprovedtime
response.
Specialty Large Diameter Elbow
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39
A3tubesanitaryelbowthermowellisshown
hereandrevealstheinternalthermowellwhichis
3/8diameterandhasa.260borediameter.
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
Bore diameter
Surface finish
Plug
Testing
Certifications
40
Standardvariablelettersareusedtodescribe
thermowelldimensions.
Coatings
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Specifying Typical Drawing
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41
OfthesetheimmersionlengthUandthebore
depthAaremostcommonlyusedforspecifying
thelengthofthesensor.
Specifying Some Need to Know Details
42
Thread size
1/2, 3/4, or 1 NPT
Socket weld
3/4 refers to O.D. of connection based on pipe size.
3/4 = 1.05 OD of fitting
Flange
2.0 x 150 LB or class 150
1.5 x 300 LB
Sanitary flange
1.5, 2, 2.5 etc.
Flange size refers to the tube size it is used to connect and
not the actual flange diameter. For example: 1.5 sanitary
flange measures 2.0 diameter
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Specifying - Testing and Certifications
43
A few of the available certifications:

Hydrostatic internal or external pressure testing per ASTM
Dye penetrant testing per ASTM
X-ray examination per ASTM
Material certification
Mechanical Surface Finish Certification
Canadian Registration Number (CRN)
Material Certificate of Conformance
No ADM (Animal Derived Material)
Certification that no polishing compound was used
Certification of NACE Approval
Electropolish and Surface Finish Certification
Positive material identification (PMI)
Inspection Certificate (ISO 10474, EN 10204, DIN 50049) 3.1B
Passivation
Weld Map - location & numerical identification of every weld
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Specifying - Options
Some available options:
Plug and chain

Marked with tag number (customer specific information)
Open ended thermowell
1/8 Diameter weep hole
Full weld penetration on flanged well, includes certification
British Standard Pipe process threads (BSP)
Deep Tap threads (for explosion proof applications)
Velocity collar (not recommended per the ASME standard)
Coatings for corrosion or erosion resistance
Flange facing options
Cleaned for oxygen service
Root and tip Q and D dimension options
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Someknowledgeofthevarioustypesofprocess
connectionsisrequiredtochoosethecorrect
size.ThreadedconnectionsareNPTandfairly
straightforward.Flangeconnectionsizesreferto
thesizepipeortubewhichtheyconnect.
44
Thesearejustafewofthepossibleteststhatcan
beperformedonathermowell.Ofthese,the
mostcommonarematerialcertification,wake
frequencycalculations,andpressuretesting.
An ounce of prevention
45
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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Thermowell Selection Checklist
46
Thermowell selection
Material selection
Corrosion
Erosion
Strength
Process connection style
Flange
Threaded
Welded
Sanitary
Stem style
Immersion length
Surface finish
Time response
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Summary
47
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
Burns Engineering
Thermowellstypicallyneedonlyminimal
maintenance,keepingthemcleaninsideandout
isusuallyallthatisrequired.Heattransferpaste
shouldberenewedifthesensorisremovedfor
calibrationorreplacement.
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