WHEN AND WHEN NOT TO USE THERMOWELLS IN PROCESS TEMPERATURE

MEASUREMENT

在流体温度测量中，热电偶保护套（以下简称：保护套）应该在什
么时候用
About copyright: The original copy of this article was published on
https://www.processingmagazine.com/thermowells-in-process-temperature-measurement/ the original author takes all
the credit and rights.

Thermowells can be a design and maintenance headache, but recent innovations reduce some long-standing problems,
and alternative measuring technologies can eliminate them entirely. Which approach is best for you?

保护套从设计和后期维护上来说都是挺麻烦的。但是最近的新技术解决了一些老大难的问题，新的测量技术甚至能
根除这些问题。就看你怎么选择。

翻译 赵珑珑 llz@whmcn.com 上海万汇机械有限公司 www.whmcn.com

Within the world of process instrumentation, temperature measurement presents unique challenges due to the need for a
thermowell to protect the temperature measurement sensor from harsh process conditions. This results in the sensor being
removed from the process it is supposed to be measuring, often impacting response time and accuracy.

和其他过程控制仪器仪表相比，温度测量由于需要保护套来把传感器和恶劣的环境隔离开，使得这个领域有它独特
的困难。比如，传感器正在测量的时候却被移动了，这就影响了测量的反馈时间和精度。

A resistance temperature detector (RTD) is most commonly constructed from a platinum element with leads attached, which
is encased in a stainless-steel sheath to protect it mechanically and electrically. A thermocouple is usually more
mechanically robust, but still requires a high degree of protection. In either case, heat from the process must flow through
the protective components and any internal insulation to reach an equilibrium temperature between the sensor and
surrounding process.

电阻温度计（RTD）是用铂制成的，自带导线，外面被不锈钢套包裹着用于绝缘。热电偶通常机械性能好，但还是
要保护好。热能必须通过受保护的部件以及内在的绝缘材质，
来使得传感器的测量结果和环境温度达到一致

This heat flow takes time and creates a lag between an actual
process temperature change and the point when it is recognized
by the automation system. The relatively small enclosure of the
sensor itself, typically 5 to 7 mm in diameter, is rarely installed
such that it sees direct process contact. Most processes use a
thermowell (see Figure 1) to isolate the sensor assembly so it
can be extended into the process without direct contact.

流体的温度变化是渐进地，这使得在实际过程温度变化和测
量值之间会有一个滞后。传感器相对体积较小，一般就 5 到
7mm 的直径。很少会把它直接和过程中的流体接触。基本
上都是用保护套来隔绝传感器，通过非接触的方式伸入到流
体中。

A thermowell mounts through a vessel or pipe wall to extend

into the process fluid to the desired temperature measurement
point (see Figure 2). The sensor is inserted into the thermowell from outside the process so it can be accessed without
requiring a shutdown. The thermowell is exposed to the process fluid, so heat transfers through its wall and eventually
conducts to the sheath and sensor itself. Equilibrium is eventually reached, and the sensor then provides a reading
representative of the process fluid temperature.

保护套安装在储罐或管道的壁上并延伸进管体内合适的温度测量点。（见右图）传感器从外部通过保护套插入，不
影响流体活动。保护套是整个浸在流体里的，热能透过管壁，最终到达传感器。温度平衡点随后达到。传感器显示
过程温度。

If the process fluid temperature changes, the new temperature must make its way through all those layers. Depending on the
application, this can take a few seconds to several minutes. Few processes experience sudden temperature step changes, so
this arrangement is adequate for most real-world applications.

翻译 赵珑珑 llz@whmcn.com 上海万汇机械有限公司 www.whmcn.com

当流体温度变化时，新的变化也是通过上面的过程到达传感器的。根据不同的应用，这个变化的传递速度从几秒钟
到几分钟不等。因为很少出现温度会有急剧地变化，所以这样的传感器配置在大部分应用中都没有问题。

The tradeoffs of thermowell selection

保护套的短板在哪里？
The process engineer will often specify where a temperature reading needs to be taken. For example, the sensor needs to be
placed in the pipe coming out of a reactor, and the reading taken
from the center of the pipe. Therefore, the thermowell insertion
length needs to be half the internal diameter of the pipe.

工程师经常要指定需要测量温度的地方。比如，在流体制造的
前端，并且是管道中心的位置。因此，保护套的长度就要和管
道半径一样长。
The process engineer will also determine how much and how
quickly the temperature is likely to change in normal operation,
and how quickly the measurement point needs to be able to
communicate a change to the automation system. If the
movement needs to be recognized in a very short time, the
thermowell will need thin walls to conduct heat quickly to the
sensor.
工程师还要确定温度的变化量和变化速度，以及温度数据采集
的频率。如果希望采集数据更快，那么保护套壁厚就要做得薄
一点。
At the same time, the walls must be thick enough to withstand any mechanical stresses and pressures without distorting or
failing. Naturally, the thermowell must be made from an appropriate material able to withstand the chemical and
temperature environment, usually the same material as the pipe or vessel where it is inserted.
同时，壁厚又必须能承受机械应力和压力，不至于变形或破裂。显然，保护套应该是由承受得住一般的化学和极端
温度考验的材料制造而成。通常也就是和制造管道和容器的材料一样，就对了。
The thermowell installer will choose a connection method to fit the situation from one of four common options (see Figure
3):

保护套根据下面 4 种不同的情况来配置连接方式（见右图）。

 Threaded thermowells are threaded into the process piping or a vessel, which allows for easy installation and
removal when necessary. While this is the most common method of mounting, it has the lowest pressure rating, and
threaded connections are prone to leakage.
 螺纹保护套是旋进管道或容器的，安装和卸载都很方便。也是最普遍的安装方式，但是，耐压低，容易泄
露。
 Welded thermowells are permanently welded to process pipes or vessels and used in applications with
high-velocity flow, high temperature and/or high pressure. While reliable and leak-resistant, removal is difficult
and requires cutting the thermowell out of the system.

翻译 赵珑珑 llz@whmcn.com 上海万汇机械有限公司 www.whmcn.com

  焊接式保护套是永久性焊在管道和容器上，多用于
流速快，高温或高压的工况上。可靠性高，防漏强，
但是拆下来也很难，必须用切割
 Flanged thermowells are bolted to a mating flange, or
spud welded onto a process pipe or vessel. They are
used in applications with corrosive environments, high
fluid velocity, high temperatures and/or high pressure.
 法兰式保护套是通过螺丝连法兰拧紧的或焊紧。通
常用在腐蚀性，高流速，高温，高压的环境
 Van Stone or lap-joint thermowells are mounted
between a mating flange and the lap-joint flange. These thermowells allow use of different materials for the
thermowell coming in contact with the process and for the overlaying flange, which can save material and
manufacturing costs.
 松套法兰保护套是安装在松套法兰上的。用于不同材料的保护套，这个方式能降低材料和制造成本。

Fluid flow is the biggest challenge

流动是最大的挑战

If a correctly specified and installed thermowell is located where the fluid is largely static, such as in some vessels, it can
have a long service life. Problems arise when a thermowell is inserted in moving fluid, which is the most common type of
application. The thermowell is normally mounted perpendicular to the flow, so the fluid hits it broadside. It, therefore,
creates a partial obstruction and causes a drag on the fluid.

如果保护套安装到位，流体也相对静止，比如一些储罐或器皿，那么保护套的寿命就很长的。如果保护套用在流动
的地方，通常也是最常见的应用，保护套是垂直于流动方向安装的，因此流体打到侧面。这样一来，阻挡了流动，
对流体来说是一种牵制。

As the fluid flows past a round thermowell, high- and low-pressure vortices form at both sides. These vortices detach, first
from one side and then from the other, in an alternating pattern (see Figure 4). This phenomenon is commonly known as
vortex shedding. The differential pressure caused by the alternating vortices produces vortex-induced vibration (VIV),
resulting in stresses and causing transverse and axial deflection, which can ultimately lead to fracture. It is as if the
thermowell is being pulled up and down perpendicular to the flow.
当流体流过保护套，两边形成高，低两个旋涡。这些旋涡会散开，先从一边再到另一边。交替进行（见上图）这个
现象叫做旋涡脱落。通过交替的旋涡产生的压差又制造了涡振，导致压力以及上下左右的偏移。最终会使保护套断
裂。就好像保护套在流体里不停的被上下左右拉扯。

The frequency of the oscillations is referred to as the wake frequency and is affected by the fluid velocity. It is not a linear
relationship, so the vibration does not necessarily increase with an increase in velocity. As fluid velocity changes, VIV will
increase and recede at various points, so there are conditions where an installation can run relatively safely.

翻译 赵珑珑 llz@whmcn.com 上海万汇机械有限公司 www.whmcn.com

摆动频率是指尾流频率，受流速影响。这不是线性的关系，也就是说流速增加了，尾流不一定增加。随着流速变化，
涡振会在不同的时候，加强再消退。因此相对安全的安装点是可以被找到的。

The worst situation takes place when the wake frequency corresponds to the natural frequency of the thermowell, producing
potentially violent VIV. If the dynamic stresses exceed the maximum allowable working stress limits of the thermocouple,
it will succumb to fatigue and fail. Thermowell manufacturers should provide thermowell calculations to predict the
probability of a thermowell failing. The American Society of Mechanical Engineers (ASME) provides a method for
calculating the dimensions necessary for a thermowell to be strong enough to operate satisfactorily in a given
application here.

当尾流频率和保护套的自然频率一致时，最糟糕的情况就发生了 – 产生了潜在的强烈的涡振。如果动态压力超过
最大的允许压力，这将导致保护套因疲劳而折断。ASME 提供了一个计算保护套必要尺寸的方法，使得在类似应用
中安全的运行。

Such calculations depend on a single set of static process conditions, which is not the case in most real-world situations. The
conventional solution is to make thermowells as short as the process can accept and as thick as can be inserted, but this
increases the time lag for capturing a temperature change and can impact accuracy. The alternative is to find a profile able
to suppress VIV formation.

这个计算公式是基于静止状态下的一个设置，通常也不是实际情况所得。传统方式是尽量把保护套做短，做厚。但
这又增加了温度传递时间，并且影响测量精度。另一个方式就是找到压制涡振的方法。

Modifying thermowell geometry to reduce VIV

调整保护套结构来降低涡振
Cylindrical, stepped and tapered thermowells are all basically round – so they have similar VIV characteristics, allowing
vortices to form along the entire length. A new design (see Figure 5) disrupts formation of
the long vortices and allows them to form on both sides, so they tend to balance and cancel
each other. The result is far less VIV, up to a 90 percent reduction in some cases.

圆柱形，阶梯型保护套断面都是圆的 – 因此他们都有潜在的涡振的风险，使得涡振
在整个套壁周围形成。一种新的设计打乱了涡振的形成，它使得涡振在两边同时形成。
这样就可以互相抵消。结果当然是大大减低了涡振，有些地方甚至达到了下降 90%
的幅度。

Helical geometry like this has been used successfully with wind stacks and deepsea risers
to solve similar problems. It does not depend on a specific orientation when inserted, and
reduces the need for excessively thick thermowells and large diameter process penetrations.
Moreover, it is effective and suitable across a wide range of operating parameters.

像这样的螺旋设计已经成功在测风棒和深海提升棒上得到应用。使用时，保护套插入的方向不再重要，而且还降低
了对壁厚和直径的要求。更重要的是这个技术在更大范围的操作环境下都很奏效。

Inferring process temperature from a surface temperature reading

翻译 赵珑珑 llz@whmcn.com 上海万汇机械有限公司 www.whmcn.com

通过管壁间接测量温度
Since all temperature readings depend on the heat conductivity of the thermowell and sensor sheath, why not mount the
sensor on the outside of a pipe and infer the process temperature from the amount of heat transferred through the wall? This
eliminates the need for a thermowell, and provides an accurate reading if appropriate adjustments are taken:

既然所有的流体温度都是通过保护套和传感器来测量的，那为什么不直接通过测量管壁来测量温度呢？如果这个方
法行得通的话，就不需要保护套了。

 A surface reading will reflect the fluid near the outside wall, which may not be the same as the center of the pipe.
 管壁测量的是接近内壁的流体的温度，而不是管子中心的温度
 Thermal conductivity characteristics of the pipe, including material and thickness, must be taken into consideration.
 管道传递热量的属性，包括材料，厚度都要考虑进去。
 Ambient temperature conditions must be included in the calculation.
 管道周边的温度环境也必须要考虑进去

If the sensor can be placed in solid, direct contact with the pipe wall and thoroughly insulated, a usable reading can
sometimes be inferred from the sensor output. However, changing ambient temperature conditions will substantially affect
the accuracy of the reading, leading to a search for a better solution.

把传感器直接接触管壁并做好隔离，那么传感器的测量有时候是可以别采用的。但是这个方法受周边环境温度影响
很大，因此，我们还需要找到一个更好的办法。

New technology (see Figure 6) is designed to measure surface temperature, and corrects and compensates for heat transfer
and ambient condition effects resulting in an accurate process temperature measurement without requiring any intrusions or
penetrations into the process. The unit is installed using a simple pipe clamp assembly and then insulated. The pipe material
and wall thickness are entered into the transmitter so it can calculate heat flow and extrapolate the process temperature
inside the pipe. The unit also uses an ambient temperature reading taken inside the transmitter enclosure to account for
changing ambient conditions.

上图中的设计就是一项新的管壁测温法，它包含了对温度传输损失和周围环境温度影响的校准及补偿，同时不增加
任何多余元素或者插入任何仪器。它是通过一套简单的管壁夹具安装并密封。管道材料和壁厚参数会被输入转换器，
用来间接计算管内流体温度。该系统同时会把环境温度数据输入到转换器中做计算。

This approach has a variety of advantages:

这个系统有如下的好处

 It can be installed without a process penetration, so no shutdown is necessary.

 不需要向管道插入设备，也就意味着不需要停机
 It can be used where pipe diameters are too small for a thermowell.
 对于小管径特别是保护套查不进的地方，管用。
 Since no parts are wetted, there is no need for exotic
materials. Figure 6. A sophisticated series of calculations
 因为接触不到液体，系统在材料的选择上也不用 available in new technology makes the surface reading
太特殊 match the process temperature very closely. 上图：通过
 The assembly can be moved to a different 测量管壁温度并通过复杂的计算得出管内流体温度
measuring point if necessary.

翻译 赵珑珑 llz@whmcn.com 上海万汇机械有限公司 www.whmcn.com

  系统可移动性强
 Wired and wireless options make installation easy.
 可以有线，也可以无线，使得安装就简便。

Like any surface temperature measurement, the new technology is subject to the same time lag and near-the-inside-wall
reading characteristics, however the advantages often outweigh these limitations. Any temperature measuring application
will be a compromise, but the growing number of options now available make selection much easier.

就像其它表面温度测量，这些新技术有滞后性和接近管内测量的特性。但是，优势相对这样还是更加明显的。其它
温度测量技术都是一种折中的方案，但随着新方案的出现，选择也变多了

本文作者是 Ryan Leino is the Rosemount Temperature Global Product Manager for Emerson in Minnesota.美国，明尼苏
达州艾默生 Rosemount 温度公司全球产品经理 Ryan Leino. He holds a bachelor’s degree in chemical engineering from
the University of Wisconsin-Madison. Leino has 11 years of experience with Emerson in the areas of inside sales, product
marketing and product management. Connect with him on LinkedIn at http://www.linkedin.com/in/ryan-leino-256a8523.

翻译 赵珑珑 llz@whmcn.com 上海万汇机械有限公司 www.whmcn.com